Riello RLS 70 Quick start guide

20079454 (2) - 01/2014
Installation, use and maintenance instructions
安装、使用和维护手册
Dual fuel light oil/gas burners
双燃料轻油 / 燃气燃烧器
Two-stage operation
两段火运行
CODE - 代码 MODEL - 型号 TYPE - 类型
20079208 RLS 70 687 T1
20079215 RLS 100 688 T1
20079217 RLS 130 689 T1
GB
CN

Original instructions
说明书原文翻译

1
CONTENTS
DECLARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Choice of nozzles for the 1st and 2nd stage . . . . . . . . . . . . . . . . . .7
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Adjustments before first firing (light oil operation) . . . . . . . . . . . . . .7
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Burner calibration (light oil operation). . . . . . . . . . . . . . . . . . . . . . .12
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Gas feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Adjustment before firing (gas operation) . . . . . . . . . . . . . . . . . . . .16
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LPG - Propane - Butane operation. . . . . . . . . . . . . . . . . . . . . . . . .18
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Gas combustion checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
FAULTS - POSSIBLE CAUSES - SOLUTIONS . . . . . . . . . . . . . .22
ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
GB

2
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 burner
Model: RLS 70 - 100 - 130
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 10.10.2013 Executive Director
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. G. Conticini Mr. R. Cattaneo

3
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m s.l.m.
(2 Upstream pressure of the gas train 1)(A)p.13 as indicated by EN676 Standard, with 0 mbar in the combustion chamber and at the 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 evaluated, in line with the regulations, on a spherical surface centred on the burner and with a radius of 1 metre.
ELECTRICAL DATA
BURNER CATEGORIES
MODEL RLS 70 RLS 100 RLS 130
Output (1)
Delivery (1)
2nd stage kW
kg/h 465 - 817 39 - 69 698 - 1163 59 - 98 930 - 1512 78 - 130
min. 1st stage kW
kg/h 232 19 349 29,5 465 39
Fuel LIGHT OIL, viscosity at 20 °C: 6 mm2/s max (1,5 °E - 6 cSt)
NATURAL GAS: G20 (methane) - G21 - G22 - G23 - G25
GPL - G30 (propane) - G31 (butane)
Gas pressure at maximum delivery (2)
Gas: G20/G25/G31 mbar 7.4/10.6/9.4 11.5/17.0/13.1 14.1/12.1/18.8
Operation - Intermittent (min. 1 stop in 24 hours)
- Two-stage (high and low flame) and single-stage (all - nothing)
Nozzles number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperatur °C 0 - 40
Combustion air temperature °C max 60
Pump delivery (at 12 bar)
pressure range
fuel temperatur
kg/h
bar
° C max
220
10 - 20
60
Noise levels (3) Sound pressure
Sound power dBA 74 85 77.5 89.5 80 91
MODEL RLS 70 RLS 100 RLS 130
Main electrical supply
Control circuit power supply 3 ~ 230/400V 50Hz 1N ~ 230V 50Hz
Fan motor IE2 rpm
Hz
V
W
A
2880
50
230 / 400
1100
4.3 - 2.5
2870
50
230 / 400
1500
5.9 - 3.4
2900
50
230 / 400
2200
7.9 - 4.6
Pump motor
Pump motor capacitor
rpm
Hz
V
W
A
µF
2700
50
230
550
3.6
25
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 5 kV 1,9 A - 30 mA
Absorbed electrical power W max 2000 2400 3200
Protection level IP 44
COUNTRY CATEGORY
IT - AT - GR - DK - FI - SE II2H3B / P
ES - GB - IE - PT II2H3P
NL II2L3B / P
FR II2Er3P
DE II2ELL3B /P
BE I2E(R)B, I3P
LU - PL II2E3B/P

4
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrodes
3 Screw for combustion head adjustment
4 Sleeve
5 Relay
6 Fan motor
7 Motor contactor and thermal cut-out with
reset button
8LEDPANEL
9 Terminal strip
10 Fairleads for electrical connections by
installer
11 Two switches:
- one “burner off - on”
- one for “1st - 2nd stage”
12 Control box with lock-out pilot light and lock-
out reset button
13 Flame inspection window
14 Minimum air pressure switch
(differential operating type)
15 Slide bars for opening the burner and
inspecting the combustion head
16 Safety solenoid valve
17 1st and 2nd stage valves
18 Gas pressure test point and head fixing
screw
19 Air pressure test point
20 Servomotor. When the burner is not operat-
ing the air gate valve is fully closed in order
to reduce to a minimum heat dispersion from
the boiler due to the flue draught which
draws air from the fan suction inlet.
21 Pump motor
22 Air gate valve
23 Air inlet to fan
24 Pump
25 Gas input pipework
26 Boiler mounting flange
27 Flame stability disk
28 Screw securing fan to sleeve
29 Cell UV
30 OIL/GAS selector
Two types of burner failure may occur:
Control Box Lock-out: if the control box 12)(A)
pushbutton lights up, it indicates that the burner
is in lock-out.
To reset, press the pushbutton.
Motor trip: release by pressing the pushbutton
on thermal relay 7)(A).
PACKAGING - WEIGHT (B) - Approximate
measurements
• The burners stands on a wooden base which
can be lifted by fork-lifts. Outer dimensions of
packaging are indicated in (B).
• The weight of the burner complete with pack-
aging is indicated in Table (B).
MAX. DIMENSIONS (C) -Approximate meas-
urements
The maximum dimensions of the burner are
given in (C).
Bear in mind that inspection of the combustion
head requires the burner to be opened and the
rear part withdrawn on the slide bars.
The maximum dimension of the burnerwhen
open, without casing, is give in measurement I.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws M 10 x 35
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the
boiler: M 12 x 35
2 - Flexible hoses
2 - Nipples for flexible hoses with gasket
1 - KIT for LPG operation
1 - Label for LPG operation
1 - Instruction booklet
1 - Spare parts list
(A)
mm ABCkg
RLS 70 1405 1000 660 70
RLS 100 1405 1000 660 73
RLS 130 1405 1000 660 76
(1) Blast tube: short-long
mm ABCDE F(1) GH I LMNO
RLS 70 691 296 395 555 840 250-385 179 430 1161 214 134 221 2”
RLS 100 707 312 395 555 840 250-385 189 430 1161 214 134 221 2”
RLS 130 733 338 395 555 840 250-385 189 430 1161 214 134 221 2”
D1175
D36
D1176
(B)
(C)

5
FIRING RATES (A)
The burners can work in two ways: one-stage
and two-stage.
MAXIMUM OUTPUT must be selected in area
A.
In order to utilize also area B (RLS 130) it is nec-
essary to perform the calibration of the combus-
tion head as explained on page 8.
MINIMUM OUTPUT must not be lower than the
minimum limit shown in the diagram:
RLS 70 = 232 kW = 19.0 kg/h
RLS 100 = 349 kW = 29.5 kg/h
RLS 130 = 465 kW = 39.0 kg/h
Important:
The firing rate area values have been obtained
considering a surrounding temperature of 20°C,
and an atmospheric pressure of 1000 mbar
(approx. 100 m above sea level) and with the
combustion head adjusted as shown on page 8.
TEST BOILER (B)
The firing rates were set in relation to special
test boilers, according to EN 676 and EN 267
regulations.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example: Output 650 Mcal/h:
diameter 60 cm - length 2 m.
COMMERCIAL BOILERS
The burner/boiler combination does not pose
any problems if the boiler is CE type-approved
and its combustion chamber dimensions are
similar to those indicated in diagram (B).
If the burner must be combined with a commer-
cial boiler that has not been CE type-approved
and/or its combustion chamber dimensions are
clearly smaller than those indicated in diagram
(B), consult the manufacturer.
(A)
RLS 70
RLS 100
RLS 130
D1194
D715
(B)
Combustion chamber
pressure - mbar
Combustion chamber
pressure - mbar
Combustion chamber
pressure - mbar
Combustion chamber
lenght - m

6
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (B)
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:
Blast tube 10): RLS 70 RLS 100 RLS 130
• short 250 250 250
• long 385 385 385
For boilers with front flue passes 13) or flame
inversion chambers, protective fettling in refrac-
tory material 11) must be inserted between the
boiler fettling 12) and the blast tube 10).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the
refractory fettling 11)-12)(B) is not required
unless it is expressly requested by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER
(B)
Detach the combustion head from the burner,
fig. (B):
- Disconnect the oil pipes by unscrewing the two
connectors 6).
- Loosen the 4 screws 3) and remove the cover 1).
- Remove the screws 2) from the slide bars 5).
- Remove the 2 screws 4) and pull the burner
back on slide bars 5) by about 100 mm.
- Disconnect the electrode wires and then pull
the burner completely off the slide bars.
COMBUSTION HEAD CALIBRATION
At this point check, for model RLS 130, whether
the maximum delivery of the burner in 2nd stage
operation is contained in area A or in area B of
the firing rate. See page 5.
If it is in area A then no operation is required.
If, on the other hand, it is in area B:
- unscrew the screws 1)(C) and disassemble
the blast tube 2).
- Move the fixing of the rod 3)(C) from position
A to position B, thereby causing the shutter
4) to retract.
- Now refit the blast tube 2)(C) and the screws 1).
Once this operation has been carried out (if it
was required):
- secure the flange 9)(B) to the boiler plate,
interposing the thermal insulating screen
7)(B) supplied with the burner.
- Use the 4 screws, also supplied with the unit,
after first protecting the thread with an anti-
locking product.
The seal between burner and boiler
must be airtight.
mm A B C
RLS 70 185 275-325 M 12
RLS 100 195 275-325 M 12
RLS 130 195 275-325 M 12
(A)
(B)
(C)
D455
D1172
D1192
WARNING

7
CHOICE OF NOZZLES FOR 1ST AND 2ND
STAGE
The burner complies with the emission require-
ments of the EN 267 standard.
In order to guarantee that emissions do not vary,
recommended and/or alternative nozzles speci-
fied by Riello in the Instruction and warning
booklet should be used.
Both nozzles must be chosen from among those
listed in Table (A).
The first nozzle determines the delivery of the
burner in the 1st stage.
The second nozzle works together with the 1st
nozzle to determine the delivery of the burner in
the 2nd stage.
The deliveries of the 1st and 2nd stages must
be contained within the value range indicated on
page 3.
Use nozzles with a 60° spray angle at the rec-
ommended pressure of 12 bar.
The two nozzles usually have equal deliveries.
NOZZLE ASSEMBLY
Remove screw 1)(B) and extract the internal
part 2)(B).
Fit two nozzles with the box spanner 1)(C) (16
mm), after having removed the plastic plugs
2)(C), fitting the spanner through the central
hole in the flame stability disk or loosen screws
1)(D), remove disk 2)(D) and replace the noz-
zles using the wrench 3)(D).
Do not use any sealing products such as gas-
kets, sealing compound, or tape. Be careful to
avoid damaging the nozzle sealing seat. The
nozzles must be screwed into place tightly but
not to the maximum torque value provided by
the wrench.
The nozzle for the 1st stage of operation is the
one lying beneath the firing electrodes.
It is advisable to replace the nozzle
once a year during periodical mainte-
nance.
The use of nozzles other than those
specified by Riello S.p.A. and inade-
quate regular maintenance may re-
sult into emission limits non-
conforming to the values set forth by
the regulations in force, and in ex-
tremely serious cases, into potential
hazards to people and objects.
The manufacturing company shall not
be liable for any such damage arising
from nonobservance of the require-
ments contained in this manual.
Make sure that the electrodes are
positioned as shown in figure (E).
WARNING
CAUTION
(A)
GPH kg/h kW
12 bar
10 bar 12 bar 14 bar
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.30
8.50
9.00
9.50
10.0
10.5
11.0
12.0
12.3
13.0
13.8
14.0
15.0
15.3
16.0
17.0
19.2
21.1
23.1
25.0
26.9
28.8
30.8
31.9
32.7
34.6
36.5
38.4
40.4
42.3
46.1
47.3
50.0
53.1
53.8
57.7
58.8
61.5
65.4
21.2
23.3
25.5
27.6
29.7
31.8
33.9
35.2
36.1
38.2
40.3
42.4
44.6
46.7
50.9
52.2
55.1
58.5
59.4
63.6
64.9
67.9
72.1
23.1
25.4
27.7
30.0
32.3
34.6
36.9
38.3
39.2
41.5
43.8
46.1
48.4
50.7
55.3
56.7
59.9
63.3
64.5
69.2
70.5
73.8
78.4
251.4
276.3
302.4
327.3
352.3
377.2
402.1
417.5
428.2
453.1
478.0
502.9
529.0
553.9
603.7
619.1
653.5
693.8
704.5
754.3
769.7
805.3
855.1
D1122
(B)
(C) (D)
D1146 D1147
(E) D1124
WARNING

8
Refit the burner to the slide bars 3)(C) at
approximately 100 mm from the sleeve 4) -
burner positioned as shown in fig. (B)p.6 - insert
the ignition electrode cables and then slide the
burner up to the sleeve so that it is positioned as
shown in fig. (C).
Refit screws 2)(C) on slide bars 3).
Secure the burner to the sleeve by tightening
screws 1).
Connect the oil pipes again by screwing on the
two connectors 6)(B)p.6.
ADJUSTMENTS BEFORE FIRST FIRING
(light oil operation)
• Combustion head setting
The setting of the combustion head depends
exclusively on the delivery of the burner in the
2nd stage.
Turn screw 5)(A) until the notch shown in dia-
gram (B) is level with the front surface of flange.
Example: Burner RLS 100
2nd stage burner delivery = 72 kg/h.
If diagram (B) is consulted it is clear that for this
delivery, the combustion head must be adjusted
using notch 3, as shown in fig. (B).
• Pump adjustment
No settings are required for the pump, which is
set to 12 bar by the manufacturer. This pressure
must be checked and adjusted (if required) after
the burner has been ignited.
The only operation required in this phase is the
application of a pressure gauge on the appropri-
ate pump attachment.
• Fan gate adjustment
The first time the burner is fired leave the factory
setting unchanged for both 1st stage and 2nd
stage operation.
When fitting the burner on the two
slide bars, it is advisable to gently
draw out the high tension cables
until they are slightly stretched.
SETTING THE COMBUSTION HEAD
(B)
No. notches
Light oil delivery in 2nd stage - kg/h
D1149
D1193
D1173
(C)
(A)
WARNING

9
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM FACTORY-SET
• The burners leave the factory preset for 400V power supply.
• If 230V power supply is used, change the motor connection from
star to delta and change the setting of the thermal cut-out as well.
Key to layout (A)
C Capacitor
CMV Motor contactor
K1 Relay
LFL 1.322 Control box
I1 Switch:
burner on - off
I2 Switch: 1st - 2nd stage
I3 Olio/gas selector
MB Burner terminal strip
MV Fan motor
MP Pump motor
PA Air pressure switch
RT Thermal cut-out
SM Servomotor
TA Ignition transformer
TB Burner ground
ULEDPANEL
UV UV cell
V1 1st stage light-oil valve
V2 2nd stage light-oil valve
VS Safety oil valve
NOTE
• The burners leaves the factory preset for 400V power supply.
If 230V power supply is used, change the fan motor connection
from star to delta and change the setting of the thermal cut-out as
well.
• The burners have been type- approved for intermittent operation.
This means they should compulsorily be stopped at least once
every 24 hours to enable the control box to check its own effi-
ciency at start-up. Burner halts are normally provided for auto-
matically by the boiler load control system.
If this is not the case, a time switch should be fitted in series to IN
to provide for burner shut-down at least once every 24 hours.
• The burners are factory set for two-stage operation and must
therefore be connected to control device TR.
Alternatively, if single stage operation is required, instead of con-
trol device TR install a jumper lead between terminals 6 and 7 of
the terminal strip.
WARNING
Do not invert the neutral with the phase wire in the electricity supply
line.
D3493
(A)

10
ELECTRICAL CONNECTIONS
Use flexible cables according to EN 60 335-1
Regulations:
• if in PVC sheath, use at least HO5 VV-F;
• if in rubber sheath, use at least H05 RR-F.
All the wires to connect to the burner terminal
strip 8)(A) must enter through the supplied fair-
leads.
The fairleads and hole press-outs can be used
in various ways; the following lists show one
possible solution:
1- Pg 13.5 Three-phase power supply
2- Pg 11 Single-phase power supply
3- Pg 11 Remote control device TL
4- Pg 9 Remote control device TR
5- Pg 13.5 Gas valves
6- Pg 13.5 Gas pressure switch or gas valve
leak detection control device
7- Pg 11 Open the hole, if a pipe union is to
be added
LAYOUT (B)
Electrical connection without leak detection
control device
LAYOUT (C)
Electrical connection with leak detection
control device
Gas valve leak detection control takes place
immediately before every burner start-up.
Fuses and cables cross-section layouts (B-C),
see table (D).
Cross-section when not indicated: 1,5 mm2
KEY TO LAYOUTS (B) - (C)
IN - Burner manual stop switch
XP- Plug for leak detection control device
MB- Burner terminal strip
PG- Min. gas pressure switch
RS- Remote lock-out reset button (if present)
S - Remote lock-out signal
S1- Remote lock-out signal of leak detection
control device
TR- High-low mode load remote control system:
controls operating stages 1 and 2. If the
burner is to be set up for single stage
operation, replace the remote control
device TR with a jumper.
TL - Load limit remote control system:
shuts down the burner when the boiler
temperature or pressure reaches the pre-
set value.
TS- Safety load control system:
operates when TL is faulty.
VR1-Adjustment valve 1st stage
VR2-Adjustment valve 2nd stage
VS- Safety valve
LAYOUT (C)
Calibration of thermal cut-out
This is required to avoid motor burn-out in the
event of a significant increase in power absorp-
tion caused by a missing phase.
• If the motor is star-powered, 400V, the cursor
should be positioned to "MIN".
• If the motor is delta-powered, 230V, the cur-
sor should be positioned to "MAX".
Even if the scale of the thermal cut-out does not
include rated motor absorption at 400V, protec-
tion is still ensured in any case.
(A)
WITHOUT LEAK DETECTION CONTROL DEVICE
WITH VPS LEAK DETECTION CONTROL DEVICE
(B)
(C)
CALIBRATION OF THERMAL RELAY
(D)
RLS 70 RLS 100 RLS 130
230 V 400 V 230 V 400 V 230 V 400 V
F A 6A aM
12A gG 4A aM 8A gG 8A aM 16A gG 4A aM 8A gG 10A aM 20A gG 6A aM 12A gG
Lmm21.5 1.5 2.5 1.5 2.5 1.5
D1174
20081670
20081671
D867
(E)

11
LIGHT OIL SUPPLY (A)
The burner is equipped with a self-priming pump
which is capable of feeding itself within the limits
listed in the table at the side.
The tank higher than the burner A
The distance "P" must not exceed 10 meters in
order to avoid subjecting the pump's seal to
excessive strain; the distance "V" must not
exceed 4 meters in order to permit pump self-
priming even when the tank is almost com-
pletely empty.
The tank lower than the burner B
Pump depression values higher than 0.45 bar
(35 cm Hg) must not be exceeded because at
higher levels gas is released from the fuel, the
pump starts making noise and its working life-
span decreases.
It is good practice to ensure that the return and
suction lines enter the burner from the same
height; in this way it will be more improbable that
the suction line fails to prime or stops priming.
Key (A)
H =Pump/Foot valve height difference
L =Piping length
Ø =Inside pipe diameter
1 =Burner
2=Pump
3=Filter
4 =Manual on/off valve
5 =Suction line
6 =Foot valve
7 =Rapid closing manual valve
remote controlled (only Italy)
8 =On/off solenoid valve (only Italy)
9 =Return line
10 =Check valve (only Italy)
HYDRAULIC CONNECTIONS (B)
The pumps are equipped with a by-pass that
connects return line and suction line. The
pumps are installed on the burner with the by-
pass closed by screw 6)(A)p. 12.
It is therefore necessary to connect both hoses
to the pump.
The pump will break immediately if it is run with
the return line closed and the by-pass screw
inserted.
Remove the plugs from the suction and return
connections of the pump.
Insert the hose connections with the supplied
seals into the connections and screw them
down.
Take care that the hoses are not stretched or
twisted during installation.
Install the hoses where they cannot be stepped
on or come into contact with hot surfaces of the
boiler and where they do not hamper the open-
ing of the burner.
Now connect the other end of the hoses to the
suction and return lines by using the supplied
nipples.
(A)
+/- H
mL m
Ø 12 mm Ø 14 mm Ø 16 mm
+ 4
+ 3
+ 2
+ 1
+ 0,5
71
62
53
44
40
138
122
106
90
82
150
150
150
150
150
0 36 74 137
- 0,5
- 1
- 2
- 3
- 4
32
28
19
10
-
66
58
42
26
10
123
109
81
53
25
(B)
6
7
9
53
2
1
4
8
- H
10 cm
+ H V
P
5
9
10
7
A
B
6
D1178
D1185

12
HYDRAULIC SYSTEM
Key (A)
1 Pump suction
2Filter
3Pump
4 Pressure governor
5 Return pipe
6 By-pass screw
7 Pump return
8 Safety solenoid
9 1st stage valve
10 2nd stage valve
11 Filter
M Pressure gauge
V Vacuometer
PUMP (B)
1 - Suction G 1/4”
2 - Return G 1/4”
3 - Pressure gauge attachment G 1/8”
4 - Vacuum meter attachment G 1/8”
5 - Pressure governor
A - Min. delivery rate at 12 bar pressure
B - Delivery pressure range
C - Max. suction depression
D - Viscosity range
E - Max light oil temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H-Filtermeshwidth
PUMP PRIMING
-Before starting the burner, make sure that
the tank return line is not clogged.
Obstructions in the line could cause the
sealing organ located on the pump shaft
to break. (The pump leaves the factory with
the by-pass closed).
- Also check to make sure that the valves
located on the suction line are open and that
there is sufficient fuel in the tank.
- For self-priming to take place, one of the
screws 3)(B) must be loosened in order to
bleed off the air contained in the suction line.
- Start the burner by closing the control
devices, with switch 1)(A) in the "ON" posi-
tion and with switch 30)(A)p.4 in the "OIL"
position.
- The pump can be considered to be primed
when the light oil starts coming out of the
screw 3)(B).
Stop the burner: switch 1)(C) set to "OFF"
and tighten the screw 3)(B).
The time required for this operation depends
upon the diameter and length of the suction tub-
ing. If the pump fails to prime at the first starting
of the burner and the burner locks out, reset the
burner, and then repeat the starting operation.
Do not illuminate the cell UV or the burner will
lock out.
BURNER CALIBRATION (light-oil operation)
N.B.
It is advisable to first set the burner for operating
on oil and then for gas.
WARNING
Execute the fuel exchange when the burner
is off.
FIRING
Set switch 1)(C) to "ON".
During the first firing, during the passage from
the 1st to the 2nd stage, there is a momentary
lowering of the fuel pressure caused by the fill-
ing of the 2nd stage nozzle tubing.
This lowering of the fuel pressure can cause the
burner to lock-out and can sometimes give rise
to pulsations.
(B)
PUMP - SUNTEC AJ6 CC
AJ6 CC
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
220
10 - 20
0,45
2.8 - 75
60
2
12
0.15
D1177
(A) D1184
(C)
Burner OFF 1st stage
2nd stage
12
Burner ON
D469

13
OPERATION
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet
and interventions on the following points.
• 1st and 2nd stage nozzles
See the information listed on page 11.
• Combustion head
The adjustment of the combustion head already
carried out (page 8) need not be altered unless
the 2nd stage delivery of the burner is changed.
• Pump pressure
12 bar: This is the pressure calibrated in the fac-
tory which is usually sufficient for most pur-
poses. Sometimes, this pressure must be
adjusted to:
10 bar in order to reduce fuel delivery. This
adjustment is possible only if the surrounding
temperature remains above 0 °C;
14 bar in order to increase fuel delivery or to
ensure firings even at temperatures of less than
0 °C.
In order to adjust pump pressure, use the screw
5)(B)p. 12.
• 1st stage fan air gate valve
Keep the burner operating at 1st stage by set-
ting the switch 2)(C)p. 12 to the 1st stage posi-
tion. The fan air gate valve is adjusted by
moving the orange lever of the servomotor.
• 2nd stage fan air gate valve
Set switch 2)(C)p. 12 to the 2nd stage position.
The fan air gate valve is adjusted by moving the
red lever of the servomotor.
SERVOMOTOR (A)
The servomotor adjusts the air gate valve.
The servomotor rotates through 90° in 5 sec-
onds.
Do not alter (for the time-being) the factory set-
ting for the 4 levers.
A graduated plate with 4 coloured sectors marks
the lever operation point.
Blue lever
Sets the position of the air gate valve while the
burner is shut down: air gate valve closed.
Orange lever
Sets the position of the air gate valve during 1st
stage operation.
Red lever
Sets the position of the air gate valve during 2nd
stage operation.
Black lever
Establishes when the 2nd stage gas or light oil
valve opens.
It must always operate (just) before the red lever
and after the orange lever.
It must not operate with the red lever as this
may prevent the gas or light oil valve from open-
ing at all.
It must not operate straight after the orange
lever to avoid combustion in the absence of air.
For gas or light oil valve opening to approach
that of 2nd stage air gate valve position, rotate
the black lever to the left; to delay opening time,
rotate the lever to the right.
In brief, the levers must be operated in the fol-
lowing sequence:
1° Blue lever
2° Orange lever
3° Black lever
4° Red lever
(A)
SERVOMOTOR
LEVER
BLACK
RED
ORANGE
BLUE
D1195

14
GAS FEEDING
KEY (A)
1 Gas input pipe
2 Manual valve
3 Vibration damping joint
4 Pressure gauge with pushbutton cock
5Filter
6A Includes:
–Filter
– working valve
–safetyvalve
– pressure adjuster
6C Includes
–safetyvalve
– working valve
6D Includes:
–safetyvalve
– working valve
– pressure adjuster
–filter
7 Minimum gas pressure switch
8 Leak detection device, supplied as an ac-
cessory or incorporated, based on the gas
train code. In compliance with the EN 676
standard, the leak detection control is com-
pulsory for burners with maximum outputs
over 1200 kW.
9 Gasket, for “flanged” versions only
10 Pressure adjuster
11 Train-burner adaptor, supplied separately
P2 Upstream pressure of valves/adjuster
P3 Upstream pressure of the filter
L Gas train supplied separately
L1 The responsibility of the installer
GAS TRAIN
Type-approved in accordance with EN 676 and
supplied separately from the burner.
To select the correct model of the gas train, refer
to the “burner-gas train combination” manual
supplied.
See the accompanying instructions for the ad-
justment of the gas train.
GAS TRAIN INSTALLATION
• The gas train must be connected to the gas
attachment 1)(B), using flange 2), gasket 3)
and screws 4) supplied with the burner.
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient, see fig. (B).
• Make sure that the pressure governor cali-
bration range (colour of the spring) com-
prises the pressure required by the burner.
Explosion danger due to fuel leaks in
the presence of a flammable source.
Precautions: avoid knocking, attri-
tion, sparks and heat.
Make sure that the fuel interception
tap is closed before performing any
operation on the burner.
The fuel supply line must be installed
by qualified personnel, in compliance
with current standards and laws.
The gas solenoids must be as close
as possible to the burner, to ensure
that the gas reaches the combustion
head within the safety time of 3s.
Ensure that the maximum pressure
to the burner is within the calibration
range of the pressure regulator.
(A)
20057264
MB
20062223
MBC
20062227
DMV
20062228
CB
(B) D722
WARNING
WARNING

15
GAS PRESSURE
The adjacent table shows minimum pressure
losses along the gas supply line depending on
the burner output in 2nd stage operation.
The values shown in the table refer to:
- Natural gas G20 PCI 9.45 kWh/Sm3
(8.2 Mcal/Sm3)
- LPG G31 PCI 27 kWh/Sm3(23,2 Mcal/Sm3)
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0 mbar
• Burner operating in 2nd stage
• Gas G20 (methane) - G31 (propane)
Calculate the approximate 2nd stage output of
the burner thus:
- subtract the combustion chamber pressure
from the gas pressure measured at test point
1)(B).
- Find the nearest pressure value to your result
in column 1 of the table for the burner in ques-
tion.
- Read off the corresponding output on the left.
Example - RLS 100
• 2nd stage operation
• Natural gas G20 PCI 10 kWh/Sm3
• Gas pressure at test point 1)(B)= 11,4 mbar
• Pressure in combustion chamber= 2 mbar
11,4 - 2 = 9,4 mbar
A 2nd stage output of 1007 kW shown in table
corresponds to 9,4 mbar pressure, column 1,
gas G20.
This value serves as a rough guide, the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B), set the output required from the
burner in 2nd stage operation:
- find the nearest output value in the table for
the burner in question.
- Read off the pressure at test point 1)(B) on the
right in column 1.
- Add this value to the estimated pressure in the
combustion chamber.
Example - RLS 100
• Required burner output in 2nd stage operation:
1007 kW
• Natural gas G20 PCI 10 kWh/Sm3
• Gas pressure at burner output of 1007 kW,
taken from colomn 1, G 20= 9,4 mbar
• Pressure in combustion chamber= 2 mbar
9,4 + 2 = 11,4 mbar
pressure required at test point 1)(B).
For LPG use the gas train with 1”1/2
or 2” diameter.
Mod.
kW 1 p (mbar)
G20 G31
RLS 70
465 5.5 6.3
504 5.6 6.4
543 5.7 6.5
582 5.7 6.5
621 5.8 6.6
661 5.9 6.8
700 6 7
739 6 7.2
778 6.1 7.5
817 6.2 7.8
RLS 100
695 8 10.3
747 8.2 10.5
799 8.5 10.7
851 8.7 10.9
903 9 11.2
955 9.2 11.4
1007 9.4 11.6
1059 9.6 11.7
1111 9.8 11.9
1163 10 12
RLS 130
930 9.3 10.5
995 9.4 10.8
1059 9.6 11.2
1124 9.8 11.7
1189 10.1 12.3
1253 10.4 12.9
1318 10.8 13.6
1383 11.2 14.5
1447 11.9 15.8
1512 13 17.5
(A)
S9000
(B)
WARNING

16
ADJUSTMENTS BEFORE FIRST FIRING (gas
operation)
Adjustment of the combustion head has been
illustrated on page 8.
In addition, the following adjustments must also
be made:
- Open manual valves up-line from the gas train.
- Adjust the minimum gas pressure switch to the
start of the scale (A).
- Adjust the air pressure switch to the zero posi-
tion of the scale (B).
- Purge the air from the gas line.
Continue to purge the air (we recommend
using a plastic tube routed outside the build-
ing) until gas is smelt.
- Fit a U-type manometer (C) to the gas pres-
sure test point on the sleeve.
The manometer readings are used to calculate
the 2nd stage operation burner power using
the tables on page 7.
- Connect two lamps or testers to the two gas
line solenoid valves VR1 and VS to check the
exact moment at which voltage is supplied.
This operation is unnecessary if each of the
two solenoid valves is equipped with a pilot
light that signals voltage passing through.
Before starting up the burner it is good practice
to adjust the gas train so that ignition takes
place in conditions of maximum safety, i.e. with
gas delivery at the minimum.
BURNER STARTING (gas operation)
N.B.: It is advisable to first set the burner for
operating on oil and then for gas.
WARNING
Execute the fuel exchange when the burner
is off.
Close the control devices and set:
• switch 1)(D) to "ON" position
• switch 2)(D) to "1st stage" position
As soon as the burner starts make sure that the
lamps or testers connected to the solenoids, or
pilot lights on the solenoids themselves, indicate
that no voltage is present. If voltage is present,
then immediately stop the burner and check
electrical connections.
BURNER FIRING (gas operation)
Having completed the checks indicated in the
previous heading, the burner should fire. If the
motor starts but the flame does not appear and
the control box goes into lock-out, reset and wait
for a new firing attempt.
If firing is still not achieved, it may be that gas is
not reaching the combustion head within the
safety time period of 3 seconds.
In this case increase gas firing delivery.
The arrival of gas at the sleeve is indicated by
the U-type manometer (C).
Once the burner has fired, now proceed with
global calibration operations.
BURNER CALIBRATION (gas operation)
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet.
Adjust successively:
1 - 2nd stage burner output
2 - 1st stage burner output
3 - First firing output
4 - Air pressure switch
5 - Minimum gas pressure switch
(A) (B)
MIN GAS PRESSURE SWITCH AIR PRESSURE SWITCH
(C)
D897
D1180
Burner OFF 1st stage
2nd stage
12
Burner ON
(D) D469

17
1 - 2ND STAGE OUTPUT
2nd stage output of the burner must be set
within the firing rate range shown on page 5.
Set switch 2)(A) to the 2nd stage position: the
servomotor will open the air gate valve at the
previously set value for oil and will control the
opening of the 2nd stage gas valve VR2.
Gas calibration
Adjust gas delivery to the amount of air.
- If delivery needs to be reduced, diminish outlet
gas pressure and, if it is already very low,
slightly close 2nd stage adjustment valve VR2.
- If delivery needs to be increased, increase out-
let gas pressure.
2 - 1ST STAGE OUTPUT
Burner power in 1st stage operation must be
selected within the firing rate range shown on
page 5.
Set the switch 2)(A) to the 1st stage position: the
servomotor will close the air gate valve at the
previously set value for oil and will control the
opening of the 1st stage gas valve VR1.
Adjusting gas delivery
Adjust gas delivery to the amount of air by
adjusting the 1st stage gas valve VR1.
3 - FIRING OUTPUT (gas operation)
According to EN 676 Regulations:
Burners with MAX output up to 120 kW
Firing can be performed at the maximum opera-
tion output level. Example:
• Max. operation output : 120 kW
• Max. firing output : 120 kW
Burners with MAX output above 120 kW
Firing must be performed at a lower output than
the max. operation output. If the firing output
does not exceed 120 kW, no calculations are
required. If firing output exceeds 120 kW, the
regulations prescribe that the value be defined
according to the control box safety time "ts":
- For ts = 2s, firing output must be equal to or
lower than 1/2 of max. operation output.
- For ts = 3s, firing output must be equal to or
lower than 1/3 of max. operation output.
Example: MAX operation output of 600 kW.
Firing output must be equal to or lower than:
• 300 kW con ts = 2s
• 200 kW con ts = 3s
In order to measure the firing output:
- Extract the UV cell 29)(A)p.4 (the burner will
ignite and lock-out at the end of a safety
period).
- Perform 10 firings with consecutive lock-outs.
On the meter read the quantity of gas burned.
- This quantity must be equal to or lower than
the quantity given by the formula:
Example: for gas G 20 (10 kWh/Sm3):
Max. operation output: 600 kW corresponding to
60 Sm3/h
After 10 firings with lock-outs, the delivery read
on the meter must be equal to or lower than:
60 : 360 = 0,166 Sm3
Firing output must be adjusted on the gas valve
throttle.
Burner OFF 1st stage
2nd stage
12
Burner ON
(A) D469
Sm3/h (max. burner delivery)
360

18
4 - AIR PRESSURE SWITCH (A) - CO CHECK
Adjust the air pressure switch after having per-
formed all other burner adjustments with the air
pressure switch set to the start of the scale (A).
With the burner operating in 1st stage, increase
adjustment pressure by slowly turning the rela-
tive knob clockwise until the burner locks out.
Then turn the knob anti-clockwise by about 20%
of the set point and repeat burner starting to
ensure it is correct.
If the burner locks out again, turn the knob anti-
clockwise a little bit more.
Attention: as a rule, the air pressure switch
must limit the CO in the fumes to less than 1%
(10.000 ppm).
To check this, insert a combustion analyser into
the chimney, slowly close the fan suction inlet
(for example with cardboard) and check that the
burner locks out, before the CO in the fumes
exceeds 1%.
The air pressure switch may operate in "differ-
ential" operation in two pipe system. If a nega-
tive pressure in the combustion chamber during
pre-purging prevents the air pressure switch
from switching, switching may be obtained by fit-
ting a second pipe between the air pressure
switch and the suction inlet of the fan. In such a
manner the air pressure switch operates as dif-
ferenzial pressure switch.
Warning: the use of the air pressure switch with
differential operation is allowed only in industrial
applications and where rules enable the air
pressure switch to control only fan operation
without any reference to CO limit.
5 - MINIMUM GAS PRESSURE SWITCH (B)
Adjust the minimum gas pressure switch after
having performed all the other burner adjust-
ments with the pressure switch set at the start of
the scale (B).
With the burner operating in 2nd stage, increase
adjustment pressure by slowly turning the rela-
tive knob clockwise until the burner locks out.
Then turn the knob anti-clockwise by 2 mbar
and repeat burner starting to ensure it is uni-
form.
If the burner locks out again, turn the knob anti-
clockwise again by 1 mbar.
LPG - PROPANE - BUTANE OPERATION
The burners can also operate on LPG-Propane-
Butane gases.
In this case it is necessary to assemble the noz-
zles 2)(C) on the holes 1)(C) and the caps 3)(C)
on the small pipes 4)(C) supplied with the
burner.
Apply the self-adhesive label for LPG operation
near the characteristic label.
The firing rate range and burner adjustment are
similar to those for natural gas.
The G31 (Propane) gas pressure is shown on
page 26.
Gas train: use the gas train for natural gas, see
page 28, with 1"1/2 or 2" diameter.
(A)
AIR PRESSURE SWITCH
MIN. GAS PRESSURE SWITCH
(B)
(C)
D521
D896
D1181