Riello RLS 1000/M C13 Quick start guide

Installation, use and maintenance instructions
20040160 (4) - 05/2012
Dual fuel gas oil/gas burners
Progressive two-stage or modulating operation
CODE MODEL TYPE
20034254 RLS 1000/M C13 1311 T
20034255 RLS 1200/M C13 1312 T
GB

Translation of the original instructions

1 20040160
GB
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 Burner weight.............................................................................................................................................................. 9
4.7 Maximum dimensions.................................................................................................................................................. 9
4.8 Firing rates ................................................................................................................................................................ 10
4.9 Test boiler.................................................................................................................................................................. 10
4.10 Burner description..................................................................................................................................................... 11
4.11 Electrical panel description........................................................................................................................................ 12
4.12 Burner equipment...................................................................................................................................................... 12
4.13 Control box (LFL1.333..) ........................................................................................................................................... 13
4.14 Servomotor (SQM10.1....)......................................................................................................................................... 14
5 Installation ................................................................................................................................................................................ 15
5.1 Notes on safety for the installation............................................................................................................................ 15
5.2 Handling.................................................................................................................................................................... 15
5.3 Preliminary checks.................................................................................................................................................... 15
5.4 Operating position..................................................................................................................................................... 16
5.5 Preparing the boiler................................................................................................................................................... 16
5.5.1 Boring the boiler plate ............................................................................................................................................... 16
5.5.2 Blast tube length........................................................................................................................................................ 16
5.6 Securing the burner to the boiler............................................................................................................................... 16
5.7 Access to head internal part...................................................................................................................................... 17
5.8 Electrode position...................................................................................................................................................... 17
5.9 Nozzle installation ..................................................................................................................................................... 18
5.9.1 Recommended nozzle............................................................................................................................................... 18
5.10 Combustion head adjustment.................................................................................................................................... 19
5.11 Light oil supply........................................................................................................................................................... 20
5.11.1 Double-pipe circuit..................................................................................................................................................... 20
5.11.2 The loop circuit.......................................................................................................................................................... 20
5.11.3 Hydraulic connections............................................................................................................................................... 21
5.11.4 Hydraulic circuit diagram........................................................................................................................................... 21
5.11.5 Pressure variator....................................................................................................................................................... 21
5.12 Pump......................................................................................................................................................................... 22
5.12.1 Technical data........................................................................................................................................................... 22
5.12.2 Priming pump............................................................................................................................................................ 22
5.13 Gas feeding............................................................................................................................................................... 23
5.13.1 Gas feeding line ........................................................................................................................................................ 23
5.13.2 Gas train.................................................................................................................................................................... 24
5.13.3 Gas train installation.................................................................................................................................................. 24

20040160 2
GB
Contents
5.13.4 Gas pressure .............................................................................................................................................................24
5.13.5 Pilot - gas train connection.........................................................................................................................................25
5.13.6 Ignition pilot burner ....................................................................................................................................................25
5.14 Activation of the burner lance ....................................................................................................................................26
5.15 Electrical connections ................................................................................................................................................27
5.15.1 Supply cables and external connections passage.....................................................................................................27
5.16 Calibration of the thermal relay..................................................................................................................................28
6 Start-up, calibration and operation of the burner..................................................................................................................29
6.1 Notes on safety for the first start-up...........................................................................................................................29
6.2 Adjustments prior to ignition (light oil)........................................................................................................................29
6.2.1 Nozzle........................................................................................................................................................................29
6.2.2 Combustion head.......................................................................................................................................................29
6.2.3 Pump pressure...........................................................................................................................................................29
6.2.4 Fan damper................................................................................................................................................................29
6.3 Burner ignition (light oil) .............................................................................................................................................29
6.4 Adjustments prior to ignition (gas) .............................................................................................................................30
6.5 Burner start-up (gas)..................................................................................................................................................30
6.6 Burner ignition............................................................................................................................................................30
6.7 Change of fuel............................................................................................................................................................30
6.8 Servomotor adjustment..............................................................................................................................................31
6.9 Combustion air adjustment........................................................................................................................................31
6.10 Burner adjustment and output modulation.................................................................................................................32
6.10.1 Maximum output ........................................................................................................................................................32
6.10.2 Minimum output .........................................................................................................................................................32
6.10.3 Intermediate outputs..................................................................................................................................................32
6.11 Air / fuel adjustment...................................................................................................................................................32
6.11.1 Burner calibration procedure......................................................................................................................................32
6.12 Pressure switch adjustment.......................................................................................................................................34
6.12.1 Air pressure switch - check CO..................................................................................................................................34
6.12.2 Maximum gas pressure switch...................................................................................................................................34
6.12.3 Minimum gas pressure switch....................................................................................................................................34
6.13 Operation sequence of the burner .............................................................................................................................35
6.13.1 Burner start-up...........................................................................................................................................................35
6.13.2 Operation ...................................................................................................................................................................35
6.13.3 Burner flame goes out during operation.....................................................................................................................35
6.13.4 Ignition failure.............................................................................................................................................................35
6.14 Final checks (with burner operating)..........................................................................................................................36
7 Maintenance ..............................................................................................................................................................................37
7.1 Notes on safety for the maintenance.........................................................................................................................37
7.2 Maintenance programme...........................................................................................................................................37
7.2.1 Maintenance frequency..............................................................................................................................................37
7.2.2 Checking and cleaning...............................................................................................................................................37
7.3 Opening the burner....................................................................................................................................................39
7.4 Closing the burner......................................................................................................................................................39
8 Faults - Possible causes - Solutions.......................................................................................................................................40
8.1 Light oil operation.......................................................................................................................................................40
8.2 Gas operation ............................................................................................................................................................43
A Appendix - Accessories ...........................................................................................................................................................45
B Appendix - Electrical panel layout...........................................................................................................................................46

3 20040160
GB
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 gas oil/ gas burners
Model: RLS 1000/M C13
RLS 1200/M C13
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard
“1.BImSchV revision 26.01.2010”.
Product Type Model Output
Dual fuel gas oil/gas burners 1311 T RLS 1000/M C13 1200 - 10600 kW
1312 T RLS 1200/M C13 1500 - 11500 kW
Legnago, 30.06.2011
Burners Division Department
RIELLO S.p.A. Mr. G. Conticini Eng. R. Cattaneo
CE- Class 3 (EN 676) - Class 2 (EN 267)

20040160 4
GB
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
Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20040160
GB
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 Assist-
ance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
the use of non-original components, including spare parts,
kits, accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20040160 6
GB
Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly 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 cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures neces-
sary to prevent unauthorised people gaining
access to the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20040160
GB
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 Voltage Start-up Code
RLS 1000/M C13 TC 3/400/50 Star/Triangle 20034254
RLS 1200/M C13 TC 3/400/50 Star/Triangle 20034255
Class 3 EN267 - Class 3 EN676
Series : R
Size
Fuel : Natural gas
Light oil
Light oil / Methane
Adjustment :
Flame control system :
FS1
FS2 Standard (1 stop every 24 h) Continuous working (1 stop every 72 h)
Electrical supply of the system :
3/400/50
3/230/50
Auxiliary voltage :
230/50/60
110/50/60
RLS 1000 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
C13
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with 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
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L
FR I2Er
BE I2E(R)B
LU - PL I2E

20040160 8
GB
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 on the socket 5)(Fig. 5) with zero pressure in the combustion chamber and at maximum burner output.
(3) Noise emission tests carried out as per Directive EN 15036-1, with measurement accuracy ó= ± 1.5 dB, in the manufacturer's combustion lab
with burner operating on test boiler at maximum output.
4.5 Electrical data
Motor IE1
Motor IE2
Tab. B
Model RLS 1000/M C13 RLS 1200/M C13
Type 1311 T 1312 T
Output (1)
Delivery (1) min - max kW kg/h 1200/3750 - 10600 100/315 - 867 1500/5500 - 11500 171/462 - 942
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 67.1/101.2 97.2/145
Operation – Intermittent (min. 1 stop in 24 hours)
– Progressive two-stage or modulating by kit (See ACCESSORIES).
Pump Output at 30 bar
Pressure range
Fuel temperature
kg/h
bar
°c max
1400
9/40
140
1826
9/40
140
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 85.4 100.6 84.4 99.7
Model RLS 1000/M C13 RLS 1200/M C13
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor rpm
V
kW
A
2940
400/690
21
39.6 - 23
2920
400/690
25
47.5 - 27.4
Pump motor rpm
V
kW
A
1400
230 - 400
2.2
8.8 - 5.1
1400
400
4
8.7
Ignition transformer V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
Electrical power consumption Light oil
Gas kW max 26 23 31 27
Protection level IP 54
Model RLS 1000/M C13 RLS 1200/M C13
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor rpm
V
kW
A
2964
400/690
21
41.8 - 24.2
2920
400/690
25
44.1 - 25.5
Pump motor rpm
V
kW
A
1400
230 - 400
2.2
9.3 - 5.4
1400
400
4
8.2
Ignition transformer V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
Electrical power consumption Light oil
Gas kW max 26 23 31 27
Protection level IP 54

9 20040160
GB
Technical description of the burner
4.6 Burner weight
The weight of the burner complete with its packaging is shown in
Tab. C.
Tab. C
4.7 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 2.
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. D
Model kg
RLS 1000/M C13 500
RLS 1200/M C13 540
Fig. 1
D11330
Fig. 2
D11331
mm ABCDEFGH I LR
RLS 1000/M C13 1575 675 200 413 885 DN80 1220 1315 485 1425 1165
RLS 1200/M C13 1575 658 200 455 885 DN80 1295 1315 462 1425 1165

20040160 10
GB
Technical description of the burner
4.8 Firing rates
The MAXIMUM OUTPUT is chosen from within the continuous
diagram area (Fig. 3).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RLS 1000/M C13 = 3750 kW
RLS 1200/M C13 = 5500 kW
4.9 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. 4).
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, consult the manufac-
turer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 4 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 7000 kW - diameter 120 cm - length 6 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 4:1
WARNING
The firing rate value (Fig. 3) 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 pag. 19.
1000 1800 2600 3400 4200 5000 5800 6600 7400 8200 9000 10600
0
2
4
6
8
10
12
14
16
18
20
22
24
26
9800 11400 12200
D11552
Combustion chamber
pressure - mbar
Thermal power - kW Fig. 3
RLS 1200/M C13RLS 1000/M C13
Fig. 4
Combustion chamber
m
D2448

11 20040160
GB
Technical description of the burner
4.10 Burner description
1 Lifting rings
2Fan
3Fanmotor
4 Air damper servomotor
5 Combustion head gas pressure test point
6 Combustion head
7 Ignition pilot
8 Flame stability disk
9 Electrical panel casing
10 Hinge for opening the burner
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas train flange
15 Shutter
16 Combustion head movement lever
17 Air damper movement levers
18 Minimum air pressure switch (differential operating type)
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 Cell UV
22 Pressure test point for air pressure switch “+”
23 Pump
24 Pump motor
25 Minimum oil pressure switch
26 Maximum oil pressure switch
27 Nozzle return pressure gauge
28 Nozzle delivery pressure gauge
29 Oil modulator
30 Gauge connection
31 Pilot gas train
32 3-way valve for the mechanical activation of the burner
lance
13
1
2
3
4
29
6
7
8
910
11
12 5
27
25
21
23
30
15 24
18
22
24
16 17
14
31
19
1
20
26
32
Fig. 5
D11332
CAUTION
The burner can be opened to the right or to the left
without links to the fuel supply side.

20040160 12
GB
Technical description of the burner
4.11 Electrical panel description
1 Main terminal supply board
2 Clean contacts output relay
3 Ignition transformer
4 Stop push-button
5 OFF-automatic-manual selector
6 Power increase - power reduction selector
7 Motor, fan/pump motor thermal relay indicator light
8 Light signalling of burner lockout and reset switch
9 Electrical control box
10 Timer
11 Air pressure switch
12 Fan motor contactor and thermal relay, star-triangle starter
13 Supply cables, external connections and kits
14 Fuel selector and enable signal to remote fuel selector
15 Auxiliary circuits fuse
16 Plug/socket servomotor
17 Valve plug/socket/Pump motor/PGm (Deriv. unit)
18 Pump motor contactor and thermal relay
19 Oil/Gas selection relay
20 Flame sensor plug/sensor socket
21 Light signalling of mains live state
22 Heat request indicator light
23 Light signalling of main fuel valve open
24 Terminal board for RWF40 kit
NOTE
Two types of burner failure may occur:
Control box lockout: if the control box button (red led)
9)(Fig. 6) and the backlit button 8) light up, it indicates that
the burner is in lockout.
Release by pressing the pushbutton 8).
Motors lockout: release by pressing the button on the rele-
vant thermal relay.
4.12 Burner equipment
Gasket for gas train flange . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M 16 x 70 gas flange fastener screws . . . . . . . . . . . . . . . . No. 8
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M 20 x 70 screws to secure the burner
flange to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Light gas flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Fitting 1” 1/2 - 3/4” (RLS 1200/M C13). . . . . . . . . . . . . . . . No. 1
Fitting 3/4” - 1/2” (RLS 1200/M C13) . . . . . . . . . . . . . . . . . No. 1
Rotating elbow 1/2” (RLS 1000/M C13). . . . . . . . . . . . . . . No. 1
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 6
D11333

13 20040160
GB
Technical description of the burner
4.13 Control box (LFL1.333..)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the LFL1333...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 opera-
tions, 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 func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
Do not press the reset button or the remote reset button of
the control box for more than 10 seconds because this will
damage the internal relay.
For safety and reliability, comply with the following instruc-
tions:
– avoid conditions that can favour the development of conden-
sate 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 LFL1.333.. is a control and supervision system of
medium and large capacity forced draught burners for intermit-
tent operation (at least one controlled shut-down every 24 hours).
Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble 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.
•
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 elec-
trocution. When connected to the electricity supply, the ioni-
sation 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).
Technical data
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box LFL1.333.. is a safety device!
Avoid opening or modifying it, or forcing its opera-
tion. Riello S.p.A. cannot assume any responsibil-
ity for damage resulting from unauthorised
interventions!
Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ±6 %
Fuse (Internal) T6.3H250V
Primary fuse (external) max. 10 A
Weight approx. 1 kg
Power absorption approx. AC 3.5 V
Protection level IP40
Safety class II
Input current at terminal 1 max. 5 A continuous (peaks of
20 A / 20 ms)
Load on the control
terminals max. 4 A continuous (peaks of 20 A / 20 ms)
Environmental conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60°C
< 95% RH
Fig. 7
S8414

20040160 14
GB
Technical description of the burner
4.14 Servomotor (SQM10.1....)
Warnings
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 ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. 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 damp-
er, the gears can be disengaged by means of a lever, allow-
ing the drive shaft to be easily adjusted in both directions of
rotation.
Technical data
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
Operating voltage AC 220...240V, 50 Hz –15 % / +10 %
AC 220 V, 60 Hz –15 % / +10 %
Auxiliary and limit switch-
es switching capacity 10 (3) A, AC 24...250 V
Angular positioning up to 160 ° (base scale)
Assembly position optional
Electrical protection IP 54, DIN 40050
Safety class IT
Weight approx. 1.7 kg
Actuator motor synchronous motor
Power absorption 9 VA
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-1
Class 1K3
Class 1M2
-20...+70°C
< 95% RH
Fig. 8
S8413

15 20040160
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The 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.
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 pos-
sibilities (H) (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
the 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.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 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 burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected and
disposed of in the appropriate places.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
and makes any installation or maintenance work
difficult.
R.B.L.
GAS-KAASU
GAZ-AEPIO
0085
RIELLO S.p.A.
I-37045 Legnago (VR)
CE
HEIZÖLFUEL
Fig. 9
D9243
ABC
EDF
HG
GH
I
L

20040160 16
GB
Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
5.5.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling.
For boilers with front flue passes 1)(Fig. 12) or flame inversion
chamber, a protection in refractory material 5) must be inserted
between the boiler fettling 2) and the blast tube 4).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 2)-
5)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
5.6 Securing the burner to the boiler
Insert the thermal protection supplied with the blast tube 4).
Insert the entire burner on the boiler hole, previously fitted,
as in Fig. 11, and fix it with the screws supplied.
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 10).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 10
2 3 4 51
D7739
mm A B C
RLS 1000/M C13 460 608 M 20
RLS 1200/M C13 500 608 M 20
Fig. 11
D455
Prepare a suitable lifting system using rings
3)(Fig. 12).
WARNING
The seal between burner and boiler must be
airtight.
7
83
1
2
4
1
5
D11334 Fig. 12

17 20040160
GB
Installation
5.7 Access to head internal part
In order to reach inside the combustion head (Fig. 13) proceed as
follows:
disconnect the electrical connections of the derivation unit
servomotor pump motor;
disconnect the leverages related to the cam and the move-
ment of the head 12);
unscrew the 4 fixing screws 1) and open the burner on the
hinge;
disconnect the cable 14) from the electrode 2);
disconnect the light oil pipes unscrewing the two pipe fit-
tings 3).
Release the ignition pilot fitting 13);
remove the screw/gas pressure socket 6) of the head;
unscrew the locking screw of the oil lance 9) and extract
the oil lance from the combustion head 10);
pull out the inner part of the head 5).
5.8 Electrode position
Be careful as some drops of fuel may leak out dur-
ing this phase.
Fig. 13
D11557
WARNING
Place the electrode on the ignition pilot observing
the dimensions specified in Fig. 14.
Fig. 14
18.5
0
-2
71.5
±1
Diffuser Electrode
D9218

20040160 18
GB
Installation
5.9 Nozzle installation
The burner complies with the emission requirements of the
EN 267 standard. In order to guarantee that emissions do not
vary, recommended and/or alternative nozzles specified by Riello
in the Instruction and warning booklet should be used.
Fit the nozzle with a 24 mm (for RLS 1000/M C13) and 41 mm
(for RLS 1200/C13 M) box wrench, passing from the centre open-
ing of the flame stability disc (Fig. 15).
Fit the nozzles with the fuel interception rod on the nozzle holder.
To calibrate the delivery range of operation of the nozzle, adjust
the fuel pressure on the nozzle return line, according to Tab. E.
5.9.1 Recommended nozzle
Complete range of nozzles:
• Bergonzo type B5 60°
350 - 375 - 400 - 425 - 450 - 475 - 500 - 525 - 550 - 575 - 600
650 - 700 - 750 - 800 - 850 - 900.
• Bergonzo type C3 - C5 60°
700 - 800 - 900 - 1000 - 1100
• Fluidics type W2 60°:
375 - 400 - 450 - 500 - 550 - 600 - 650 - 700 - 750.
Tab. E
WARNING
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.
WARNING
Do not use any sealing products such as gas-
kets, sealing compound, or tape.
Be careful to avoid damaging the nozzle seal-
ing seat.
The nozzle must be screwed into place tightly
but not to the maximum torque value pro-
vided by the wrench.
11.4 mm
Fig. 15
D11310
Model Nozzle
RLS 1000/E C13 – Bergonzo type B5 60°
– Fluidics type W2 60°
RLS 1200/E C13 – Bergonzo type C3 - C5 60°
Nozzle
kg/h Delivery
pressure
bar
Return
pressure
(bar) kg/h kW
Bergonzo B5 60°
350 18 8100 1200
20 17.5 315 3750
600 20 6140 1675
22 16 563 6700
750 20 6.5 180 2150
22 19 722 8600
900 16 4168 2000
20 15 867 10300
Bergonzo C3 - C5 60°
700 18 3172 2043
20 16 462 5500
700 18 3172 2043
20 19 635 7550
900 17 5237 2815
18 17.5 791 9400
1100 16 6273 3242
18 16.5 961 11425