Riello RLS 190/M MZ Quick start guide

20164195 (2) - 11/2020
Installation, use and maintenance instructions
Dual fuel light oil/gas burner
Two-stage progressive or modulating operation gas side / two-stage light oil side
CODE MODEL TYPE
20159361 RLS 190/M MZ 784 T
20159359 RLS 190/M MZ 784 T
20146760 RLS 190/M MZ 784 T
GB

Translation of the original instructions

1 20164195
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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 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 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 7
4.4 Technical data............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rates .................................................................................................................................................................. 9
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Commercial boiler ..................................................................................................................................................... 10
4.10 Burner equipment...................................................................................................................................................... 10
4.11 Burner description ..................................................................................................................................................... 11
4.12 Electrical panel description........................................................................................................................................ 12
4.13 Control box RFGO-A22............................................................................................................................................. 13
4.14 Servomotor (SQN31...).............................................................................................................................................. 14
5 Installation ................................................................................................................................................................................ 15
5.1 Notes on safety for the installation ............................................................................................................................ 15
5.2 Handling .................................................................................................................................................................... 15
5.3 Preliminary checks .................................................................................................................................................... 15
5.4 Preparing the boiler................................................................................................................................................... 16
5.4.1 Boring the boiler plate ............................................................................................................................................... 16
5.4.2 Blast tube length........................................................................................................................................................ 16
5.5 Securing the burner to the boiler............................................................................................................................... 16
5.5.1 Choice of nozzles for 1st and 2nd stage ................................................................................................................... 16
5.6 Nozzle installation ..................................................................................................................................................... 17
5.7 Pump motor rotation.................................................................................................................................................. 18
5.8 Light oil supply........................................................................................................................................................... 19
5.8.1 Double-pipe circuit..................................................................................................................................................... 19
5.8.2 Loop circuit................................................................................................................................................................ 19
5.8.3 Hydraulic circuit diagram ........................................................................................................................................... 20
5.8.4 Hydraulic connections ............................................................................................................................................... 20
5.8.5 Priming pump ............................................................................................................................................................ 20
5.8.6 Suntec J7 C pump..................................................................................................................................................... 20
5.9 Gas supply ................................................................................................................................................................ 21
5.9.1 Gas supply line.......................................................................................................................................................... 21
5.9.2 Gas train.................................................................................................................................................................... 22
5.9.3 Gas train installation.................................................................................................................................................. 22
5.9.4 Gas pressure............................................................................................................................................................. 22
5.10 Electrical wiring ......................................................................................................................................................... 23
5.10.1 Supply cables and external connections passage .................................................................................................... 23
5.11 Calibration of the thermal relay ................................................................................................................................. 24
5.12 Motor rotation ............................................................................................................................................................ 24
6 Start-up, calibration and operation of the burner ................................................................................................................. 25
6.1 Notes on safety for the first start-up .......................................................................................................................... 25
6.2 Adjustments prior to ignition (light oil) ....................................................................................................................... 25
6.2.1 Combustion head adjustment.................................................................................................................................... 25
6.2.2 Pump adjustment ...................................................................................................................................................... 25
6.2.3 Fan damper adjustment ............................................................................................................................................ 25
6.3 Burner ignition (light oil)............................................................................................................................................. 25

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Contents
6.4 Burner adjustment (light oil) .......................................................................................................................................25
6.5 Adjustments prior to ignition (gas) .............................................................................................................................26
6.6 Burner start-up ...........................................................................................................................................................26
6.7 Burner ignition............................................................................................................................................................26
6.7.1 Burner adjustment......................................................................................................................................................26
6.7.2 Ignition output ............................................................................................................................................................26
6.7.3 Maximum output ........................................................................................................................................................27
6.7.4 Minimum output .........................................................................................................................................................28
6.7.5 Intermediate outputs ..................................................................................................................................................28
6.8 Servomotor adjustment..............................................................................................................................................29
6.9 Change of fuel............................................................................................................................................................29
6.10 Pressure switch adjustment .......................................................................................................................................30
6.10.1 Air pressure switch - check CO..................................................................................................................................30
6.10.2 Maximum gas pressure switch...................................................................................................................................30
6.10.3 Minimum gas pressure switch....................................................................................................................................30
6.11 Burner operation ........................................................................................................................................................31
6.11.1 Burner start-up ...........................................................................................................................................................31
6.11.2 Steady state operation ...............................................................................................................................................31
6.11.3 Ignition failure.............................................................................................................................................................31
6.11.4 Final checks (with burner operating)..........................................................................................................................31
7 Maintenance ..............................................................................................................................................................................32
7.1 Notes on safety for the maintenance .........................................................................................................................32
7.2 Maintenance programme ...........................................................................................................................................32
7.2.1 Maintenance frequency..............................................................................................................................................32
7.2.2 Safety test - with no gas supply .................................................................................................................................32
7.2.3 Checking and cleaning...............................................................................................................................................32
7.2.4 Flame presence check...............................................................................................................................................33
7.2.5 Combustion control (gas)...........................................................................................................................................34
7.2.6 Safety components ....................................................................................................................................................34
7.3 Opening the burner ....................................................................................................................................................35
7.4 Closing the burner......................................................................................................................................................35
8 LED indicator and special function.........................................................................................................................................36
8.1 Description of LED lamps ..........................................................................................................................................36
8.2 Check mode function .................................................................................................................................................36
8.3 Flame control lock-out or emergency stop condition .................................................................................................36
8.4 LED lamps: burner operating status ..........................................................................................................................37
9 Problems - Causes - Remedies signalled by LED indicators ...............................................................................................38
A Appendix - Accessories ...........................................................................................................................................................43
B Appendix - Electrical panel layout...........................................................................................................................................45

3 20164195
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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: Dual fuel light oil/ gas burners
Model and type: RLS 190/M MZ 784 T
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
GAR 2016/426/UE Gas Devices Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
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
Dual fuel light oil/gas burners 784T RLS 190/M MZ 550 - 2150 kW
Legnago, 21.04.2018 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini
CE-0085BP0439

20164195 4
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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
Centre 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 warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not
carried out correctly, cause serious injury, death
or long-term health risks.
ATTENTION
This symbol indicates operations which, if not
carried out correctly, may cause serious injury,
death or long-term health risks.
CAUTION
This symbol indicates operations which, if not
carried out correctly, may cause damage to the
machine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not
carried out correctly, lead to electric shocks with
lethal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive
atmosphere may be present. An explosive
atmosphere 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 COVER
AND ALL THE SAFETY AND PROTECTION
DEVICES
This symbol signals the obligation to reassemble
the cover 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 20164195
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Information and general warnings
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
Assistance Centre
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer
recommends the drawing up of a Maintenance Contract.
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
sale 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,
incorrectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
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
established 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
responsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
ATTENTION
Failure to observe the information given in this
manual, operating negligence, incorrect
installation and carrying out of non authorised
modifications will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20164195 6
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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 safety
technical rules 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
confidence 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.
Specifically:
it can be applied to boilers operating with water, steam,
diathermic oil, and to other uses expressly named by the
manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion
chamber and the ambient temperature must all be within the
values indicated in the instruction manual.
Modification of the burner to alter its performance and
destinations is not allowed.
The burner must be used in exemplary technical safety
conditions. 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
responsible for the machine and for the training of the people
working around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties;
Personnel must observe all the danger and caution
indications shown on the machine.
Personnel must not carry out, on their own initiative,
operations 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
compromise 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
ATTENTION
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to
prevent unauthorised people gaining access
to the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident
prevention systems are noticed, along with
any presumed danger situation;
personnel must always use the personal
protective equipment envisaged by legislation
and follow the indications given in this
manual.

7 20164195
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4.3 Burner categories - Countries of destination
4 Technical description of the burner
Designation Start-up Code
RLS 190/M MZ TC TC 3 ~ 400V +/-10% 50 Hz Direct 20159361
RLS 190/M MZ TC TC 3 ~ 230V +/-10% 50 Hz Direct 20159359
RLS 190/M MZ TL TL 3 ~ 400V +/-10% 50 Hz Direct 20146760
Class 2 EN267 - Class 3 EN676
Series: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50
110/50/60
RLS 190 MTC
Emission: C11 or... Class 1 EN267 - EN676
C22 or MZ Class 2 EN267 - EN676
C33 or BLU Class 3 EN267 - EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
MZ
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam and variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Extended head
C23 or MX
C13 Class 1 EN267 - Class 3 EN676
Flame control system:
Standard (1 stop every 24 h)
FS2 Continuous operation only with the use of a flame detection
electrode (ionisation)
FS1
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L - I2E - I2(43.46 ÷ 45.3 MJ/m3(0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E

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Technical description of the burner
4.4 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 5) (Fig. 5) with zero pressure in combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output.
The sound power is measured using the "Free Field" method, required by the EN 15036 standard, and according to an “Accuracy: Category 3”
measurement, as described in EN ISO 3746.
4.5 Electrical data
Tab. B
Model RLS 190/M MZ
Type 784T
Output (1)
Delivery (1)
2nd stage
min - max
kW
kg/h
1100 ÷ 2150
93 ÷ 181
1st stage
min
kW
kg/h
550
46
Fuels – LIGHT OIL, max. viscosity at 20 °C: 6 mm2/s (1.5 °E - 6 cSt)
– NATURAL GAS: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2) -
Gas: G20/G25 mbar 14 / 21
Operation –FS1: Intermittent (min. 1 stop in 24 hours)
– Oil: two-stage (high and low flame) and one-stage (all - nothing)
– Gas: progressive two-stage or modulating by kit (see accessories)
Pump Output at 12 bar
Pressure range
Fuel temperature
kg/h
bar
°c max
230
10 - 21
90
Nozzles number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 85 96
Weight Kg 160
Model RLS 190/M MZ
Code 20159361 - 20146760 20159359
Electric power supply 3 ~ 400V +/-10% 50 Hz 3 ~ 230V +/-10% 50 Hz
Auxiliary circuit electrical supply 1N ~ 220V 60 Hz
Fan motor
Running current
Start-up current
rpm
V
W
A
A
2895
400
4500
8.7
69.6
2895
230
4500
15
120
Pump motor rpm
V
W
A
µF
2700
230
550
3.6
25
Ignition transformer V1 - V2
I1 - I2
230 V - 2 x 5 kV
1.9 A - 35 mA
Absorbed electric power W max (light oil)
W max (gas)
6000
5400
Protection level IP 44

9 20164195
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Technical description of the burner
4.6 Maximum dimensions
The 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 turned on the hinge.
The maximum dimensions of the open burner are indicated by
the L and R positions.
The l position is reference for the refractory thickness of the boiler
door.
Tab. C
4.7 Firing rates
The MAXIMUM OUTPUT is to be chosen within area A of the
diagram (Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RLS 190/M MZ = 550 kW
mm A B C D E F G H I L M N O
RLS 190/M MZ 843 366 477 555 863 412-542 222 430 1442-1587 237 141 186 Rp2
Fig. 1
D3169
ATTENTION
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 25.
Pressure in the chamber
pressure - mbar
Thermal power - kW
D3170
Fig. 2
A

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Technical description of the burner
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram (Fig. 3), consult the
manufacturer.
The firing rates were obtained in special test boilers, according to
EN 676 standard.
In (Fig. 3) you can see the diameter and length of the test
combustion chamber.
Example:
Output 650 Mcal/h
diameter 60 cm
length 2 m
MODULATING RATIO
The modulating ratio, obtained in the test boilers, according to
standard (EN 676 for gas, EN 267 for light oil), is of:
- 3 : 1 (gas);
- 2 : 1 (light oil).
4.9 Commercial boiler
The burner RLS 190/M MZ is suitable for operating on boilers
with combustion chamber with bottom outflow (three passes), on
which the best NOxemissions are obtained.
The boiler front door maximum thickness must not exceed 250
mm (Fig. 4).
4.10 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Seal for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to fix the flange M 10 x 40 to the gas
butterfly valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to fix the burner flange pipe coupling
to the boiler: M 16 x 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Nipples for flexible hoses with gaskets . . . . . . . . . . . . . . . No. 2
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Combustion chamber
m
D715
Fig. 3
Fig. 4
250 mm MAX
D1079

11 20164195
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Technical description of the burner
4.11 Burner description
1 Flame stability disc
2 Ignition electrodes
3 Combustion head
4 Gas pressure test point and head fixing screw
5 Screws to secure fan to pipe coupling
6 Pump motor
7Pump
8 Slide bars for opening the burner and inspecting the
combustion head
9 Electrical control box with lockout pilot light and reset button
10 Air damper
11 Air inlet to fan
12 Gas input pipe
13 Gas butterfly valve
14 Screw for combustion head adjustment
15 Sleeve with flange for securing the burner to the boiler
16 Maximum gas pressure switch
17 Safety valve
18 Servomotor controlling the gas butterfly valve and the air
damper, by means of a variable profile cam mechanism.
When the burner is not operating the air damper 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.
19 Fan motor
20 Extensions for slide bars 8)
21 1st and 2nd stage valves
22 Air pressure test point
23 Flame inspection window
Fig. 5
20159592

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Technical description of the burner
4.12 Electrical panel description
1 Ignition transformer
2 Switch for:
for automatic-manual-off operation
Switch for:
output increase-decrease
3 Motor contactor and thermal relay with reset button
4 Bracket for RWF kit application
5 Protection against radio interference
6 Terminal board for electrical connection
7 Cable-grommets for external connections to be carried out
by the installer
8 Air pressure switch (differential type)
9 Control box base
10 Oil- gas switch
11 Flame sensor
12 Output relay
13 Relay
14 Clean contacts relay
15 Plug for the connection of the RWF kit for modulating opera-
tion
Fig. 6
4
5
6
78910
11
1
2
315
14
12 13
20159602

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Technical description of the burner
4.13 Control box RFGO-A22
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation
operations, assistance, etc.), ensure the wiring is in order
and that the parameters are correctly set, then make the
safety checks.
Falls and collisions can negatively affect the safety
functions. In this case, the control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following
instructions:
– avoid conditions that can favour the development of
condensate and humidity. Otherwise, before switching on
again, make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Use
The control box is a control and supervision system of medium
and large capacity forced draught burners.
If used with the flame detection electrode the system can operate
continuously whereas, with the use of UV sensors it operates
intermittently with stop and restart request at least once every
24h.
Installation notes
• Make sure that the electrical wiring inside the boiler complies
with national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with
neighbouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as
possible from the control box and the other cables.
• When wiring the unit, make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
Technical data
Tab. D
Electrical wiring of the flame detector
It is important for signal transmission to be almost totally free of
any disturbances or loss:
• Always separate the detector cables from the other cables:
– The capacitive reactance of the line reduces the size of the
flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
• The ionisation probe is not protected against the risk of
electrocution. When connected to the electricity supply, the
ionisation probe must be protected against any accidental
contact.
• Position the ignition electrode and the ionisation probe so
that the ignition spark cannot form an arc on the probe (risk
of electric overcharge).
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. The
Manufacturer cannot assume any responsibility
for damage resulting from unauthorised work!
Mains voltage AC 230 V -15% / +10%
Mains frequency 50 / 60 Hz
Primary fuse (external) Refer to the electric
system
Weight approx. 1.1 kg
Power absorption approx. AC 7 VA
Protection level IP40
Safety class II
Environmental conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K2
Class 1M2
-40...+60°C
< 90% RH (non-condensing)
Fig. 7
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Technical description of the burner
4.14 Servomotor (SQN31...)
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the connection area of the
servomotor, fully disconnect the burner control device from
the power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection
terminals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety
functions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• When assembling the servomotor and connecting the
damper, the gears can be disengaged by means of a lever,
allowing the drive shaft to be easily adjusted in both
directions of rotation.
Technical data
Tab. E
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the
actuators.
Operating voltage AC 220...240 V - 15% / +10%
AC 100...110 V - 15% / +10%
Mains frequency 50...60 Hz 6%
Switching capacity of
auxiliary devices and
limit switches
10 (3) A, AC 24...250 V
Angle
positioning up to 160° (full scale)
Assembly position option
Protection level IP 54, DIN 40050
Safety class I
Weight approx. 0.8 kg
Actuator motor synchronous motor
Power absorption 6.5 VA
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-1
Class 1K2
Class 1M2
-20...+60°C
< 95% RH
Fig. 8
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15 20164195
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to handle the burner (still packaged) with a pallet 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 (A)(Fig. 9) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the data for electrical supply and the protection level (E);
the absorbed electrical power (F);
the types of gas used and the relative supply pressures (G);
the data of the burner's minimum and maximum output
possibilities (H)(see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
category of the appliance/countries of destination (I).
light oil maximum viscosity (L).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
ATTENTION
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and
regulations of the laws in force.
DANGER
The combustion air inside the boiler must be free
from hazardous mixes (e.g.: chloride, fluoride,
halogen); if present, it is highly recommended to
carry out cleaning and maintenance more
frequently.
ATTENTION
Burner handling operations can be highly
dangerous if not carried out with the greatest
attention: distance unauthorised personnel, check
integrity and suitability of the means available.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can
quickly move if the burner should fall).
When handling, keep the load at no more than 20-
25 cm 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
burner will be installed.
CAUTION
After removing all the packaging, check the
integrity of the contents. In the event of doubt, do
not use the burner; contact the supplier.
The packaging elements (wooden cage or
cardboard 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.
ATTENTION
A burner label that has been tampered with,
removed or is missing, along with anything else
that prevents the definite identification of the
burner makes any installation or maintenance
work difficult
R.B.L.
GAS- KAASU
GAZ- AEPIO
0085
RIELLOS.p.A.
I-37045 Legnago (VR)
CE
HEIZÖLFUEL
D9243
ABC
EDF
HG
GH
I
L
Fig. 9

20164195 16
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Installation
5.4 Preparing the boiler
5.4.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 10.
The position of the threaded holes can be marked using the
thermal insulation screen supplied with the burner.
5.4.2 Blast tube length
The length of the blast tube must be selected according to the
indications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door
complete with its fettling.
The range of lengths available, L (mm), is as follows:
• standard 412
• extended 542
For boilers with front flue passes 15) (Fig. 11) or flame inversion
chamber, a protection in refractory material 13) (Fig. 11) must be
inserted between the boiler fettling (14) (Fig. 11) and the blast
tube (12) (Fig. 11).
This protection must not compromise the extraction of the blast
tube.
For boilers with a water-cooled front piece, a refractory lining 13)-
14)(Fig. 11) is not necessary, unless expressly requested by the
boiler manufacturer.
5.5 Securing the burner to the boiler
Separate the combustion head from the rest of the burner,
Fig. 11:
disconnect the light oil pipes unscrewing the two fittings (6);
disengage the articulated coupling (7) from the graduated
sector (8);
loosen the 4 screws (3) and remove the cover (1);
remove screws (2) from the two slide bars (5);
remove the two screws (4) and pull the burner back on slide
bars (5) by about 100 mm;
disconnect the electrode cables, then fully extract the burner
from the slide bars;
fix the pipe coupling with flange (11) to the boiler plate
interposing the insulating gasket (9) supplied.
Use the 4 screws, also supplied, after protecting their thread
with anti-locking product.
5.5.1 Choice of nozzles for 1st and 2nd stage
Both nozzles must be chosen from among those listed in Tab. G.
The first nozzle determines the delivery of the burner at the
1st stage.
The second nozzle works together with the 1st nozzle to
determine the delivery of the burner in the 2nd stage.
The deliveries of the 1st and 2nd stages have to be within the
value range indicated on Tab. A.
Use nozzles with a 60° spray angle at the recommended
pressure of 12 bar.
Generally the two nozzles have the same delivery, but the 1st
stage nozzle can have a delivery that is 50% lower than the total
delivery. This is useful when you want to reduce the back pressure
peak on ignition (the burner provides good combustion values
even with 40-100% ratios between the 1st and 2nd stages).
Example:
boiler output = 1630 kW - yield 90%
power required by the burner = 1630 : 0.9 = 1812 kW;
1812: 2 = 906 kW per nozzle
so two equal nozzles of 60°, 12 bar are required:
1st = 18 GPH - 2nd = 18 GPH,
or the following two different nozzles: 1st = 16 GPH - 2nd = 20
GPH.
mm ABC
RLS 190/M MZ 230 325 - 368 M 16
D455 Fig. 10
ATTENTION
The seal between burner and boiler must be
airtight.
Fig. 11
D3171

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Installation
5.6 Nozzle installation
The burner complies with the emission requirements of EN 267
standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by Riello in the Instruction
and warning booklet should be used.
Remove the screw 1)(Fig. 12) and extract the internal part
2)(Fig. 12).
Assemble the two nozzles with the socket spanner 1)(Fig. 13) (16
mm), after removing the plastic plugs 2)(Fig. 13), passing
through the central opening of the flame stability disc.
Alternatively, loosen the screws 1)(Fig. 14), remove the disc
2)(Fig. 14), and replace the nozzles using the spanner
3)(Fig. 14).
The nozzle for the 1st stage of operation is the one beneath the
ignition electrodes, Fig. 16.
Check that the electrodes are placed as in Fig. 16.
Refit the burner on the slide bars 3)(Fig. 15), approximately 100
mm from the pipe coupling 4)(Fig. 15) - burner in the position
shown in Fig. 11 insert the electrode cables and then slide the
burner up to the pipe coupling, burner in the position shown in
Fig. 15.
Refit screws 2)(Fig. 15) on slide bars 3).
Fix the burner to the pipe coupling with the screws 1).
Reconnect the light oil pipes by screwing the two fittings
6)(Fig. 11).
Reconnect the articulated coupling 7) to the graduated sector 5).
ATTENTION
It is advisable to replace the nozzle once a year
during periodical maintenance.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards
to people and objects.
The manufacturing Company shall not be liable
for any such damage arising from non-
observance of the requirements contained in this
manual.
ATTENTION
Do not use any sealing products such as:
gaskets, tape or sealants.
Be careful to avoid damaging the nozzle
sealing seat.
The nozzle must be screwed into place tightly
but not to the maximum torque value
provided by the wrench.
ATTENTION
Position the ignition electrodes according to the
dimensions shown in Fig. 12.
ATTENTION
On closing the burner on the two guides it is
advisable to gently pull the high voltage wires
outwards until they are under slight tension.
D3172
Fig. 12
Fig. 13
D1146
Fig. 14
D1147
Fig. 15
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Installation
Tab. G
5.7 Pump motor rotation
Refer to Fig. 17 for the pump motor rotation.
ATTENTION
Do not use any sealing products such as:
gaskets, tape or sealants.
Be careful to avoid damaging the nozzle
sealing seat.
The nozzle must be screwed into place tightly
but not to the maximum torque value
provided by the wrench.
Fig. 16
D2995
GPH kg/h kW
10 bar 12 bar 14 bar 12 bar
11.0 42.3 46.7 50.7 553.9
12.0 46.1 50.9 55.3 603.7
13.0 50.0 55.1 59.9 653.5
13.5 51.7 57.0 62.0 681.4
14.0 53.8 59.4 64.5 704.5
15.0 57.7 63.6 69.2 754.3
15.5 59.3 65.5 71.1 782.3
16.0 61.5 67.9 73.8 805.3
17.0 65.4 72.1 78.4 855.1
17.5 67.3 74.2 80.7 880.0
18.0 69.2 76.4 83.0 906.1
19.0 73.0 80.6 87.6 956.0
19.5 75.0 82.7 89.9 980.9
20.0 76.9 84.8 92.2 1005.8
21.5 82.7 91.2 99.1 1081.7
22.0 84.6 93.3 101.4 1106.6
24.0 92.2 101.8 110.6 1207.3
26.0 99.9 110.3 119.9 1308.2
28.0 107.6 118.8 129.1 1409.0
Fig. 17
D8861