Riello RL 42 BLU Quick start guide

20023224 (9) - 09/2016
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Light oil burners
Quemadores de gasóleo
Two stage operation
Funcionamiento a dos llamas
CODE
CÓDIGO MODEL MODELO TYPE TIPO
20027567 RL 42 BLU 998T1
GB
E

1
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual........................................................................................................................ 4
2.1.1 Introduction..................................................................................................................................................................... 4
2.1.2 General dangers............................................................................................................................................................. 4
2.1.3 Danger: live components................................................................................................................................................ 4
2.2 Guarantee and responsibility.......................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction..................................................................................................................................................................... 6
3.2 Personnel training........................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Technical data ................................................................................................................................................................ 7
4.2 Electrical data ................................................................................................................................................................. 7
4.3 Models available............................................................................................................................................................. 7
4.4 Overall dimensions ......................................................................................................................................................... 8
4.5 Firing rate........................................................................................................................................................................ 8
4.6 Test boiler....................................................................................................................................................................... 9
4.6.1 Commercial boilers......................................................................................................................................................... 9
4.7 Packaging - Weight......................................................................................................................................................... 9
4.8 Burner description......................................................................................................................................................... 10
4.9 Burner equipment......................................................................................................................................................... 10
5 Installation ................................................................................................................................................................................ 11
5.1 Notes on safety for the installation................................................................................................................................ 11
5.2 Handling........................................................................................................................................................................ 11
5.3 Preliminary checks........................................................................................................................................................ 11
5.4 Operating position......................................................................................................................................................... 12
5.5 Preparing the boiler ...................................................................................................................................................... 12
5.5.1 Boring the boiler plate................................................................................................................................................... 12
5.6 Securing the burner to the boiler .................................................................................................................................. 13
5.7 Nozzle installation......................................................................................................................................................... 13
5.7.1 Choice of nozzle........................................................................................................................................................... 13
5.7.2 Recommended nozzle.................................................................................................................................................. 13
5.7.3 Nozzle assembly........................................................................................................................................................... 14
5.8 Hydraulic system .......................................................................................................................................................... 15
5.8.1 Fuel supply ................................................................................................................................................................... 15
5.8.2 Double-pipe siphon-type systems................................................................................................................................. 15
5.8.3 Double-pipe suction-type systems................................................................................................................................ 15
5.8.4 Single-pipe systems...................................................................................................................................................... 16
5.8.5 The loop circuit ............................................................................................................................................................. 16
5.8.6 Hydraulic connections................................................................................................................................................... 16
5.8.7 Pump ............................................................................................................................................................................ 17
5.8.8 Pump priming................................................................................................................................................................ 17
6 Start-up, calibration and operation of the burner ................................................................................................................. 18
6.1 Notes on safety for the first start-up.............................................................................................................................. 18
6.2 Adjustments before first firing ....................................................................................................................................... 18
6.2.1 Combustion head setting.............................................................................................................................................. 18
6.2.2 Pump adjustment.......................................................................................................................................................... 18
6.2.3 Fan gate adjustment..................................................................................................................................................... 18
6.2.4 Servomotor................................................................................................................................................................... 19
6.3 Burner calibration.......................................................................................................................................................... 19
6.3.1 Firing............................................................................................................................................................................. 19
6.3.2 Operation...................................................................................................................................................................... 19
6.3.3 Combustion head.......................................................................................................................................................... 19
6.4 Burner operation........................................................................................................................................................... 20
6.4.1 Burner starting.............................................................................................................................................................. 20
6.4.2 Steady state operation.................................................................................................................................................. 21

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Contents
6.4.3 Firing failure...................................................................................................................................................................21
6.4.4 Undesired shutdown during operation...........................................................................................................................21
6.5 Final checks ..................................................................................................................................................................21
7 Maintenance ..............................................................................................................................................................................22
7.1 Notes on safety for the maintenance.............................................................................................................................22
7.2 Maintenance programme ..............................................................................................................................................22
7.2.1 Maintenance frequency.................................................................................................................................................22
7.2.2 Checking and cleaning..................................................................................................................................................22
7.3 Burner start-up cycle diagnostics ..................................................................................................................................23
7.4 Resetting the control box and using diagnostics...........................................................................................................23
7.4.1 Resetting the control box...............................................................................................................................................24
7.4.2 Visual diagnostics..........................................................................................................................................................24
7.4.3 Software diagnostics.....................................................................................................................................................24
7.5 Opening burner .............................................................................................................................................................24
7.6 Closing the burner.........................................................................................................................................................24
8 Faults - Possible causes - Solutions.......................................................................................................................................25
A Appendix - Electrical connections ..........................................................................................................................................27

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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burner
Model: RL 42 BLU
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.riello.com
Distributed 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 declara-
tion and they are produced and placed in circulation in conformity with the provisions defined in L.D. dated January 8, 2004 and July
17, 2009.
Type of product: Light oil burner
Model: RL 42 BLU
Regulation applied: EN 267 and A.R. dated January 8, 2004 - July 17, 2009
Values measured: CO max: 5 mg/kWh
NOx max: 69 mg/kWh
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard
“1. BImSchV reliese 26.01.2010”.
Product Type Model Power
Light oil burner 998T1 RL 42 BLU 191 - 598 kW
Legnago, 01.12.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
➤is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the
burner even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
➤is designed for use by qualified personnel;
➤offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Danger: live components
Other symbols
➤This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
➤the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
➤The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assis-
tance Centre.
➤The system supplier must carefully inform the user about:
- how to use the system,
- any further tests that may be required before activating
the system,
- maintenance, and the fact that the system should be
checked at least once a year by a representative of the
manufacturer or another specialised technician.
To ensure a periodic check, the Manufacturer recom-
mends the drawing up of a Maintenance Contract.
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
riedout correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
........................................................................................
........................................................................................
........................................................................................
........................................................................................

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Information and general warnings
2.2 Guarantee and responsibility
The Manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
➤the incorrect installation, start-up, use and maintenance of
the burner;
➤the improper, incorrect or unreasonable use of the burner;
➤the intervention of unqualified personnel;
➤the carrying out of unauthorised modifications on the equip-
ment;
➤the use of the burner with safety devices that are faulty,
incorrectly applied and/or not working;
➤the installation of untested supplementary components on
the burner;
➤the powering of the burner with unsuitable fuels;
➤faults in the fuel power supply system;
➤the use of the burner even following an error and/or an
irregularity;
➤repairs and/or overhauls incorrectly carried out;
➤the modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
➤the insufficient and inappropriate surveillance and care of
those burner components most likely to be subject to wear
and tear;
➤the use of non-original components, including spare parts,
kits, accessories and optionals;
➤force majeure.
The Manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and the carrying out of unauthorised modifica-
tions will result in the annulment by the
Manufacturer of the guarantee that it supplies with
the burner.

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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
➤The burner must only be used as expressly described. Any
other use should be considered improper and therefore
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the man-
ufacturer;
the type and pressure of the fuel, the voltage and frequency
of the electrical power supply, the minimum and maximum
deliveries for which the burner has been regulated, the
pressurisation of the combustion chamber, the dimensions
of the combustion chamber and the room temperature must
all be within the values indicated in the instruction manual.
➤Modification of the burner to alter its performance and desti-
nations is not allowed.
➤The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety
must be quickly eliminated.
➤Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
➤Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
➤undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
➤must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
➤undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
➤must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
➤Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
➤Personnel must observe all the danger and caution indica-
tions shown on the machine.
➤Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
➤Personnel must inform their superiors of every problem or
dangerous situation that may arise.
➤The assembly of parts of other makes or any modifications
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
3 Safety and prevention

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Technical description of the burner
4.1 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated
output. The sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category
3” measuring accuracy, as set out in EN ISO 3746.
4.2 Electrical data
Motor IE2
Tab. B
4.3 Models available
4 Technical description of the burner
Model RL 42 BLU
Output
(1)
Delivery
(1)
2
nd
stage
(high pressure) kW Mcal/h
kg/h
323 - 598
278 - 514
27 - 50.3
1
st
stage
(low pressure) kW Mcal/h
kg/h
191 - 311
164 - 267
16 - 26.2
Fuel
- Net calorific value
- Density
- Viscosity at 20 °C
kWh/kg
Mcal/kg
kg/dm
3
mm
2
/s max
Light oil
11.8
10.2 (10.200 kcal/kg)
0.82 - 0.85
6 (1.5 °E - 6 cSt)
Operation - Intermittent (min. 1 stop in 24 hours)
- Two-stage (high and low flame) and single-phase (all - nothing)
Pump - delivery (at 12 bar)
- pressure range
- fuel temperature
kg/h
bar
°C max
60
4 - 25
60
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels
(2)
Sound pressure
Sound power dB(A) 76 87
Model RL 42 BLU
Electrical supply 230-400V/3/50Hz
Electric motor rpm
W
V
A
2880
1100
230/400
4.3 - 2.5
Capacitor µF/V 12.5/450
Ignition trasformer V1 - V2
I1 - I2 230 V - 2 x 12 kV 0.2 A - 30 mA
Electrical power consumption W max 1650
Electrical protection IP 44
Designation Voltage Code
RL 42 BLU 230-400/3/50 20027567

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Technical description of the burner
4.4 Overall dimensions
The maximum dimensions of the burner are given in Fig. 1.
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 I.
Tab. C
4.5 Firing rate
The burners can work in two ways: one-stage and two-stage.
1
st
stage DELIVERY must be selected within area Aof the adja-
cent diagrams.
2
nd
stage DELIVERY must be selected within area B.
This area provides the maximum delivery of the burner in relation
to the pressure in the combustion chamber.
The work point may be found by plotting a vertical line from the
desired delivery and a horizontal line from the pressure in the
combustion chamber.
The intersection of these two lines is the work point which must
lie within area B.
D
CB A
I
G
E F
H
L
Fig. 1
D7461
mm A B C D E F G H I L
RL 42 BLU 533 300 238 490 477 291-316 163 335 680 - 815 60
WARNING
The firing rate area values have been obtained
considering a surrounding temperature of 20
°C, and an atmospheric pressure of 1000 mbar
(approx. 100 m above sea level) and with the
combustion head adjusted as shown on pag. 18.
AB
Fig. 2
D10340
Combustion chamber
pressure - mbar

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Technical description of the burner
4.6 Test boiler
The firing rate was set in relation to special test boilers in accord-
ance with the methods defined in EN 267 standards.
Fig. 3 indicates the diameter and length of the test combustion
chamber.
Example:
Delivery 16 kg/h
diameter 40 cm
length 1 m
Whenever the burner is operated in a much smaller commercial-
ly-available combustion chamber, a preliminary test should be
performed.
4.6.1 Commercial boilers
The burners are designed exclusively for combustion chambers
with flue gas outlet from the bottom (for example three flue gas
passes), accessible via the door.
Max thickness of the frontal boiler wall: 150 mm.
4.7 Packaging - Weight
The burners are shipped in cardboard boxes with the maximum
dimensions shown in Tab. D.
The weight of the burner complete with packaging is indicated in
Tab. D.
Tab. D
Fig. 3
D814
Combustion chamber
length - m
Fig. 4
D1863
150 mm max.
mm A B C Kg
RL 42 BLU 1200 520 42
Fig. 5
D88

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Technical description of the burner
4.8 Burner description
1Ignition electrodes
2Combustion head
3Screw for combustion head adjustment
4UV Sensor for flame presence control
5Screw for fixing fan to flange
6Servomotor
7Slide bars for opening the burner and inspecting the com-
bustion head
8Pressure stage pump
9Plate prearranged to drill 4 holes for the passage of hoses
and electrical cables.
10 Air inlet to fan
11 Fan pressure test point
12 Boiler mounting flange
13 Flameholder
14 Flame inspection window
15 Starter
16 Extensions for slide bars 7)
17 Control box with lock-out pilot light and lock-out reset button
18 Two switches:
- one "burner off - on"
- one for "1
st
- 2
nd
stage operation"
19 Plugs for electrical connections
20 Air gate valve
21 Pump adjustment (low pressure)
22 Pump adjustment (high pressure)
23 Motor protection
NOTE:
If the control box 18)(Fig. 6) pushbutton lightsup, it indicates that
the burner is in lock-out.
To reset,press the pushbutton, no sooner than 10 safter the lock-
out.
4.9 Burner equipment
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flexible hoses (L = 1530 mm) . . . . . . . . . . . . . . . . . . . . . . No. 2
Gaskets for flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Nipples for flexible hoses. . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M8 x 25 to secure the burner flange to the boiler . No. 4
Fairleads for electrical connections . . . . . . . . . . . . . . . . . . No. 3
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 6
D10339
D1861
D1866
D1865
Partial view from H
H

11
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, so it is possi-
ble to move the burner (still packaged) with a transpallet truck or
fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Controllare la targhetta di identificazione del bruciatore, nella
quale sono riportati:
➤the model A)(Fig. 7) and type of burner B);
➤the year of manufacture, in cryptographic form C);
➤the serial number D);
➤the electrical power consumption E);
➤the types of fuel used and the relative supply pressures F);
➤the data of the burner's minimum and maximum output pos-
sibilities G) (see Firing rate).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations MUST be carried out with the electrici-
ty supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
During the handling, keep the load at not more
than 20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected
and disposed of in the appropriate places.
WARNING
The burner output must be within the boiler's firing
rate.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
and makes any installation or maintenance work
difficult.
Fig. 7
ABC
D E
G
F
D10539

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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in Fig. 10.
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
Tab. E
WARNING
The burner is designed to work only in the posi-
tions 1, 2, 3 and 4 (Fig. 8).
Installation 1is preferable, as it is the only one
that allows the maintenance operations as de-
scribed in this manual.
Installations 2, 3 and 4 allow the working, but
make the operations of maintenance and check-
ing of the combustion head more difficult pag. 18.
DANGER
Any other position could compromise the correct
working of the appliance.
Installation 5is forbidden, for safety reasons.
Fig. 8
D7466
1 2 3 4 5
WARNING
Before assembling the casing, it is necessary to
fix the engine protection supplied 1)(Fig. 9) onto
the bracket 2) using the appropriate screws 3)
with a nut and a washer.
Fix the bracket to the front shield of the burner, us-
ing the screws 4).
Fig. 9
4
3
1
2
D7648
mm A B C
RL 42 BLU 185 275 - 325 M12
D455
Fig. 10

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Installation
5.6 Securing the burner to the boiler
Protective fettling in refractory material 8) must be inserted be-
tween the boiler's fettling 9) and the blast tube 7).
➤This protective fettling must not compromise the extraction
of the blast tube.
➤Remove the screws 2) from the two slide bars 3).
➤Remove the screw 1) fixing the burner 4) to the flange 5).
➤Withdraw the combustion head 10) from the burner 4).
➤Secure flange 5) to the boiler plate interposing the supplied
gasket 6).
➤Use the 4 screws provided after having protected the thread
with antiscruffing products (high-temperature grease, com-
pounds, graphite). The burner-boiler seal must be airtight.
5.7 Nozzle installation
The burner complies with the emission requirements of the
EN 267 standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by the manufacturer in the In-
struction and warning booklet should be used.
5.7.1 Choice of nozzle
The nozzle must be chosen from among those listed in Tab. F.
The deliveries of the 1
st
and 2
nd
stages must be contained within
the value range indicated on pag. 8.
Tab. F
5.7.2 Recommended nozzle
• Delavan type A 60°
Fig. 11
D1751
WARNING
It is advisable to replace nozzles every year dur-
ing regular maintenance operations.
CAUTION
The use of nozzles other than those specified by
the manufacturer and inadequate regular mainte-
nance may result into emission limits non-con-
forming to the values set forth by the regulations
in force, and in extremely serious cases, into po-
tential hazards to people and objects.
The manufacturing company shall not be liable for
any such damage arising from nonobservance of
the requirements contained in this manual.
GPH Kg/h
8 bar 10 bar 11 bar 12 bar 14 bar 21 bar
6 20.4 22.4 23.6 24.6 26.4 32.2
6.5 22.1 24.3 25.5 26.7 28.5 34.9
7 23.8 26.2 27.5 28.7 30.7 37.6
7.5 25.5 28 29.5 30.8 32.9 40.3
8 27.2 29.9 31.4 32.8 35.1 43
8.5 28.9 31.8 33.4 34.9 37.3 45.7
9 30.6 33.6 35.3 37 39.5 48.4
9.5 32.3 35.5 37.3 39 41.7 51.1
10 34 37.4 39.3 41.1 43.9 53.8
WARNING
Use nozzles Delavan type A 60°.
In case of moisture due to narrow combustion
chamber, it is possible to use nozzles Delavan
type A 45°.

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Installation
5.7.3 Nozzle assembly
➤Loosen the screws 2)(Fig. 12) and remove the flameholder
unit 1), remove the plastic plugs 3) and assemble the noz-
zles: do not use any sealing products such as gaskets, seal-
ing compound, or tape.
➤Be careful to avoid damaging the nozzle sealing seat.
➤The nozzles must be screwed into place tightly but not to
the maximum torque value provided by the wrench.
➤Make sure that the electrodes are positioned as shown in
Fig. 13.
➤Finally remount the burner 4)(Fig. 14) to the slide bars 3)
and slide it up to the flange 5), keeping it slightly raised to
prevent the flameholder unit from pressing against the slide
bars 6) of the blast tube.
➤Tighten the screws 2)(Fig. 14) on the slide bars 3) and
screw 1) that attaches the burner to the flange.
➤If it proves necessary to change the nozzle with the burner
already fitted to the boiler, open the burner on the slide bars
as shown in Fig. 11, pag. 13, after having mounted the
extensions 16)(Fig. 6, pag. 10), and proceed as described
above.
NOTE:
The nozzle supplied may be used if it matches required de-
livery, otherwise it should be replaced with a different one
whose delivery suits the system.
Fig. 12
D1752
Fig. 13
D1753
Fig. 14
D818

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Installation
5.8 Hydraulic system
5.8.1 Fuel supply
The burner is equipped with aself-priming pump which is capable
of feeding itself within the limits listed in the table at the side.
There are three types of fuel hydraulic circuits:
– Double-pipe circuits (the most common)
– Single-pipe circuits
– Loop circuits
According to the burner/tank layout, either of two fuel supply sys-
tems can be used:
• siphon-type (with the tank higher than the burner)
• suction-type (with the tank lower than the burner)
5.8.2 Double-pipe siphon-type systems
The distance P (A, Fig. 15) must not exceed 10 meters in order
to avoid subjecting the pump's seal to excessive strain; the dis-
tance V must not exceed 4 meters in order to permit pump self-
priming even when the tank is almost completely empty.
5.8.3 Double-pipe suction-type systems
Pump depression values higher than 0.45 bar (35 cm Hg)(B,
Fig. 15) must not be exceeded because at higher levels gas is re-
leased from the fuel, the pump starts making noise and its work-
ing 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 more im-
probable that the suction line fails to prime or stops priming.
Useful suggestions for both systems A and B
➤Use copper pipes whenever possible.
➤Any curves used in the system should be made with the
widest possible radius.
➤Use biconic connectors at both ends of the pipe.
➤Whenever the burner is installed in areas with extremely
cold winter climates (temperatures lower than - 10°C), we
recommend insulating both the tank and the piping. Avoid
the smallest of the three pipe diameters provided in the
Table and lay the piping along the most sheltered route pos-
sible. The paraffin in the fuel begins to solidify below 0°C,
and the filters and nozzle begin to clog accordingly.
➤Install a filter on the suction lines with a transparent plastic
bowl if possible in order to permit the regular flow of fuel and
quick checking of the state of the filter.
➤The return pipe does not require an on/off valve, but if the
user desires to insert one, a lever-type valve should be
selected which clearly indicates when the valve is open or
closed (if the burner starts with the return pipe closed, the
sealing organ located on the pump shaft will break).
➤Copper pipes must be installed to a position with respect to
the burner that allows the latter to be fully retracted on its
slide bars without stretching or twisting the flexible hoses.
➤If more than one burner is operating in the same room, each
one must be equipped with its own suction pipe; the return
pipe may be shared by all, providing it is sufficiently sized.
➤The suction line must be perfectly airtight. In order to check
the seal, close the pump's return line. Install a T union on
the vacuum meter attachment.
On one branch of this T install a pressure gauge and on the
other branch inject air at a pressure of 1 bar. After the air
injection, the gauge must remain at a constant pressure.
Tab. G
Legend (Fig. 15)
HPump/Foot valve height difference
LPiping length
values calculated for light oil:
• viscosity 6 cSt / 20 °C
• density 0,84 kg/dm
3
• temperature 0 °C
• max. altitude 200 m (s.l.m.)
øInside pipe diameter
1Burner
2Pump
3Filter
4Manual on/off valve
5Suction line
6Foot valve
7Return line
+H -H L m
m ø 8 mm ø 10 mm ø 12 mm
+4
+3
+2
+1
+0,5
52
46
39
33
30
134
119
104
89
80
160
160
160
160
160
0 27 73 160
-0,5
-1
-2
-3
-4
24
21
15
8
-
66
58
43
28
12
144
128
96
65
33
Fig. 15
20101772

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Installation
5.8.4 Single-pipe systems
There are two solutions possible:
➤Pump external by-pass (A, Fig. 16) (recommended)
Connect the two flexible hoses to an automatic degassing
unit.
In this case screw 7)(Fig. 25) must not be removed: pump in-
ternal by-pass closed.
➤Pump internal by-pass (B, Fig. 16)
Connect only the flexible suction hose to the pump.
Remove screw 7)(Fig. 25), which can be accessed from the
return union: pump internal by-pass open.
Plug the pump return line connection.
This solution is possible only with low pump depression val-
ues (max. 0.2 bar) and perfectly-sealed piping.
5.8.5 The loop circuit
A loop circuit consists of a loop of piping departing from and re-
turning to the tank with an auxiliary pump that circulates the fuel
under pressure.
A branch connection from the loop goes to feed the burner.
This circuit is extremely useful whenever the burner pump does
not succeed in self-priming because the tank distance and/or
height difference are higher than the values listed in the Tab. G.
5.8.6 Hydraulic connections
The pumps are equipped with a by-pass that connects return line
with suction line.
The pumps are installed on the burner with the by-pass closed by
screw 7)(Fig. 25). It is therefore necessary to connect both hoses
to the pump.
The pump will break down immediately if it is run with the return
line closed and the by-pass screw inserted.
Remove the plugs from the suction and return connections of the
pump.
Insert the hose connections with the supplied seals into the con-
nections and screw them down.
Take care that the hoses are not stretched or twisted during in-
stallation.
Route the hoses through the holes in the plate, preferably using
those on the rh side:
➤unscrew the screws 1)(Fig. 17), 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 nip-
ples, using two wrenches, one to hold the nipple steady
while using the other one to turn the rotary union on the
hose.
Fig. 16
D828
A B
Fig. 17

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Installation
5.8.7 Pump
Legend (Fig. 18)
1Suction G 1/4”
2Return with screw for by-pass G 1/4”
3Outlet at the nozzle G 1/8”
4Pressure gauge attachment G 1/8”
5Vacuum meter attachment G 1/8”
6Screw for low pressure regulation
7Screw for high pressure regulation
8Pressure output or pressure gauge attachment
9Low/high pressure switch valve
10 Safety valve
5.8.8 Pump priming
➤Also check to make sure that the valves located on the suc-
tion line are open and that there is sufficient fuel in the tank.
➤In order for self-priming to take place, one of the screws 4)-
8)(Fig. 18) of the pump must be loosened in order to bleed
off the air contained in the suction line.
➤Start the burner by closing the control devices and with
switch 1)(Fig. 19) 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 4) or 8). Stop the burner:
switch 1)(Fig. 19) set to “OFF” and tighten the screw 4) or
8).
The time required for this operation depends upon the diameter
and length of the suction tubing.
If the pump fails to prime at the first starting of the burner and the
burner locks out, wait approx. 15 seconds, reset the burner, and
then repeat the starting operation as often as required.
After 5 or 6 starting operations allow 2 or 3 minutes for the trans-
former to cool.
Technical data
Min. delivery rate at 12 bar pressure 60 kg/h
Delivery pressure range 4 - 25 bar
Max. suction depression 0.45 bar
Viscosity range 2 - 12 cSt
Light oil max. temperature 60° C
Max. suction and return pressure 2 bar
Pressure calibration in the factory high pressure 22 bar
low pressure 9 bar
Filter mesh width 0.150 mm
Fig. 18
D1475
WARNING
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).
WARNING
The a.m. operation is possible because the pump
is already full of fuel when it leaves the factory.
If the pump has been drained, fill it with fuel
through the opening on the vacuum meter prior to
starting; otherwise, the pump will seize.
Whenever the length of the suction piping ex-
ceeds 20-30 meters, the supply line must be filled
using a separate pump.
Fig. 19
1 2
1°
2°
D469
Off
On
StageBurner

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Start-up, calibration and operation of the burner
6.1 Notes on safety for the first start-up
6.2 Adjustments before first firing
6.2.1 Combustion head setting
The setting of the combustion head depends exclusively on the
delivery of the burner in the 2
nd
stage - in other words, the com-
bined delivery of the two nozzles selected on pag. 13.
Turn screw 4)(Fig. 20) until the notch shown in diagram (Fig. 21)
is level with the front surface of flange 5)(Fig. 20).
Example:
Burner with 8.00 GPH nozzle and 14 bar pump pressure: from
Tab. F, pag. 13 a delivery of 35.1 kg/h is obtained.
Diagram (Fig. 21) indicates that for a delivery of 35.1 kg/h the
burner requires the combustion head to be set to approx. 4 notch-
es, as shown in Fig. 20.
6.2.2 Pump adjustment
No settings are required for the pump, which is set by the manu-
facturer to:
– 22 bar: high pressure
– 9 bar: low pressure
this pressure must be checked and adjusted (if required) after the
burner has been ignited.
6.2.3 Fan gate adjustment
For the first time the burner is fired leave the factory setting un-
changed for both 1
st
stage and 2
nd
stage operation.
In summing up, the adjustments to be executed prior to the first
firing are:
➤Selection and installation of the nozzle
➤Adjustment of combustion head
The following aspects need not be modified:
➤Pump pressure
➤Air gate valve adjustment, 1
st
stage
➤Air gate valve adjustment, 2
nd
stage
6 Start-up, calibration and operation of the burner
WARNING
The first start-up of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
Check the correctworking of the adjustment, com-
mand and safety devices.
Fig. 20
D819
Fig. 21
Light oil delivery in 2
nd
stage - Kg/h
No. noches
⇒