Riello RL 34 MZ 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 2 llamas
Funcionamento a 2 chamas
2916230 (7) - 04/2010
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3470200 - 3470210 RL 34 MZ 972 T
3470201 - 3470211 RL 34 MZ 972 T
3470300 - 3470310 RL 44 MZ 973 T
3470301 - 3470311 RL 44 MZ 973 T
3470330 - 3470340 RL 44 MZ 973 T
3470331 - 3470341 RL 44 MZ 973 T
GB
E
P

CONFORMITY DECLARATION A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
I - 37045 Legnago (VR)
Tel. [phone]
http:// www.rielloburners.com
Put into circulation by: RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE
conformity declaration and they are produced and placed in circulation in conformity with the provisions defined
in L.D. dated January 8, 2004 and 17 July 2009.
Type of product: Light oil burners
Standard applied: EN 267 and A.R. Dated 8 January, 2004 - 17 July 2009.
Date: 31/03/2010 RIELLO S.p.A.
Model
972 T 973 T
RL 34 MZ RL 44 MZ
VALUES
MAX
NOx (mg/kWh) 123 138
CO (mg/kWh) 8 6

³The burner has CE marking and conforms to the basic requisites of the following Directives:
– Electromagnetic Compatibility Directive 89/336/EEC - 2004/108/EC;
– Low Voltage Directive 73/23/EEC - 2006/95/EC;
– Machine Directive 2006/42/EC;
– Efficiency Directive 92/42/EEC.
³The burner meets protection level of IP 40 pursuant to EN 60529 standard.
The following symbols are used in this manual:
ATTENTION = for actions requiring special care and adequate preparation.
FORBIDDEN = for actions THAT MUST NOT be performed.
!
IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and perform-
ance data. If the Identification Plate is tampered with, removed or missing, the product cannot be clearly
identified thus making any installation or maintenance work potentially dangerous.
GENERAL WARNINGS
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guaran-
tee a combustion with the lowest polluting emissions rate.
You are therefore advised to consult the Technical Assistance Department before choosing this type of
burner for the combination with a boiler.
Qualified personnel are those with the professional and technical requirements indicated by law no. 46 dat-
ed March 5, 1990. The commercial organisation has a widespread network of agencies and technical offic-
es whose personnel participates periodically in instructional and refresher courses at the company training
centre.
This burner must only be used for the application it was designed for.
The manufacturer cannot accept liability for any damage to persons, animals or property due to error in in-
stallation or in the burner adjustment, or due to improper or unreasonable use or non observance of the tech-
nical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
USER INFORMATION
If faults arise in ignition or operations, the burner performs a "safety stop", which is signalled by the red
burner lock out Led. To rearm start up conditions, press the release button. When the burner starts up
again, the red Led goes out.
This operation can be repeated a maximum of 3 times. If the "safety stop" recurs, then the Technical
Assistance Centre must be called out.
BASIC SAFETY MEASURES
³Children or inexpert persons must not use the appliance.
³Under no circumstances must the intake grids, dissipation grids and ventilation vents in the installa-
tion room be blocked with cloths, paper or any other material.
³Unauthorised persons must not attempt to repair the appliance
³It is dangerous to pull or twist the electric leads.
³Cleaning operations must not be performed if the appliance is not disconnected from the main power
supply.
³Do not clean the burner or its parts with inflammable substances (e.g. petrol, alcohol, etc.).
The cover must be cleaned with soapy water.
³Do not place anything on the burner.
³Do not leave containers and inflammable products in the installation room.

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
Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 5
Choice of nozzles for 1st and 2nd stage . . . . . . . . . . . . . . . . . . . 6
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 15
Resetting the control box and using diagnostics . . . . . . . . . . . . 15
Faults - Possible causes - Solutions . . . . . . . . . . . . . . . . . . . . . 16
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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.
INFORMATION ABOUT THE INSTRUCTION
MANUAL
INTRODUCTION
The instruction manual supplied with the burner:
- is an integral and essential part of the product and must not be
separated from it; it must therefore be kept carefully for any nec-
essary consultation and must accompany the burner even if it is
transferred to another owner or user, or to another system. If the
manual is lost or damaged, another copy must be requested from
the Technical Assistance Service of the area;
- is designed for use by qualified personnel;
- offers important indications and instructions relating to the instal-
lation safety, start-up, use and maintenance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUCTION
MANUAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the system
manufacturer, with the recommendation to keep it in the room
where the heat generator is to be installed.
- The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assistance
Centre;
- The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system is
started up,
- maintenance and the need to have the system checked at
least once a year by the manufacturer or another specialised
technician.
To ensure a periodic check, recommends the draw-
ing up of a Maintenance Contract.
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
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..................................................................................

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ= ± 1.5 dB, in the manufacturer's combustion cham-
ber with burner operating on test boiler at maximum output.
VARIANTS
ACCESSORIES (optional):
•LONG HEAD KIT:
•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 con-
sequence of depressurisation 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 variations 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 output : 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 34 MZ RL 44 MZ RL 44 MZ
TYPE 972 T 973 T 973 T
POWER (1)
OUTPUT (1)
2nd stage kW 154 - 395 235 - 485 235 - 485
Mcal/h 132 - 340 204 - 418 204 - 418
kg/h 13 - 33,6 20 - 41 20 - 41
1st stage kW 97 - 154 155 - 235 155 - 235
Mcal/h 83 - 133 133 - 204 133 - 204
kg/h 8,3 - 13 13 - 20 13 - 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% 50/60 - single-phase 230 - 400 with neutral ~ +/-10% 50/60 - three-phase
ELECTRIC MOTOR rpm
W
V
A
2800
300
220 - 240
2,4
2800
420
220 - 240
3.0
2800
450
220/240 - 380/415
2.0 - 1.2
MOTOR CAPACITOR µF/V 12.5/450 12.5/450
IGNITION TRANSFORMER V1 - V2
I1 - I2 230 V - 2 x 12 kV 0.2 A - 30 mA
PUMP output (at 12 bar)
pressure range
fuel temperature
kg/h
bar
°C max
45
7 - 14
60
67
10 - 20
60
67
10 - 20
60
ELECTRICAL POWER CONSUMPTION W max 600 700 750
PROTECTION LEVEL IP40
IN CONFORMITY WITH EC DIRECTIVES 2006/42 - 89/336 - 2004/108 - 73/23 -2006/95 - 92/42
NOISE LEVEL (2) SOUND PRESSURE
SOUND POWER dB(A) 68
79 70 81
Model Code Electrical
supply
Blast tube
length mm
RL 34 MZ 3470200 - 3470210
3470201 - 3470211 single-phase single-phase 216 351
RL 44 MZ
3470300 - 3470310
3470301 - 3470311
3470330 - 3470340
3470331 - 3470341
single-phase
single-phase
three-phase
three-phase
216
351
216
351
Burner RL 34 MZ RL 44 MZ
Code 3010426 Code 3010425
• CLEAN CONTACT KIT Code 3010419
• KIT POST-PURGING Code 3010453
• KIT HOURCOUNTER Code 3010450
• KIT GROUND FAULT INTERRUPTER Code 3010448
• RADIO DISTURBANCEPROTECTION KIT
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m)
owing to the presence of an INVERTER, or in applications where the length of the thermostat connections exceeds
20 metres, a protection kit is available as an interface between the control box and the burner. Code 3010386

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 1st and 2nd stage valve assembly
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 RELAY reset
button (RL 44 three-phase MZ )
18 Motor capacitor
(RL 34 MZ - RL 44 MZ single-phase)
19 Control box with lockout pilot light and lock-
out reset button
20 Two switches:
- one “burner off - on”
- one for “1st - 2nd stage operation”
21 Sockets for electrical connections
22 Air damper
23 Pump pressure adjustment
24 Plate prearranged to drill 2 holes for the pas-
sage of hoses.
Two types of burner failure may occur:
Control box lockout: if the control box 19)(A)
pushbutton (red led) lights up, it indicates that
the burner is in lockout.
To reset, hold the pushbutton down for between
1 and 3 seconds.
Motor lockout (RL 44 MZ three-phase): release
by pressing the pushbutton on thermal relay
17)(A).
PACKAGING-WEIGHT (B) - approximate
measurements
• The burners are shipped in cardboard boxes
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 meas-
urements.
The maximum dimensions of the burner are
given 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 given by measurement O.
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
2 - Plugs for electrical connections
(RL 34 MZ and 44 MZ single-phase)
3 - Plugs for the electrical connection
(RL 44 MZ three-phase)
1 - Instruction booklet
1 - Spare parts list
(A)
(B)
(C)
1
2
8
6
7
9
11
13 14
12
16
19 20 153
10
22
23
5
18
24
4
21
17
A
D
E
F
H
I
L
O
mm A B C kg
RL 34 MZ 1000 500 485 32
RL 44 MZ 1000 500 485 33
(1) Blast tube: short-long
mm A D E F (1) HGBL O (1)
RL 34 MZ 442 422 508 216 - 351 140 305 138 780 - 915
RL 44 MZ 442 422 508 216 - 351 152 305 138 780 - 915
D3865
D3864
D88
D3937

4
FIRING RATES (A)
The RL 34 MZ - RL 44 MZ model burners can
work in two ways: one-stage and two-stage.
1st stage OUTPUT must be selected within
area A of the adjacent diagrams.
2nd stage OUTPUT must be within area B. This
are supplies the maximum output of the burner
according to the pressure in the combustion
chamber.
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.
Attention:
The FIRING RATE area values have been
obtained considering a surrounding temperature
of 20 °C, and an atmospheric pressure of 1013
mbar (approx. 0 m above sea level) and the
combustion head adjusted as shown on page 7.
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 Output 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)
Pressure in combustion
RL 34 MZ
RL 44 MZ
D3866
D454
chamber – mbar
Pressure in combustion
chamber mbar
length of combustion
chamber – m

5
INSTALLATION
THE BURNER MUST BE INSTALLED
IN CONFORMITY WITH LEGISLATION
AND LOCAL STANDARDS.
OPERATING POSITION (A)
The burner is designed to work only in
the positions 1, 2,3 and 4.
Installation 1is preferable, as it is the
only one that allows performing maintenance
operations as described in this manual. Instal-
lations 2, 3 and 4 permit operation but make
maintenance and inspection of the combus-
tion head difficult, page 14.
Any other position could compromise
the correct working of the appliance.
Installation 5is prohibited for safety
reasons.
BOILER PLATE (B)
Drill the combustion chamber locking plate as
shown in (B). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (C)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling. The range of
lengths available, L, is as follows:
Blast tube 7): RL 34 MZ RL 44 MZ
• short 216 216
• long 351 351
For boilers with front flue passes 10) or flame
inversion chambers, protective fettling in refrac-
tory 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
refractory fettling 8)-9)(C) is not required unless
it is expressly requested by the boiler manufac-
turer.
SECURING THE BURNER TO THE BOILER (C)
Dismantle the nozzle assembly 7) and the pipe
coupling 5) from the burner 4):
- Remove the screws 2) from the two slide
bars 3).
- Remove the screw 1) and move the burner on
the guides 3).
Fix assembly 5) and 7) (C) to the boiler plate
and insert the supplied insulating gasket 6) C).
Use the four screws supplied after protecting the
thread with antiseizing products. The burner-
boiler seal must be airtight.
2 3 4 51
D3928
(B)
(C)
6
5
3
1
4
29
8
10
10
7
L
mm A B C
RL 34 MZ 160 224 M 8
RL 44 MZ 160 224 M 8
D455
D3867
(A)
!
!

6
CHOICE OF NOZZLES FOR 1st AND 2nd
STAGE
The burner complies with the emission require-
ments of the EN 267 standard.
In order to guarantee that emissions do not vary,
recommended and/or alternative nozzles speci-
fied by Riello in the Instruction and warning
booklet should be used.
Warning: It is advisable to replace noz-
zles every year during regular mainte-
nance operations.
Caution: The use of nozzles other than
those specified by Riello S.p.A. and inad-
equate 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 nonobser-
vance of the requirements contained in this
manual.
Both nozzles must be chosen from among those
listed in table (A).
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 rec-
ommended 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
reduced at the moment of firing;
• a delivery higher than 50% of the total deliv-
ery whenever the combustion during the 1st
stage must be improved.
Example with RL 34 MZ
Boiler power = 270 kW - efficiency 90%
Power 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.
(1) light oil: density 0.84 kg/dm3
viscosity 4.2 cSt/20 °C
temperature 10 °C
GPH kg/h (1) kW
12 bar Nozzles recommended
10 bar 12 bar 14 bar
RL 34 MZ 1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
4.00
4.50
3.9
4.8
5.8
6.8
7.7
8.6
9.6
10.7
11.5
12.4
13.5
15.6
17.3
4.3
5.4
6.5
7.5
8.5
9.5
10.6
11.8
12.7
13.7
14.8
17.2
19.1
4.7
5.8
7.0
8.2
9.2
10.4
11.5
12.8
13.8
14.9
16.1
18.7
20.7
51.0
64.0
77.0
89.0
100.8
112.7
125.7
139.3
150.6
162.5
175.5
203.5
226.5
DANFOSS 60° H
DELAVAN 60° A
MONARCH 60° PL
HAGO 60° P
RL 44 MZ 1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.50
4.00
4.50
5.00
5.50
6.00
5.8
6.8
7.7
8.6
9.6
10.7
11.5
13.5
15.4
17.3
19.2
21.1
23.1
6.5
7.5
8.5
9.5
10.6
11.8
12.7
14.8
17.0
19.1
21.2
23.3
25.5
7.0
8.2
9.2
10.4
11.5
12.8
13.8
16.1
18.4
20.7
23.0
25.3
27.7
77.0
89.0
100.8
112.7
125.7
139.3
150.6
175.5
201.6
226.5
251.4
276.3
302.4
DELAVAN 45° A
MONARCH 45° PL-PLP
HAGO 60° P
60
(A)
!
!

7
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
compound, or tape. Be careful to avoid damag-
ing the nozzle sealing seat. The nozzle 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:
- Open the burner on its guides as shown in
fig. (C) p.5.
- Remove the nuts 1)(D) and the diffuser disc
assembly 2)
- Use spanner 3(D) to change the nozzles.
1 3 2
(A)
(C)
(B)
D458
D590
D3868
D3869
1
2
3 4 5
(D)

8
COMBUSTION HEAD ADJUSTMENT
At this point of the installation, nozzle and pipe
coupling are fixed to the boiler as in fig. (C) p. 5.
The setting of the combustion head depends
exclusively on the output of the burner in the
2nd stage - in other words, the combined output
of the two nozzles selected on page 6 is a par-
ticularly simple operation.
Turn screw 1)(A) until the notch on the sheet
2(A) is level with the plate 3)(A).
Example
The RL 44 MZ Model with two 3.00 GPH noz-
zles and 12 bar pump pressure.
Find the delivery of the two 3.00 GPH nozzles in
table (A), page 6:
12.7 + 12.7 = 25.4 kg/h
(corresponding to 300 kW).
Diagram (B) shows that for an output of 25.4 kg/h
the burner RL 44 MZ needs a combustion head
notch regulation 3 approx.
Note
If the pressure in the chamber is equal to 0 mbar,
the air must be adjusted with reference to the
hatched line on the diagram (B).
Once the regulation of the head has been con-
cluded, refit the burner 4)(C)p.5 on the guides
3)(C)p.5 at approximately 100 mm from the pipe
coupling 5)(C).5, insert the electrode cables and
then slide the burner as far as the pipe coupling.
Replace the screws 2)p.5 on the guides 3)p.5.
Fix the burner to the pipe coupling with the
screw 1)p.5.
Attention
On closing the burner on the two guides it is
advisable to gently pull the high voltage wires
outwards until they are under slight tension.
COMBUSTION HEAD ADJUSTMENT
(A)
Notches nr.
Light oil output in 2nd stage kg/h
D3870
3
2
1
D3910
(B)

9
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 higher than the burner A
The distance "P" must not exceed 10 meters in
order to avoid subjecting the pump's seal to
excessive strain; the distance "V" must not
exceed 4 meters in order to permit pump self-
priming even when the tank is almost com-
pletely 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 depart-
ing from and returning to the tank with an auxil-
iary 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 suc-
ceed in self-priming because the tank distance
and/or height difference are higher than the val-
ues listed in the table.
Key to lay-out (A)
H = Pump/Foot valve height difference
L = Piping length
Ø = Inside pipe diameter
1 = Burner
2=Pump
3=Filter
4 = Manual on/off valve
5 = Suction line
6 = Foot valve
7 = Rapid closing manual valve remote 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.11.
It is therefore necessary to connect both hoses
to the pump.
The pump will break down immediately if it is run
with the return line closed and the by-pass
screw inserted.
Remove the plugs from the suction and return
connections of the pump.
Insert the hose connections with the supplied
seals into the connections and screw them
down.
Take care that the hoses are not stretched or
twisted during installation.
Pass the hoses through the holes on the left-
hand plate 5)(B), removing the thin diaphragm
that closes the two holes or as per the following
instructions: 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)
95
7
10
6
6
753
9
4
A
B
P
+H
8
10 cm
-H V
12
1
2
3
4
5
+ H
- H
(m)
L (m)
RL 34 MZ
Ø (mm) RL 44 MZ Ø (mm)
8 10 12 8 10 12
+ 4.0 52 134 160 35 90 152
+ 3.0 46 119 160 30 80 152
+ 2.0 39 104 160 26 69 152
+ 1.0 33 89 160 21 59 130
+ 0.5 30 80 160 19 53 119
0 27 73 160 17 48 108
- 0.5 24 66 144 15 43 97
- 1.0 21 58 128 13 37 86
- 2.0 15 43 96 9 27 64
- 3.0 8 28 65 4 16 42
- 4.0 - 12 33 - 6 20
D3871
D3911

10
PUMP (A)
1 - Suction line G 1/4"
2 - Return line G 1/4"
3 - Gauge connection G 1/8"
4 - Vacuometer connection 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. Obstruc-
tions 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.10 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.10 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
approx. 15 seconds, reset the burner, and then
repeat the starting operation as often as
required. And so on. After 5 or 6 starting opera-
tions allow 2 or 3 minutes for the transformer to
cool.
Do not illuminate the photocell or the burner will
lock out; the burner should lock out anyway
about 10 seconds after it starts.
Attention: 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 AN 67 C
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
45
7 - 14
0.45
2 - 75
60
2
12
0.150
67
10 - 20
0.45
2 - 75
60
2
12
0.150
SUNTEC AN 57 C
RL 34 MZ
D481
SUNTEC AN 67 C
RL 44 MZ

11
BURNER CALIBRATION
QUALIFIED PERSONNEL WITH THE RIGHT
INSTRUMENTS MUST HANDLE THE
BURNER'S START-UP.
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 fill-
ing of the 2nd stage nozzle tubing. This lowering
of the fuel pressure can cause the burner to
lockout and can sometimes give rise to pulsa-
tions.
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 fir-
ing in respect to the opening of the light oil
solenoid valve occur, see the suggestions pro-
vided on p. 14: 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 follow-
ing points:
• 1st and 2nd nozzles
See the information listed on page 6.
• 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 pur-
poses. Sometimes, this pressure must be
adjusted to:
10 bar in order to reduce fuel delivery. This is
only possible if the room temperature is above
0 °C. Never fall below 10 bar: at which pres-
sures the cylinders may have difficulty in open-
ing;
14 bar in order to increase fuel delivery or to
ensure firings even at temperatures of less than
0°C.
In order to adjust pump pressure, use the screw
5)(A), p. 9.
• 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 44 MZ - 1st stage nozzle 3.00 GPH:
notch 22° aligned with index 7(A).
When the adjustment is terminated lock the hex
element 4) with the ring nut 3).
• 2nd stage fan air damper 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
34 56 8 1
7
2
(C)
1st STAGE
α= Notch Nr.
RL 34 MZ RL 44 MZ
kg/h mbar kg/h mbar
13
14
16
18
20
22
24
26
28
30
32
34
5.4
5.6
5.7
5.9
6.0
6.2
6.4
6.6
6.7
6.9
7.0
7.1
20
22
24
26
29
32
35
38
40
41
4.2
4.7
4.9
5.1
5.4
5.6
6.3
7.4
8.6
9.0
2nd STAGE
mbar = Air pressure in 1) with zeropressure in 2)
D3872
D469
(D)
D3873
RL 34 MZ RL 44 MZ
GPH αGPH α
2,25
2,50
3,00
3,25
3,50
4,00
4,50
20
23
27
30
33
37
40
3,00
3,50
4,00
4,50
5,00
22
26
28
30
32
RL 34 MZ RL 44 MZ
GPH αGPH α
2,25
2,50
3,00
3,25
3,50
4,00
4,50
20
22
25
28
30
32
35
3,00
3,50
4,00
4,50
5,00
20
24
26
28
30
50 Hz Versions 60 Hz Versions
!
ATTENTION

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), 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 : The solenoid valves open 8); 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
passes on to the control device TR that controls
boiler temperature or pressure.
• When the temperature or the pressure
increases until the control device TR opens,
solenoid valve 11) closes, and the burner
passes from the 2nd to the 1st stage of opera-
tion.
• 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
remote control device TL opens, solenoid
valve 8) closes, the flame immediately goes
out. The fan's air damper valve closes com-
pletely.
System 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 lockout
within 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 sec-
ond and automatically attempts to start again by
repeating the starting cycle.
(B)
(A)
TL
TR
0
1°
2°
A
A
TL
Off Yellow Green Red
For further details see page 14.
*
D3912
D3939
D3938
LED
RMO *
LED
RMO *

13
FINAL CHECKS
• Obscure the photocell and switch on the con-
trol devices: the burner should start and then
lockout 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 lockout 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 lockout.
• Switch off control device TL followed by con-
trol device TS while the burner is operating:
the burner should stop.
MAINTENANCE
The burner requires periodic maintenance
carried out by a qualified and authorised
technician in conformity with legislation and
local standards.
Periodic maintenance is essential for the
reliability of the burner, avoiding the
excessive consumption of fuel and consequent
pollution.
Before carrying out any cleaning or con-
trol always first switch off the electrical
supply to the burner acting on the main switch of
the system.
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
detached 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 vacu-
ometer 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 fil-
ter 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.
Fan
Check to make sure that no dust has accumu-
lated inside the fan or on its blades, as this con-
dition 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
combustion head are in good condition, posi-
tioned correctly, free of all impurities, and that
no deformation has been caused by operation at
high temperatures.
Nozzles
Do not clean the nozzle openings.
It is advisable to replace nozzles every year dur-
ing regular maintenance operations.
The change of nozzle requires the combustion
to be controlled.
Photocell
Clean the glass cover from any dust that may
have accumulated.To extract the photocell 4)
(A)p.3 pull it outward forcefully. it is only pressed in
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 accompany-
ing instructions in order to maintain all the origi-
nal combustion characteristics intact, especially
the flue gas temperature and combustion cham-
ber pressure.
(A) D482
!
!
!

14
TO OPEN THE BURNER (A)
- Switch off the voltage
- Remove screw 1 and withdraw the casing 2)
- Unscrew screw 3)
- Fit the two extensions 4), on the burner, on the
guides 5) (model with nozzle 351 mm)
- Pull part A backward keeping it slightly raised
to avoid damaging the disk 6) on blast tube 7).
MAINTENANCE OF THE ELECTRICAL
PANEL (B)
If it is necessary to maintain the electrical panel
A)(Fig. A) it is possible just to remove the fan
assembly B)(Fig. A) to get better access to the
electrical components.
With the burner open as in fig. (A), disconnect
the electrode cables and remove the head unit
8)(A) by undoing the two screws 9)(A).
Disconnect the cables relative to the fan motor,
remove the 3 screws 10)(A) on the protective
sheet and the two screws 11)(A) and slide out
the fan assembly B)(Fig. A) from the guides 4) -
5)(A).
Finally it is possible to use 2 of the 3 screws
10)(A) to fix the electrical panel to the pipe cou-
pling in the points indicated on fig. (B), and then
perform the maintenance operations.
POSSIBLE PUMP AND/OR COUPLING
REPLACEMENT (C)
Carry out the fitting following the instructions in
the figure (C).
123 7
456
8
9
10
A
B
11
(A)
(B)
(C)
D3875
D3962
D3877

15
BURNER START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the following 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 (lockout), 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 lockout.
To view diagnostics, proceed as follows:
- Hold the button down for more than 3 seconds once the red LED (burner lockout) 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 lockout) 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 lockout 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

16
SIGNAL FAULT POSSIBLE CAUSE SOLUTION
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. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetcontrol box (no sooner than 10 s
after the lockout)
4 - Pump is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace
5 - Erroneous electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check connections
6 - Defective control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace
7 - Defective electrical motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace
8 - Defective motor capacitor
(RL 34 MZ - RL 44 MZ single-phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace it
4 pulses The burner starts and
then goes into lockout 9 - Photocell short-circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace photocell
10 - Light is entering or flame is simulated. . . . . . . . . . . . . . . . . . . . . . . . . . .Eliminate light or replace control box
2 pulses After pre-purge and the
safety time, the burner
goes to lockout 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 7 and 10
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 - Defective control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 - Photocell dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean
29 - 1st stage operation of cylinder is faulty. . . . . . . . . . . . . . . . . . . . . . . . . .Change the cylinder
30 - Motor lockout (RL 44 MZ three-phase - RL) . . . . . . . . . . . . . . . . . . . . . .Reset thermal relay
31 - Defective motor command remote control device (RL 44 MZ three-phase - RL) . . Substitute it
32 - Electrical power supply two-phase (RL 44 MZ three-phase). . . . . . . . . .Reset thermal relay
thermal cut-out trips when third phases are re-connected
33 - Incorrect motor rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Change motor electrical connec-
tions
7 pulses Flame detachment 34 - Poorly adjusted head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust, see page 7, fig. (F)
35 - Poorly adjusted or dirty firing electrodes. . . . . . . . . . . . . . . . . . . . . . . . .Adjust, see page 7, 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 - Pump pressure not suitable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust it: between 10 - 14 bar
41 - 1st stage nozzle unsuited to burner or boiler . . . . . . . . . . . . . . . . . . . . .See Nozzle Table, page 6; reduce
1st stage nozzle
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 air damper, see
page 7 and 10
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 disc dirty, loose, or deformed . . . . . . . . . . . . . . . . . . . . .Clean, tighten in place, or replace
68 - Boiler room air vents insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Increase
69 - Too much air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust head andfan air damper, see
page 7 and 10
Dirty combustion head 70 - Nozzle or filter dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace
71 - Unsuitable nozzle delivery or angle . . . . . . . . . . . . . . . . . . . . . . . . . . . .See recommended nozzles, page 6
72 - Loose nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten
73 - Impurities on flame stability spiral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean
74 - Erroneous head adjustment or not enough air . . . . . . . . . . . . . . . . . . . .Adjust, see page 10; open gate
valve
75 - Blast tube length unsuited to boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contact boiler manufacturer
10 pulses 76 - Connection or internal fault
77 - Presence of electromagnetic disturbance. . . . . . . . . . . . . . . . . . . . . . . .Use theradio disturbance protection
kit)