Riello RLS 38/E Quick start guide

20027066 (9) - 03/2016
Installation, use and maintenance instructions
Dual fuel light oil/gas burners
Progressive two-stage or modulating operation for gas applications
Progressive two-stage operation for light oil applications
CODE MODEL
20110085 RLS 38/E
C9333453 RLS 50/E
C9333400 - C9333410 - C9333401 RLS 50/E
GB

Original instructions

1
20027066
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Delivery of the system and the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Packaging - weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Burner dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Control box for the air/fuel ratio (LMV36.5...). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Actuators (SQM33.5...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Nozzle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7.1 Choice of nozzles for 1st and 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7.2 Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.8 Burner refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9.1 Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.10 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10.1 Fuel supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.11 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.12 Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.13 Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.14 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.15 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.15.1 Supply cables and external connections passage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Adjustments before first firing - light oil operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.1 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.2 Minimum oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.3 Pump adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3 Adjustments before first firing - gas operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.1 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Contents
5.4 Burner start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.1 Adjusting gas/air delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.2 Adjusting oil/air delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 Burner calibration - light oil operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.1 Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.3 Minimum oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Burner calibration - gas oparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6.1 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.8 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.9 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.1 To close the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
B Appendix - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Information and general instructions
1.1 Information about the instruction manual
1.1.1 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 sys-
tem. 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 youwill see triangular DANGER signs.
Pay great attention to these, as they indicate a situation of potential
danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 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 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 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 DEVICES
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 ma-
chine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤This symbol indicates a list.

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Information and general instructions
1.1.4 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 Assis-
tance 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.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installation
date, in accordance with the regulations in force and/or the sales
contract. At the moment of the first start-up, check that the burner
is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to peo-
ple, 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;
➤use of the burner even following an error and/or an irregularity;
➤repairs and/or overhauls incorrectly carried out;
➤modification of the combustion chamber with inserts that pre-
vent 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;
➤the use of non-original components, including spare parts,
kits, accessories and optional;
➤force majeure.
The manufacturer furthermore declines any and every respon-
sibility for the failure to observe the contents of this manual.
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WARNING
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.

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Safety and prevention
2.1 Introduction
The burners have been designed and built in compliance with cur-
rent 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, 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 room temperature must all be within the values indicated in
the instruction manual.
➤Modification of the burner to alter its performance and destina-
tions is not allowed.
➤The burner must be used in exemplary technical safety condi-
tions. 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.
2.2 Personnel training
The user is the person, body or company that has acquired the ma-
chine and intends to use it for the specific purpose. He is responsi-
ble 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, he 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, 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:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
➤the user 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 pro-
tective equipment envisaged by legislation and
follow the indications given in this manual.

20027066
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Technical description of the burner
3.1 Technical data
Tab. A
(1)
Reference conditions: ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2)
Pressure at test point 7) (Fig. 2 at page 8) with zero pressure in the combustion chamber and maximum burner output.
(3)
Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output.
The sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set
out in EN ISO 3746.
(4)
Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
3.2 Electrical data
Tab. B
3 Technical description of the burner
Model RLS 38/E RLS 50/E
Output
(1)
Delivery
(1)
2
nd
stage MBtu/hr
(4)
kW
GPH
882 - 1666
258 - 488
6.3 - 11.9
1092 - 2198
320 - 644
7.8 - 15.7
min. 1
st
stage MBtu/hr
(4)
kW
GPH
434
127
3.1
546
160
3.9
Fuel #2 Light oil
Natural gas / Propane gas
Gas pressure at maximum delivery
(2)
Gas: Natural gas ” WC 5.11 5.51
Operation Light oil: low-high-low
Gas: low-high-low or modulating
Nozzles number 2
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Noise Levels
(3)
Sound pressure
Sound power dB(A) 70 81 72 83
Model RLS 38/E RLS 50/E
RBNA Code 20110085 C9333453
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/-10%) V/Ph/Hz 120/1/60
Fan motor rpm
W - HP
V
A
3400
370 - 0.5
120
5.2
3450
550 - 0.75
115
9.8
Motor capacitor µF 50 20
Pump motor rpm
V
W - HP
A
3250
120
90 - 0.12
2.2
Pump motor capacitor µF 12.5
Ignition transformer
Oil V1 - V2
I1 - I2 120 V - 2 x 5 kV 3.7 A - 35 mA
Gas V1 - V2
I1 - I2 120 V - 1 x 7 kV 1.6 A - 23 mA
Electrical power consumption W 600 1100
Electrical control circuit cons. W max 750
Total electrical consumption W 1350 1850
Electrical protection NEMA 1

7
20027066
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Technical description of the burner
Tab. C
3.3 Burner models designation
Tab. D
3.4 Packaging - weight
The burners are skid mounted. Outer dimensions of packaging are
indicated in (Tab. E).
The weight of the burner complete with packaging is indicated in
(Tab. E).
Tab. E
Model RLS 50/E
RBNA Code C9333400 C9333410 C9333401
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/-10%) V/Ph/Hz 208-220/3/60 460/3/60 575/3/60
Fan motor rpm
W - HP
V
A
3400
550 - 0.75
208 - 230
3.2
3400
550 - 0.75
460
1.6
3450
550 - 0.75
575
1.3
Pump motor
Pump motor capacitor
rpm
W - HP
V
A
µF
3250
90 - 0.12
120
1.55
12.5
Ignition transformer V1 - V2
I1 - I2 120 V - 2 x 5 kV 2.7 A - 30 mA
Electrical power consumption W 950
Electrical control circuit cons. W max 750
Total electrical consumption W 1700
Electrical protection NEMA 1
Model Code RBNA code Voltage Flame safeguard
RLS 38/E 20109673 20110085 120/1/60 Burner mounted
RLS 50/E 20108619 C9333453 120/1/60 Burner mounted
RLS 50/E 20027085 C9333400 208/220/3/60 Burner mounted
C9333410 460/3/60
RLS 50/E 20025562 C9333401 575/3/60 Burner mounted
inch A B C lbs
RLS 38/E 47
1
/
4“
23
5
/
8“
27
31
/
32“
154
RLS 50/E 47
1
/
4“
23
5
/
8“
27
31
/
32“
154
Fig. 1
D36

20027066
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Technical description of the burner
3.5 Burner description
1 Combustion head
2 Ignition electrodes
3 Screw for combustion head adjust-
ment
4 Sleeve
5 Air pressure switch
6 Air pressure test point-head
7 Gas pressure test point and head fix-
ing screw
8 Screw securing fan to sleeve
9 Slide bars for opening the burner and
inspecting the combustion head
10 Pump
11 Safety solenoid valve
12 Low fire oil valve
13 Air servomotor
14 UV scanner
15 Gas servomotor
16 Air inlet to fan
17 Gas input connection
18 Boiler mounting flange
19 Flame stability disk
20 Flame inspection window
21 Oil / gas selector switch
22 Fan motor contactor and thermal over-
load with reset button
23 Control box for checking flame and air/
fuel ratio
24 Switch “OFF-ON”
25 Burner terminal strip
26 Minimum oil pressure switch
27 Pump motor
28 Lifting rings
29 High fire oil valve
30 Air pressure switch test point
31 Pump motor capacitor
32 Switch “Local-Remote”
33 Button “alarm silence”
34 Optional holes
35 Alarm predisposition
36 Power supply and safety/control
device entry cables
37 Auxiliary fuse
38 Ground terminals
39 RWF55 terminal board
40 Oil/gas ignition transformer
41 Terminl board (oil side)
42 Power ON signal lamp
43 Call for heat lamp
44 Alarm signal lamp
45 Fuel ON lamp
46 Ignition ON lamp
47 RWF55 modulator (with analog output
4-20 mA)
48 Timer module and relay K01
49 Timer module and relay KG1
50 “KG2” relay
51 “K2” relay
52 “K1” relay
53 “K3” relay
54 “K5” relay
55 DIN bar for OCI 412.10 device or
accessory/optional
56 DIN bar for fuse holder step-down
trasformer or accessory/optional
57 Operator panel with LCD display and
lock-out reset button
58 “X4” terminal strip accessory/optional
59 Fan motor
Two types of burner failure may occur:
–Flame safeguard lock-out
If the alarm signal lamp in “ON”
44)(Fig. 2) lights up, it indicates that the
burner is in lock-out. To reset, press the
reset pushbutton 57).
–Motor trip
Release by pressing the pushbutton on
thermal overload 22)(Fig. 2).
5
914
27
23
40
41
48
49
50
51
54
53
52
3057
55
56
10
12
11
13
16 17 18
19 20
2625
28
31
36
29
12
3
46 7
8
15
32
21
33
42
46
45
34 43
44
24
47
34
59
38
23
37
22
35
36
39
28
58
Fig. 2
D10464

9
20027066
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Technical description of the burner
3.6 Burner dimensions
The maximum dimensions of the burners are given in Fig. 3.
Note that if you need to examine the combustion head, the burner
must be pulled backward on the slide bars and turned upward.
The maximum dimension of the burner, without the cover, when
open is given by measurement H.
Tab. F
(1)
Blast tube: short - long (obtainable with kit)
3.7 Standard equipment
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange fixing screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 4
Screws to secure the burner flange to the boiler 318 Wx1” . .No. 4
Adaptor G 1/8“ / 1/8“ NPT . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
inch A B C D
(1)
E F G H I L M
RLS 38/E 25
31
/
32”
20
7
/
32”
26
3
/
4”
7
29
/
32”
- 13
7
/
32”
5
31
/
32”
13
5
/
16”
6
7
/
16”
37
7
/
32”
4
1
/
4”
6
5
/
8”
1
1
/
2”
RLS 50/E 25
31
/
32”
20
7
/
32”
26
3
/
4”
8
1
/
2”
- 13
13
/
16”
5
31
/
32”
13
5
/
16”
6
7
/
16”
37
7
/
32”
4
1
/
4”
6
5
/
8”
1
1
/
2”
DG
C
M
L
E
F
IA
B
H
Fig. 3
D10233

20027066
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Technical description of the burner
3.8 Firing rate
The burner can work in two ways: low and high fire.
MAXIMUM OUTPUT must be selected in area A.
MINIMUM OUTPUT must not be lower than the minimum limit
shown in the diagram:
Tab. G
NOTE:
the firing rate areas given in Fig. 4 have been reduced by 10% with
respect to the maximum range that can be reached.
Consult procedure below to refer burner operating condition in high
altitude plants.
Model MBtu/hr GPH
RLS 38/E 434 3.1
RLS 50/E 546 3.9
WARNING
The firing rate area values have been obtained con-
sidering an ambient temperature of 68 °F (20 °C),
and an atmospheric pressure of 394” WC and with
the combustion head adjusted as shown on
page 26.
Fig. 4
20110622
Combustion chamber pressure
“WC
Combustion chamber pressure
“WC

11
20027066
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Technical description of the burner
3.9 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 5 indicates the diameter and length of the test combustion
chamber.
Example:
output 1388 MBtu/hr: diameter 20 inch - length 4.9 ft.
D2918
Length (ft)
Furnace dimensions
Diameter (inches)
Fig. 5

20027066
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Technical description of the burner
3.10 Control box for the air/fuel ratio (LMV36.5...)
Warning notes
➤All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
➤Before making any wiring changes in the connection area,
completely isolate the plant from mains supply (all-polar dis-
connection). Ensure that the plant cannot be inadvertently
switched on again and that it is indeed dead. If not observed,
there is a risk of electric shock hazard.
➤Ensure protection against electric shock hazard by providing
adequate protection for the burner control’s connection termi-
nals.
➤Each time work has been carried out (mounting, installation,
service work, etc.), check to ensure that wiring and parame-
ters is in an orderly state.
➤Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Introduction
The control box for the air/fuel ratio (Fig. 6), (hereafter referred to
simply as the control box), that equips the burners, carries out a se-
ries of integrated functions in order to optimise burner functioning,
both for single operation and together with other units (e.g. double
furnace boiler or more than one generator at the same time).
The basic functions carried out by the control box relate to:
➤flame control;
➤the dosage of air and fuel via the positioning (with direct servo-
control) of the relative valves, excluding the possible play in
the mechanical cam calibration systems;
➤the modulation of burner output, on the basis of the load
requested by the system, maintaining the pressure or tem-
perature of the boiler at the working values set;
➤the safety diagnostic of the air and fuel circuits, via which it is
possible to easily identify any causes of malfunctioning.
Mechanical design
The following system components are integrated in the LMV36.5...
basic unit:
• Burner control with gas valve proving system
• Electronic air / fuel ratio control
• Control frequency converter air fan
• Modbus interface
Installation notes
• Always run high-voltage ignition cables separately while ob-
serving the greatest possible distance to the unit and to other
cables.
• Do not mix up live and neutral conductors (fire hazard, danger-
ous failures, loss of protection against electric shock hazard,
etc.).
• Do not lay the connecting cable from the LMV36.5... to the
AZL2… together with other cables.
Electrical connection of the flame detectors
It is important to achieve practically disturbance- and loss-free sig-
nal transmission:
• Never run the detector cable together with other cables.
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the maximum permissible detector cable lengths.
• The ionization probe is not protected against electric shock
hazard. It is mainspowered and must be protected against ac-
cidental contact.
• Locate the ignition electrode and the ionization probe such that
the ignition spark cannot arc over to the ionization probe (risk
of electrical overloads).
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
must be observed!
The LMV36.5... is a safety device!
Do not open, interfere with or modify the unit.
The manufacturer will not assume responsibili-
ty for any damage resulting from unauthorized
interference!
WARNING
The first start-up, like every further operation for
the internal settings of the control box, requires
access by means of a password and is only to
be carried out by personnel of the Technical As-
sistance Service who have been specifically
trained in the internal programming of the tool.
Fig. 6
S8168

13
20027066
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Technical description of the burner
Technical data
LMV36.5... basic unit Mains voltage AC 120 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power consumption < 30 W (typically)
Safety class I, with parts according to II and III to DIN EN 60730-1
Terminal loading
‘Inputs’ Unit fuse F1 (internally) 6.3 AT
Perm. mains primary fuse (externally) Max. 16 AT
Undervoltage
• Safety shutdown from operating position
at mains voltage
• Restart on rise in mains voltage
Approx. AC 93 V
Approx. AC 95 V
Terminal loading
‘Outputs’ Total contact loading: • Nominal voltage
• Unit input current (safety loop) from:
- Fan motor contactor
- Ignition transformer
- Valves
- Oil pump / magnetic clutch
AC 120 V, 50 / 60 Hz
Max. 5 A
Individual contact loading:
Fan motor contactor
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cosϕ> 0.4
Alarm output
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1 A
cosϕ> 0.4
Ignition transformer
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372 or 250 VA ignition
load declaration to UL372
cosϕ> 0.2
Fuel valves
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cosϕ> 0.4
Operation display
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
0.5 A
cosϕ> 0.4
Cable lengths Mains line
Display, BCI
External lockout reset button
Max. 100 m (100 pF/m)
- For used outside the burner cover or the control panel:
Max. 3 m (100 pF/m)
- For use outside the burner hood or in the control panel:
Max. 10 m (100 pF/m)
Max. 20 m (100 pF/m)
Environmental
conditions Operation Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60 °C
< 95 % r.h.

20027066
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Technical description of the burner
Sequence diagrams
Operation
Preignition ignition (Z) = ON
Interval 1 t44 Operation 1 (stationary)
Atmospheric test Pressure test Postpurge time t8
OUTPUTS INPUTS
Fan motor (M)
Fuel
Air
Actuators
0°
0°
t1
p
P
P
P
Control thermostat or pressurestat (R) ON
Air pressure switch (LP)
Pressure switch - leakage test (P LT)
Ignition transformer (Z)
Alarm (AL)
POC (alternative to pressure switch-max (Pmax)
Fuel valve 1 (V1)
Fuel valve 2 (V2)
0°
Test pressure switch-min (Pmin) Postpurge time 3 Fan motor (M) = ON
Safety valve (SV) = ON
Air damper (LK) => Fuel valve (V) - POS
Air damper (LK) => Ignition (Z) - POS
Operation 2 air damper (LK) =>
Low-fire load (KL) - POS
Air damper (LK) => Nominal load (NL) - POS
5 s
P
Required position
Required position
Required position
Fig. 7
S8169
Gas direct ignition «G»,
«G mod», «Gmod pneu»

15
20027066
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Technical description of the burner
0°
0°
t1
p
P
P
0°
5 s
Operation
Preignition ignition (Z) = ON
Interval 1 t44
Operation 1 (stationary)
Postpurge time t8
OUTPUTS INPUTS
Fan motor (M)
Fuel
Air
Actuators
Control thermostat or pressurestat (R) ON
Air pressure switch (LP)
Ignition transformer (Z)
Alarm (AL)
POC (alternative to pressure switch-max (Pmax)
Fuel valve 1 (V1)
Fuel valve 2 (V2)
Postpurge time 3
Fan motor (M) = ON Safety valve (SV) = ON
Air damper (LK) => Fuel valve (V) - POS
Air damper (LK) =>
Ignition (Z) - POS
Operation 2 air damper (LK) =>
Low-fire load (KL) - POS
Air damper (LK) => Nominal load (NL) - POS
Required position
Required position
Required position
Fig. 8
S8170
Light oil direct ignition «Lo»,
«Lo mod», «Lo 2-stage», «Lo 3-stage»

20027066
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Technical description of the burner
Legend to sequence diagrams (Fig. 7 and Fig. 8)
Valve proving takes place depending on the parameter:
Between phase 62 and phase 70 or / and between phase 24 and
phase 30
1 Parameter: Short / long preignition time for oil only
Short / long oil pump – switch-on time – time
2 Only with valve proving on startup
3 Parameter: With / without alarm in the event of prevention of
startup
4 In the event of an erroneous signal on startup, followed by
phase 10, otherwise phase 70
5 27 s = maximum time safety phase, followed by lockout
6 5 s = time between occurrence of prevention of startup and
indication
7 Only with valve proving on startup (valve proving via pressure
switch-min)
8 Only in case of startup without valve proving (valve proving
via pressure switch-min)
9 Inverse logic in case of valve proving via pressure switch-min
10 Parameter: Oil pressure min input
1 = active from phase 38
2 = active from safety time
11 Only with fuel train Lo with 2 fuel valves
Assignment of times:
0° / 10% Position as supplied (0°)
90° / 100% Actuator fully open (90°)
AL Alarm
FS Flame signal
LP Air pressure switch
M Fan motor N Postpurging
P LT Valve proving (pressure switch)
Pmin Pressure switch-min
Pmax Pressure switch-max
POC Proof of closure
PV Pilot valve
SA… Actuator
SB Safety limiter
SV Safety shutoff valve
STB Safety limit thermostat
V Prepurging
V… Fuel valve
t1 Prepurge time
TSA Safety time
Permissible position range
In standby: the actuator can travel within the permissible
positioning range, but is always driven to the no-load po-
sition. When changing phases, it must be in the no-load
position.
Signal ON
Signal OFF
Permissible signal

17
20027066
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Technical description of the burner
3.11 Actuators (SQM33.5...)
Warning notes
➤All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
➤Before making any wiring changes in the connection area of
the units, completely isolate the equipment from mains supply
(all-polar disconnection). If not observed, there is a risk of
electric shock hazard.
➤Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
➤After any kind of activity (mounting, installation and service
work, etc.), check wiring.
Also ensure that the parameters are correctly set.
➤Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Use
The actuators (Fig. 9) are used to drive and position the air damper
and the gas butterfly valve, without mechanical leverages but via
the interposition of an elastic coupling.
They are commanded by the control box, which constantly checks
their position by means of a return signal from the optic sensor in-
side the actuator.
The position (in degrees) of the actuators can be seen on the dis-
play of the Operator Panel.
Index “0” for fuel actuator, index “1” for air actuator.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible dis-
tance.
• The holding torque is reduced when the actuator is disconnect-
ed from power.
Technical data
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
should be observed!
Do not open, interfere with or modify the actua-
tors!
WARNING
The actuator’s housing must not be opened.
The actuator contains an optical feedback sys-
tem.
WARNING
When servicing or replacing the actuators, take
care not to invert the connectors.
Operating voltage AC / DC 24 V ±20 %
(load on interface)
Safety class 2 to EN 60 730 part 1 and parts 2…14
Power consumption max. 10 W
Degree of protection IP54 to EN 60 529-1
Opening time 0 - 90° min: 5s, max.: 120s
(depending on the type of control box)
Firing rate 0 - 90°
Cable connection RAST2,5 connectors
Direction of rotation Clockwise/anticlockwise
(can be selected from the control box)
Nominal output torque 3 Nm
Holding torque
(when live) 3 Nm
Holding torque
(when dead) 2.6 Nm
Weight approx. 1 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
class 3K5
class 3M4
-20...+60 ×C
< 95 % r.h.
D8271
Fig. 9

20027066
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Installation
4.1 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.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
With regard to the transport in the obligatory passages, refer to
the overall dimensions shown in Fig. 1 at page 7.
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).
During the handling, keep the load at not more than 10” from the
ground.
4.3 Preliminary checks
Checking the consignment
4.4 Boiler plate
Drill the combustion chamber mounting plate as shown in (Fig. 10).
The position of the threaded holes can be marked using the head
gasket supplied with the burner.
4 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 regulations of
the laws in force.
WARNING
The handling operations for the burner can be high-
ly dangerous if not carried out with the greatest at-
tention: keep any unauthorised people at a
distance; check the integrity and suitableness of the
available means of handling.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
CAUTION
After removing all the packaging, check the integrity
of the contents. In the event of doubt, donot 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 dan-
ger and pollution; they should be collected and dis-
posed of in the appropriate places.
WARNING
The output of the burner must be within the boiler's
firing rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
inch A B C
RLS 38/E 6
9
/
32“
8
13
/
16“ 3
/
8
W
RLS 50/E 6
9
/
32“
8
13
/
16“ 3
/
8
W
D455
Fig. 10