Riello RL 70 Quick start guide

20076157 (1) - 07/2013
Installation, use and maintenance instructions
Instructions pour installation, utilisation et entretien
Light oil burners
Brûleurs fioul
Two stage operation
Fonctionnement à 2 allures
CODE MODEL - MODÈLE TYPE
20054723 RL 70 660T2
20054725 RL 70 660T2
20054823 RL 100 661T2
20054825 RL 100 661T2
20054420 RL 130 662T2
20054425 RL 130 662T2
GB
F

1 20076157
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general instructions....................................................................................................................................... 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
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 Models available.......................................................................................................................................................... 7
4.2 Technical data............................................................................................................................................................. 7
4.3 Electrical data.............................................................................................................................................................. 8
4.4 Maximum dimensions.................................................................................................................................................. 8
4.5 Burner equipment........................................................................................................................................................ 8
4.6 Firing rates .................................................................................................................................................................. 9
4.6.1 Test boiler.................................................................................................................................................................... 9
4.7 Burner description ..................................................................................................................................................... 10
5 Installation ................................................................................................................................................................................ 11
5.1 Notes on safety for the installation ............................................................................................................................ 11
5.2 Handling .................................................................................................................................................................... 11
5.3 Preliminary checks .................................................................................................................................................... 11
5.4 Preparing the boiler................................................................................................................................................... 12
5.4.1 Boring the boiler plate ............................................................................................................................................... 12
5.4.2 Blast tube length........................................................................................................................................................ 12
5.5 Securing the burner to the boiler............................................................................................................................... 12
5.5.1 Combustion head calibration..................................................................................................................................... 13
5.6 Choice of nozzles for 1st and 2nd stage ................................................................................................................... 13
5.7 Nozzle assembly ....................................................................................................................................................... 14
5.8 Combustion head setting........................................................................................................................................... 15
5.9 Servomotor................................................................................................................................................................ 15
5.10 Light oil supply........................................................................................................................................................... 16
5.11 Hydraulic connections ............................................................................................................................................... 17
5.12 Pump......................................................................................................................................................................... 17
5.12.1 Pump priming ............................................................................................................................................................ 17
5.13 Electrical wiring ......................................................................................................................................................... 18
5.14 Calibration of the thermal relay ................................................................................................................................. 18
6 Start-up, calibration and operation of the burner ................................................................................................................. 19
6.1 Notes on safety for the first start-up .......................................................................................................................... 19
6.2 Burner firing............................................................................................................................................................... 19
6.3 Operation................................................................................................................................................................... 19
6.4 Operation sequence of the burner............................................................................................................................. 20
6.4.1 Starting phases of the burner.................................................................................................................................... 20
6.5 Steady state operation .............................................................................................................................................. 21
6.6 Firing failure............................................................................................................................................................... 21
6.7 Undesired shutdown during operation....................................................................................................................... 21
6.8 Final checks .............................................................................................................................................................. 21
6.9 Burner start-up cycle diagnostics .............................................................................................................................. 21

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Contents
6.10 Resetting the control box and using diagnostics........................................................................................................22
6.11 Resetting the control box ...........................................................................................................................................22
6.12 Visual diagnostics ......................................................................................................................................................22
6.13 Software diagnostics..................................................................................................................................................22
7 Maintenance ..............................................................................................................................................................................23
7.1 Notes on safety for the maintenance .........................................................................................................................23
7.2 Maintenance programme ...........................................................................................................................................23
7.2.1 Maintenance frequency..............................................................................................................................................23
7.2.2 Checking and cleaning...............................................................................................................................................23
7.3 Opening the burner ....................................................................................................................................................25
7.4 Closing the burner......................................................................................................................................................25
8 Faults - Possible causes - Solutions.......................................................................................................................................26
A Appendix - Accessories ...........................................................................................................................................................29
B Appendix - Electrical panel layout...........................................................................................................................................30

3 20076157
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burners
Model: RL 70 - 100 - 130
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchV
revision 26.01.2010”.
Product Type Model Output
Light oil burners 661T2 RL 100 356 - 1186 kW
662T2 RL 130 486 - 1540 kW
Legnago, 30.07.2013 Executive Director
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. I. Zinna Mr. R. Cattaneo
dvL01-03

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

5 20076157
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Information and general instructions
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assist-
ance Centre
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, 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:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised 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 dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

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Technical description of the burner
4.1 Models available
Tab. A
4.2 Technical data
Tab. B
(1) Reference conditions: Ambient temperature 20 °C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated
output.
4 Technical description of the burner
Designation Voltage Start-up Code
RL 70 TC 3/230-400/50 Direct 20054723
RL 70 TL 3/230-400/50 Direct 20054725
RL 100 TC 3/230-400/50 Direct 20054823
RL 100 TL 3/230-400/50 Direct 20054825
RL 130 TC 3/230-400/50 Direct 20054420
RL 130 TL 3/230-400/50 Direct 20054425
Model RL 70 RL 100 RL 130
Output (1)
Delivery (1)
2nd stage kW
Mcal/h
kg/h
474 - 830
408 - 714
40 - 70
711 - 1186
612 - 1020
60 - 100
948 - 1540
816 - 1325
80 - 130
1nd stage kW
Mcal/h
kg/h
255 - 474
219 - 408
21,5 - 40
356 - 711
306 - 612
30 - 60
486 - 948
418 - 816
41 - 80
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 Continuous (min. 1 stop in 72 hours)
Two-stage (high and low flame) and single-stage (all - nothing)
Nozzles number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Pump delivery (at 12 bar)
pressure range
fuel temperature
kg/h
bar
° C max
107
10 - 20
60
220
10 - 20
60
220
10 - 20
60
Electrical protection IP 44
Noise levels (2) dBA 75,0 77,0 78,5
Weight kg 60 63 66

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Technical description of the burner
4.3 Electrical data
Tab. C
4.4 Maximum 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 dimensions of the open burner are indicated by position I.
Tab. D
(1) Blast tube: short-long
4.5 Burner equipment
2 - Flexible hoses
2 - Gaskets for flexible hoses
2 - Nipples for flexible hoses
1 - Thermal insulation screen
2 Extensions 15)(Fig. 4 at page 10) for slide bars 5)
(for models with 385 mm blast tube)
4 - Studs M12 x 35 to secure the burner flange to the boiler
4 - Washers
4- NutsM12
1 - Instruction booklet
1 - Spare parts list
Model RL 70 RL 100 RL 130
Power supply V
Hz
230 - 400 with neutral ~ +/- 10%
50 - three-phase
Electrical motor IE2 rpm
kW
V
A
2860
1,1
230/400
4,1/2,4
2860
1,5
230/400
5,5/3,4
2860
2,2
230/400
7,9/4,6
Ignition trasformer V1 - V2
I1 - I2
230 V - 2 x 5 kV
1,9 A - 30 mA
Electrical power consumption kW max 1,9 2,5 3,1
Fig. 1
D686
mm ABCDE F
(1) GH I (1)
RL 70 580 296 284 555 680 250 - 385 179 430 951 - 1086
RL 100 599 312 287 555 680 250 - 385 179 430 951 - 1086
RL 130 625 338 287 555 680 250 - 385 189 430 951 - 1086

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Technical description of the burner
4.6 Firing rates
The burners model can work in two ways: one-stage and two-
stage.
1st stage DELIVERY must be selected within area A of the ad-
jacent diagrams.
2nd stage DELIVERY must be selected within area B (and C for
model RL 130). 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.
In order to utilize also area C (RL 130) it is necessary to perform
the calibration of the combustion head as explained on page 13.
4.6.1 Test boiler
The firing rates were set in relation to special test boilers in ac-
cordance with the methods defined in EN 267 standards.
Fig. 3 indicates the diameter and length of the test combustion
chamber.
Example:
delivery 65 kg/hour: diameter = 60 cm; length = 2 m.
Whenever the burner is operated in a much smaller commercial-
ly-available combustion chamber, a preliminary test should be
performed.
combustion chamber pressure mbar combustion chamber pressure mbar combustion chamber pressure mbar
D687
Fig. 2
WARNING
The firing rate area values have been obtained
considering a surrounding temperature of 20 °C,
and an atmospheric pressure of 1000 mbar (ap-
prox. 100 m above sea level) and with the com-
bustion head adjusted as shown on page 15.
Fig. 3
combustion chamber pressure mbar
D688

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Technical description of the burner
4.7 Burner description
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Screw for fixing fan to flange
5 Slide bars for opening the burner and inspecting the com-
bustion head
6 Safety solenoid valve
7Pump
8 Air inlet to fan
9 Air gate valve
10 Servomotor 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.
11 Fan pressure test point
12 Boiler mounting flange
13 Flame stability disk
14 Electrical motor
15 Extensions for slide bars 5)
16 Ignition transformer
17 Motor contactor and thermal cut-out with reset button
18 1st and 2nd stage valve assembly
19 Terminal strip
20 Two switches:
- one "burner off - on"
- one for "1st - 2nd stage operation"
21 Fairleads for wiring carried out by the installer
22 Control box with lock-out pilot light and lock-out reset button
23 Flame inspection window
24 Pump pressure adjustment
25 Photoresistor for flame presence control
26 Min. oil pressure switch
27 Plug for power supply
28 Plug for signals and adjustments
29 Lifting rings
Two types of burner failure may occur:
Control box lock-out:
if the control box 22)(Fig. 4) pushbutton (red led) lights up, it
indicates that the burner is in lock-out. To reset, hold the
pushbutton down for between 1 and 3 seconds.
Motor trip:
release by pressing the pushbutton on thermal cut-out
17)(Fig. 4).
Fig. 4
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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, it is therefore
possible 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
Check the identification label of the burner, showing:
the model (see A in Fig. 5) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the electrical input power (E);
the types of fuel used and the relative supply pressures (F);
the data of the burner's minimum and maximum output pos-
sibilities (G) (see Firing rate)
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
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).
When handling, keep the load at not more than
20-25cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
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 output of the burner must be within the boil-
er's firing rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
D8965
RIELLO S.p.A.
I−37045 Legnago (VR)
0036
A
BC
DE
G
F
Fig. 5

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Installation
5.4 Preparing the boiler
5.4.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in Fig. 6.
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
Tab. E
5.4.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling. The range of lengths available, L (mm), is as
follows:
Blast tube 9): RL 70 RL 100 RL 130
• short 250 250 250
• long 385 385 385
For boilers with front flue passes 12) or flame inversion cham-
bers, protective fettling in refractory material 10) must be inserted
between the boiler's fettling 11) and the blast tube 9).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers having a water-cooled front the refractory fettling 10)-
11)(Fig. 7) is not required unless it is expressly requested by the
boiler manufacturer.
5.5 Securing the burner to the boiler
In order to fix the burner to the boiler, proceed as follows:
loosen the 4 screws 3)(Fig. 7) and remove the cover 1);
lift the burner completely, hooking it to the 3 lifting rings
29)(Fig. 4 at page 10).
Fix the flange 7) to the plate of the boiler interposing the
insulating gasket 8) supplied.
Use the nuts and washers supplied to complete the fixing
operation.
mm A B C
RL 70 185 275-325 M 12
RL 100 185 275-325 M 12
RL 130 195 275-325 M 12
D455 Fig. 6
During lifting, check that the burner remains bal-
anced and in a horizontal position.
The manufacturer accepts no responsibility in the
event that lifting is performed in a manner different
to that described in this manual.
WARNING
The seal between burner and boiler must be air-
tight.
D689 Fig. 7

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Installation
5.5.1 Combustion head calibration
At this point check, for model RL 130, whether the maximum de-
livery of the burner in 2nd stage operation is contained in area B
or in area C of the firing rate. See page 9.
If it is in area B then no operation is required.
If, on the other hand, it is in area C:
unscrew the screws 1)(Fig. 8) and disassemble the blast
tube 5);
unscrew the screws 3) and remove the shutter 4);
tighten the screws 3) on the rod 2);
now refit the blast tube 5) and the screws 1).
Once this operation has been carried out (if it was required),
secure flange 7)(Fig. 7) to the boiler plate interposing the
supplied gasket 8).
Use the 4 screws provided after having protected the thread
with anti-seize products (high-temperature grease, com-
pounds, graphite).
5.6 Choice of nozzles for 1st and 2nd stage
Both nozzles must be chosen from among those listed in Tab. F.
The first nozzle determines the delivery of the burner in the 1st
stage.
The second nozzle works together with the 1st nozzle to deter-
mine the delivery of the burner in the 2nd stage.
The deliveries of the 1st and 2nd stages must be contained within
the value range indicated on page 7.
Use nozzles with a 60° spray angle at the recommended pres-
sure 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 fir-
ing: the burner allows good combustion values also with a
ratio 40 - 100 % between the 1st and 2nd stage;
a delivery higher than 50% of the total delivery whenever
the combustion during the 1st stage must be improved.
Example with the RL 70 model:
Boiler output = 635 kW - efficiency 90 %
Output required by the burner =
635 : 0,9 = 705 kW
705 : 2 = 352 kW per nozzle;
therefore, two equal, 60°, 12 bar nozzles are required:
1° = 7,0 GPH - 2° = 7,0 GPH
or the following two different nozzles:
1° = 6,0 GPH - 2° = 8,0 GPH
or:
1° = 8,0 GPH - 2° = 6,0 GPH
Tab. F
(1) light oil: density 0.84 kg/dm3- viscosity 4.2 cSt/20 °C - tem-
perature 10 °C
Fig. 8
D690
GPH kg/h (1) kW
12 bar
10 bar 12 bar 14 bar
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.30
8.50
9.00
9.50
10.0
10.5
11.0
12.0
12.3
13.0
13.8
14.0
15.0
15.3
16.0
17.0
17.5
18.0
19.0
19.5
20.0
21.5
22.0
19.2
21.1
23.1
25.0
26.9
28.8
30.8
31.9
32.7
34.6
36.5
38.4
40.4
42.3
46.1
47.3
50.0
53.1
53.8
57.7
58.8
61.5
65.4
67.3
69.2
73.0
75.0
76.9
82.7
84.6
21.2
23.3
25.5
27.6
29.7
31.8
33.9
35.2
36.1
38.2
40.3
42.4
44.6
46.7
50.9
52.2
55.1
58.5
59.4
63.6
64.9
67.9
72.1
74.2
76.4
80.6
82.7
84.8
91.2
93.3
23.1
25.4
27.7
30.0
32.3
34.6
36.9
38.3
39.2
41.5
43.8
46.1
48.4
50.7
55.3
56.7
59.9
63.3
64.5
69.2
70.5
73.8
78.4
80.7
83.0
87.6
89.9
92.2
99.1
101.4
251.4
276.3
302.4
327.3
352.3
377.2
402.1
417.5
428.2
453.1
478.0
502.9
529.0
553.9
603.7
619.1
653.5
693.8
704.5
754.3
769.7
805.3
855.1
880.0
906.1
956.0
980.9
1005.8
1081.7
1106.6

20076157 14
GB
Installation
5.7 Nozzle assembly
At this stage of installation the burner is still disassembled from
the blast tube; it is therefore possible to fit two nozzles with the
box spanner 1)(Fig. 9) (16 mm), after having removed the plastic
plugs 2)(Fig. 9), fitting the spanner through the central hole in the
flame stability disk. Do not use any sealing products such as gas-
kets, sealing compound, or tape. Be careful to avoid damaging
the nozzle sealing seat. The nozzles must be screwed into place
tightly but not to the maximum torque value provided by the
wrench.
The nozzle for the 1st stage of operation is the one lying beneath
the firing electrodes (Fig. 10).
Make sure that the electrodes are positioned as shown in
(Fig. 10).
Finally refit the burner 3)(Fig. 11) to the slide bars 2) and slide it
up to the flange 5), keeping it slightly raised to prevent the
flame stability disk from pressing against the blast tube.
Tighten the screws 1) on the slide bars 2) and screws 4) fixing the
burner to the flange.
If it proves necessary to change a nozzle with the burner already
fitted to the boiler, proceed as outlined below:
– Retract the burner on its slide bars as shown in (Fig. 7 at
page 12).
– Remove the nuts 1) (Fig. 12) and the disk 2).
– Use spanner 3)(Fig. 12) to change the nozzles.
NOTE:
The supplied nozzles can be used when meeting the re-
quired delivery only. Otherwise they must be replaced with
complying nozzles.
D691 Fig. 9
Fig. 10
D692
Fig. 11
D693
Fig. 12
D694

15 20076157
GB
Installation
5.8 Combustion head setting
The setting of the combustion head depends exclusively on the
delivery of the burner in the 2nd stage - in other words, the com-
bined delivery of the two nozzles selected on page 13.
Turn screw 4)(Fig. 13) until the notch shown in diagram (Fig. 14)
is level with the front surface of flange 5)(Fig. 13).
Example:
The RL 70 Model with two 6.0 GPH nozzles and 12 bar pump
pressure.
Find the delivery of the two 6.0 GPH nozzles in (Tab. F page 13):
25.5 + 25.5 = 51 kg/h.
Diagram Fig. 14 indicates that for a delivery of 51 kg/h the RL 70
Model requires the combustion head to be set to approx. three
notches, as shown in Fig. 13
5.9 Servomotor
The servomotor adjusts the air gate valve.
The servomotor rotates through 90° in 5 seconds. Do not alter
(for the time-being) the factory setting for the 4 levers.
A graduated plate with 4 coloured sectors marks the lever oper-
ation point (Fig. 15).
Blue lever
Sets the position of the air gate valve while the burner is shut
down: air gate valve closed.
Orange lever
Sets the position of the air gate valve during 1st stage operation.
Red lever
Sets the position of the air gate valve during 2nd stage operation.
Black lever
Establishes when the 2nd stage light oil valve opens.
It must always operate (just) before the red lever and after the or-
ange lever.
It must not operate with the red lever as this may prevent the light
oil valve from opening at all.
It must not operate straight after the orange lever to avoid com-
bustion in the absence of air.
For light oil valve opening to approach that of 2nd stage air gate
valve position, rotate the black lever to the left; to delay opening
time, rotate the lever to the right.
In brief, the levers must be operated in the following sequence:
1 Blue lever
2 Orange lever
3 Black lever
4 Red lever
Fig. 13
D462
Fig. 14
D695
Notches no.
Light oil delivery in 2nd stage kg/h
Fig. 15
D1195
Black
Red
Orange
Blue
Lever

20076157 16
GB
Installation
5.10 Light oil supply
Double-pipe circuit (Fig. 16)
The burner is equipped with a self-priming pump which is capable
of feeding itself within the limits listed in the table at the side.
The tank higher than the burner A
The distance "P" must not exceed 10 meters in order to avoid
subjecting the pump's seal to excessive strain; the distance "V"
must not exceed 4 meters in order to permit pump self-priming
even when the tank is almost completely empty.
The tank lower than the burner B
Pump depression of 0.45 bar (35 cm Hg) must not be exceeded
because at higher levels gas is released from the fuel, the pump
starts making noise and its working life-span decreases.
It is good practice to ensure that the return and suction lines enter
the burner from the same height; in this way it will be less proba-
ble that the suction line fails to prime or stops priming.
The loop circuit
A loop circuit consists of a loop of piping departing from and re-
turning to the tank with an auxiliary pump that circulates the fuel
under pressure. A branch connection from the loop goes to feed
the burner. This circuit is extremely useful whenever the burner
pump does not succeed in self-priming because the tank dis-
tance and/or height difference are higher than the values listed in
the table.
Tab. G
Key
H = Pump/Foot valve height difference
L = Piping length
Ø = Inside pipe diameter
1 = Burner
2=Pump
3=Filter
4 = Manual on/off valve
5 = Suction line
6 = Foot valve
7 = Rapid closing manual valve - remote controlled (only Italy)
8 = On/off solenoid valve (only Italy)
9 = Return line
10 = Check valve (only Italy)
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
Fig. 16
D701
+ H
- H
(m)
L (m)
RL 70
Ø (mm) RL 100 - 130 Ø (mm)
10 12 14 12 14 16
+ 4.0 51 112 150 71 138 150
+ 3.0 45 99 150 62 122 150
+ 2.0 39 86 150 53 106 150
+ 1.0 32 73 144 44 90 150
+ 0.5 29 66 132 40 82 150
0 26 60 120 36 74 137
- 0.5 23 54 108 32 66 123
- 1.0 20 47 96 28 58 109
-2.0133471194281
- 3.0 7 21 46 10 26 53
- 4.0 - 8 21 - 10 25

17 20076157
GB
Installation
5.11 Hydraulic connections
The pumps are equipped with a by-pass that connects return line
with suction line. The pumps are installed on the burner with the
by-pass closed by screw 6)(Fig. 23 at page 20).
It is therefore necessary to connect both hoses to the pump.
The pump will break down immediately if it is run with the return
line closed and the by-pass screw inserted.
Remove the plugs from the suction and return connections of the
pump.
Insert the hose connections with the supplied seals into the con-
nections and screw them down.
Take care that the hoses are not stretched or twisted during in-
stallation.
Install the hoses where they cannot be stepped on or come into
contact with hot surfaces of the boiler.
Now connect the other end of the hoses to the supplied nipples,
using two wrenches, one to hold the nipple steady while using the
other one to turn the rotary union on the hose.
5.12 Pump
1 - Suction G 1/4"
2 - Return G 1/4"
3 - Pressure gauge connectionG 1/8"
4 - Vacuum meter connectionG 1/8"
5 - Pressure adjustment screw
6 - Screw for by-pass
A - Min. delivery rate at 12 bar pressure
B - Delivery pressure range
C - Max. suction depression
D - Viscosity range
E - Light oil max. temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H - Filter mesh width
5.12.1 Pump priming
– Before starting the burner, make sure that the tank return line
is not clogged. Obstructions in the line could cause the sealing
organ located on the pump shaft to break. (The pump leaves
the factory with the by-pass closed).
– In order for self-priming to take place, one of the screws 3)
(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. 20 page 19) in the "ON" position. The pump must ro-
tate in the direction of the arrow marked on the cover.
– The pump can be considered to be primed when the light oil
starts coming out of the screw 3). Stop the burner: switch 1)
(Fig. 20 page 19) set to "OFF" and tighten the screw 3).
The time required for this operation depends upon the diameter
and length of the suction tubing. If the pump fails to prime at the
first starting of the burner and the burner locks out, wait approx.
15 seconds, reset the burner, and then repeat the starting oper-
ation as often as required. After 5 or 6 starting operations allow 2
or 3 minutes for the transformer to cool.
Do not illuminate the photoresistor or the burner will lock out; the
burner should lock out anyway about 10 seconds after it starts.
Whenever the length of the suction piping exceeds 20-30 meters,
the supply line must be filled using a separate pump.
Fig. 17
D696
Fig. 18
D706
RL 70
PUMP SUNTEC AL 95 C
RL 100 - RL 130
PUMP SUNTEC AJ6 CC
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.

20076157 18
GB
Installation
5.13 Electrical wiring
Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
Use flexible cables in compliance with the EN 60 335-1 standard.
5.14 Calibration of the thermal relay
The thermal relay (Fig. 19) serves to avoid damage to the motor
due to an excessive absorption increase or if a phase is missing.
For calibration 2), refer to the table indicated in the electrical lay-
out (electrical wiring in charge of the installer).
To reset, in case of an intervention of the thermal relay, press but-
ton "RESET" 1).
The button “STOP” 3) opens the NC contact (95-96) and stops
the motor.
Insert a screwdriver in the window “TEST/TRIP” 4) and move it in
the arrow direction (to the right) to carry out the thermal relay test.
NOTE:
the burners leave the factory preset for 400V power supply.
If 230V power supply is used, change the motor connection
from star to delta and change the setting of the thermal cut-
out as well.
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
Electrical wiring must be made in accordance with the regulations currently in force in the country of destination
and by qualified personnel. Refer to the wiring diagrams.
The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-
ing diagrams.
Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual.
The burner has been type-approved for continuous use.
This means they should compulsorily be stopped at least once every 72 hours to enable the control box to per-
form checks of its own start-up efficiency. Normally, burner stopping is guaranteed by the boiler's thermostat/pres-
sure switch.
If this is not the case, a time switch should be fitted in series to TL to stop the burner at least once every 72 hours.
Refer to the wiring diagrams.
The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event of
doubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing system
for electrical devices.
The electrical system must be suitable for the maximum power absorption of the device, as indicated on the label
and in the manual, checking in particular that the section of the cables is suitable for that level of power absorp-
tion.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use a multiple pole switch with at least a 3mm gap between the contacts (overvoltage category III), as envis-
aged by the present safety standards.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.
DANGER
Disconnect the electrical supply from the burner
by means of the main system switch.
DANGER
Turn off the fuel interception tap.
DANGER
Avoid condensate, ice and water leaks from form-
ing.
WARNING
The automatic reset can be dangerous.
This operation is not foreseen in the burner oper-
ation.
214
4
12
3
D11655 Fig. 19