Riello RLS Series Quick start guide

20020804 (3) - 06/2010
Installation, use and maintenance instructions
Dual fuel Light oil/Gas burners
Code Model Type
20019910 RLS 800/E US1 19910X
GB
Progressive two-stage or modulating operation

1 20020804
Index
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Danger: live components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Owner’s responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6.1 Burner description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6.2 Panel board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Notes on safety for the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Operation position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5.1 Boring the boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5.2 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5.3 Burner securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5.4 Accessibility to the interior of the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6 Choice of nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7 Electrode positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.8 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.9 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.9.1 Double-pipe circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.9.2 The loop circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10 Pressure variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.11 Hydraulic system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.12 Hydraulic connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.13 Rotation of fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14 Gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14.1 Gas train assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14.2 Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.14.3 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.15 Electrical wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.15.1 Notes on safety for the electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Notes on safety for the first start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Adjustments before first firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

20020804 2
Index
5.5 Combustion air adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Air/fuel control and power modulation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7 Final calibration of the pressure switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7.2 Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7.3 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.8 Final checks (with the burner working). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Maintenance programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Opening the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Exploded spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
A Appendix - Electrical panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Information and general instructions
3 20020804
1.1 Information about the instruction manual
1.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to another
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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
Maximum danger level!
This symbol indicates operations which, if not carried
out correctly, cause serious injury, death or long-
term health risks.
This symbol indicates operations which, if not carried
out correctly, may cause serious injury, death or
long-term health risks.
This symbol indicates operations which, if not carried
out correctly, may cause damage to the machine
and/or injury to people.
1.1.3 Danger: live components
This symbol indicates operations which, if not carried
out correctly, lead to electric shocks with lethal con-
sequences.
Other symbols
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
The instruction manual is supplied 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 carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system
is started up,
- maintenance and the need to have the system checked at
least once a year by the manufacturer or another special-
ised technician.
To ensure a periodic check, recommends the
drawing up of a Maintenance Contract.
1 Information and general instructions
DANGER
WARNING
CAUTION
............................................................................................
...........................................................................................
...........................................................................................
...........................................................................................
DANGER

20020804 4
Information and general instructions
1.2 Guarantee and responsibility
guarantees its new products from the installation date,
in accordance with the regulations in force and/or the sales con-
tract. At the moment of the first start-up, check that the burner is
integral and complete.
Failure to observe the information given in this man-
ual, operating negligence, incorrect installation and
the carrying out of non authorised modifications will
result in the annulment by of the guarantee
that it supplies with the burner.
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 non authorised modifications on the equip-
ment;
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 power 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 pre-
vent the regular development of the flame, as structurally
established;
insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
use of non-original components, including spare
parts, kits, accessories and optionals;
force majeure.
furthermore declines any and every responsibility
for the failure to observe the contents of this manual.
1.2.1 Owner’s responsibility
Please pay attention to the Safety Warnings contained within
this instruction manual. Keep this manual for your records and
provide it to your quali fi ed service agency for use in profession-
ally setting up and maintaining your burner.
Your burner will provide years of ef fi cient operation if it is pro-
fessionally installed and maintained by a qualifi ed service tech-
nician. If at any time the burner does not appear to be operating
properly, immediately contact your qualifi ed service agency for
consultation.
We recommend annual inspection/service of your gas heating
system by a qualifi ed service agency.
Failure to follow these instructions, misuse, or incorrect adjust-
ment of the burner could lead to equipment malfunction and re-
sult in asphyxiation, explosion or fire.
If you smell gas:
Do not touch any electrical items.
Open all windows.
Close all gas supply valves.
Contact your local gas authority immediately.
• Do not store flammable or hazardous materials in the vicinity of
fuel burning appliances.
• Improper installation, adjustment, alteration, service or mainte-
nance can cause property damage, personal injury or death.
• Refer to this manual for instructional or additional information.
• Consult a certified installer, service representative or the gas
supplier for further assistance.
• Burner shall be installed in accordance with manufacturers re-
quirements as outlined in this manual, local codes and authori-
ties having jurisdiction.
WARNING
WARNING

Safety and prevention
5 20020804
2.1 Introduction
The burners have been designed and built in compli-
ance 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 burn-
er or other items. Inattention, thoughtlessness and excessive
confidence often cause accidents; the same applies to tiredness
and sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described.
Any other use should be considered improper and therefore
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the manu-
facturer;
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 pres-
surisation of the combustion chamber, the dimensions of the
combustion chamber and the room temperature must all be
within the values indicated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety condi-
tions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
2.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people
working around it.
The user:
Undertakes to entrust the machine exclusively to suitably
trained and qualified personnel.
Must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine.
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.
Must inform the manufacturer if faults or malfunctioning of the
accident prevention systems are noticed, along with any pre-
sumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications given
in this manual.
Personnel must follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to inform their superiors of every prob-
lem 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 all responsibility for any damage that may
be caused by the use of non-original parts.
2 Safety and prevention

20020804 6
Technical description of the burner
3.1 Technical data
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394” wc - Altitude 329 ft - Fuel GCV.
(2) Pressure at test point 5) (Fig. 5), with zero pressure in the combustion chamber, and maximum burner output
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated
output.
* Firing rate for C-ETL Canadian Listing
3.2 Packaging
The packaging of the burner (Fig. 1) rests on a wooden plat-
form that is particularly suitable for lift trucks.
The overall dimensions of the packaging are shown in the
table.
The weight of the burner complete with its packaging is
shown in table.
Tab. 1
3 Technical description of the burner
MODEL RLS 800/E US1
Output (1) min. - max. kW
MBtu/hr
3885 - 8880
13256 - 30300
Oil fuel
- max. delivery (1) min. - max. Gph Oil #2
46 - 210
Gas fuel
- max. delivery
- pressure at max. delivery (2)
SCFH
PSI
Natural gas
28601
7
Operation Low - high or modulating
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Main power supply (+/-10%) Ph~V-Hz 3 ~ 460V - 60 Hz
Fan motor rpm
V
kW - HP
A
3520
460
21 - 28
36
Pump motor
rpm
V
kW - HP
A
3372
460
1.5
4
Ignition transformer V1 - V2
I1 - I2
120 V - 1 x 7 kV
1.6 A - 23 mA
Electrical power consumption kW - HP (max) 25 - 34
Electrical protection TYPE 13
inch A B C lbs
RLS 800/E US1 77 11/64“37 1/64“38 3/16“730
D36
Fig. 1

Technical description of the burner
7 20020804
3.3 Overall 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 by rotating the rear part on the hinge.
The overall dimensions of the burner when open are indicated by L and R.
Tab. 2
3.4 Burner equipment
The burner is supplied complete with:
Flange gasket
4 flange fixing screws M 16 x 50
4 screws to secure the burner flange to the boiler: M 18 x 70
2 spacers
Instruction manual and spare parts list
inch ABCDEF GH I L R S
RLS 800/E US1 52 3/16“22“ 7” 16 27/32“25” ANSI
DN3” 371/32“36” 15 17/64“46 1/4“41 17/32“12 19/32“
G
H
A B
I
D
E
C
F
R
S L
R
Fig. 2
D10071

20020804 8
Technical description of the burner
3.5 Firing rates
Maximum output must be selected in the range over the
hatched line of the diagram.
Minimum output must not be lower than the minimum limit
shown in the diagram:
The firing rate was obtained considering a room
temperature of 68 °F and an atmospheric pressure
of 394 “wc (approx. 0 ft above sea level), with the
combustion head adjusted.
The firing rates were obtained in special test boilers.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 26510 Mbtu/hr - diameter 47.7 inch - length 20 ft.
WARNING
0
2
4
6
8
10
12
14
16
18
20
mbar
22
24
9
8
7
6
5
4
3
2
0
1
w.c.
05600
5200
4800
4400
4000
360032002800
2400
20001600
1200
800
400 6000
26
9200
8800
8400
8000
760072006800
6400
MBtu/h
kW
10
0 2000 60004000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000
RLS 800/E US1
Burner power output
Combustion chamber pressure
Fig. 3
D10015
1000MBtu/hr760 1.5 7.5 11.3 18.9 37870
1.6
3.3
6.6
9.9
13.2
16.5
29.6
23.0
15.7 19.7 23.6 31.5 39.4 47.2
inches
ft
ft=0,12 MBtu
hr
22.7
Fig. 4
D9084

Technical description of the burner
9 20020804
3.6 Burner components
3.6.1 Burner description
1 Lifting eyebolts
2Fan
3 Fan motor
4 Air gate valve servomotor
5 Gas pressure test point
6 Combustion head
7 Ignition pilot
8 Flame stability disk
9 Electric panel board - cover
10 Hinge for opening burner
11 Air inlet to fan
12 Manifold
13 Thermal insulation screen for securing burner to boiler
14 Gas train flange
15 Shutter
16 Lever for movement of combustion head
17 Gears for movement of air damper
18 Air pressure switch (differential operating type)
19 Air pressure test point
20 Maximum gas pressure switch with pressure test point
21 Fireye infrared scanner
22 Air pressure test point pressure test point “+”
23 Oil modulator and gas butterfly valve servomotor
24 Pump
25 Pump motor
26 Minimum oil pressure switch
27 Oil shutoff valve
28 Nozzle delivery pressure gauge
29 Nozzle return pressure gauge
30 Oil modulator
31 Strainer
32 Check valve
33 Security relief valve
The burner can be opened either on the right or left
sides, irrespective of the side from which fuel is sup-
plied. When the burner is closed, the hinge can be re-
positioned on the opposite side.
1 1 5 67 89
11
12
14
151617 19
20 2930
2 3
4
10
13 1821 22
23 2426
OIL PIPING VIEW
2527 27 283132 33
Fig. 5
D10072
OIL PIPING VIEW
WARNING

20020804 10
Technical description of the burner
3.6.2 Panel board description
1 Ignition transformer
2 Main supply terminal strip
3 Entry for power cables and external leads
4 Air pressure switch
5 Terminal for shielded cables
Warning: used only to avoid a break in the cable’s shielding,
hence do not overtighten.
NOTA
Two types of burner failure may occur:
Flame control lockout: light 12) on the panel comes on to report
burner lockout. To reset, press pushbutton 12).
Motor trip: release by pressing the push button on thermal.
23
3
4
5
1
Fig. 6
D10073

Technical description of the burner
11 20020804
3.7 Actuators
Warning notes
To avoid injury to persons, damage to property
or the environment, the following warning notes
should be observed!
Do not open, interfere with or modify the actua-
tors!
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area of
the actuator, completely isolate the burner control from the
mains supply (all-polar disconnection).
Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
Check to ensure that wiring is in an orderly state.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not
exhibit any damage.
The housing cover may only be removed for
short periods of time for wiring or when making
the addressing.
It must be made certain that dust or dirt will not
get inside the actuator while such work is carried
out.
Use
The actuators (Fig. 7) are used to drive and position the air
damper and the gas butterfly valve, without mechanical leverag-
es but via the interposition of an elastic coupling.
When used in connection with burner controls or electronic fuel
/ air ratio control, the associated controlling elements are con-
trolled depending on burner output.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible dis-
tance.
• To ensure protection against electric shock hazard, make cer-
tain that the AC 230 V section of the actuator is strictly segregat-
ed from the functional low-voltage section.
• The holding torque is reduced when the actuator’s power supply
is switched off.
When servicing or replacing the actuators, take
care not to invert the connectors.
Technical data
Tab. 3
WARNING
WARNING
WARNING
Model SQM50.481R1Z4R
Operating voltage AC 120V
Power consumption 20 VA
Degree of protection To EN 60 529, IP 54, provided ade-
quate cable entries are used
On time 50 %, max. 3 min. continuously
Direction of rotation
(when facing the shaft)
- Standard: counterclockwise
- Reverse: clockwise
Running time (min.)
for 90° 25 s.
Holding torque (max.) 15 Nm
Weight approx. 3.3 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
class 3K3
class 3M3
-20...+60 °C
< 95 % r.h.
Fig. 7
D10074

20020804 12
Installation
4.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
All the installation, maintenance and disassembly op-
erations must be carried out with the electricity sup-
ply disconnected.
The installation of the burner must be carried out by
qualified personnel, as indicated in this manual and
in compliance with the standards and regulations of
the laws in force.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
With regard to the transport in the obligatory passages, refer to
the overall dimensions shown in Fig. 2.
The handling operations for the burner can be highly
dangerous if not carried out with the greatest atten-
tion: 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 quickly move if the burner should fall).
During the handling, keep the load at not more than 8-10” from
the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
4.3 Preliminary checks
Checking the consignment
After removing all the packaging, check the integrity
of the contents. In the event of doubt, do not use the
burner; contact the supplier.
The packaging elements (wooden cage or cardboard
box, nails, clips, plastic bags, etc.) must not be aban-
doned as they are potential sources of danger and
pollution; they should be collected and disposed of in
the appropriate places.
The output of the burner must be within the boiler's
firing rate;
A burner label that has been tampered with, removed
or is missing, along with anything else that prevents
the definite identification of the burner makes any in-
stallation or maintenance work difficult.
4.4 Operation position
The burner is designed to operate only in the positions 1, 2, 3
and 4(Fig. 8).
Installation 1is preferable, as it is the only one that allows the
maintenance operations as described in this manual. Installa-
tions 2, 3 and 4 permit operation but make maintenance and in-
spection of the combustion head more difficult.
Any other position could compromise the correct operation of
the appliance.
Installation 5is prohibited for safety reasons.
4Installation
DANGER
WARNING
WARNING
CAUTION
CAUTION
WARNING
WARNING
2 3 4 51
D7739
Fig. 8

Installation
13 20020804
4.5 Securing the burner to the boiler
4.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in (Fig. 9).
Tab. 4
4.5.2 Blast tube length
The length of the blast tube must be selected according to the
indications provided by the manufacturer of the boiler, and in
any case it must be greater than the thickness of the boiler door
complete with its fettling (the head should not jut out more than
4÷5 inch).
4.5.3 Burner securing
Create a suitable hoisting system by hooking onto the rings
4), removing the fastening screws 1) securing the cover 2)
first.
Slip the thermal protection onto the blast tube 3).
Place entire burner on the boiler hole (arranged previously,
see Fig. 9), and fasten with the screws given as standard
equipment.
The coupling of the burner-boiler must be airtight.
4.5.4 Accessibility to the interior of the combustion
head
Open burner at hinge (see Fig. 12) after removing the 4
screws 1).
Disconnect the wires 2) from the electrodes.
Disconnect the oil pipes by unscrewing the two connectors 3).
Note: While unscrewing, some fuel may leak out.
Unscrew the under part of the elbow 4) until it comes free of
its slot.
Extract the internal part 5) of the combustion head.
mm ABC
RLS 800/E US1 17 5/16“19 31/64“45/64W
Fig. 9
D455
4÷6"
REFRACTORY MATERIAL
D10002
Fig. 10
REFRACTORY MATERIAL
1 42
3
D10003
Fig. 11
Fig. 12
14
125
3
A
D3508

20020804 14
Installation
4.6 Choice of nozzle
Nozzles with no fuel shutoff needle must be fitted on the nozzle
holder.
To set the delivery range within which the nozzle must work,
nozzle return line fuel pressure must be adjusted according to
the table (Tab. 5-Tab. 6).
Tab. 5
Tab. 6
Recommended nozzle
• BERGONZO, type B5 45°;
• FLUIDICS, type N4 45°.
Intermediate flow rates may be obtained by choosing the nozzle
with a nominal flow rate slightly higher than that actually re-
quired.
Complete range of nozzles:
Bergonzo type B5 45° (Tab. 5):
350 - 375 - 400 - 425 - 450 - 475 - 500 - 525 - 550 - 575 - 600 -
650 - 700 - 750. We normally recommend 45° angles of pulver-
isation.
Fluidics type N4 45° (Tab. 6):
375 - 400 - 450 - 500 - 550 - 600 - 650 - 700 - 750. We normally
recommend 45° angles of pulverisation.
Fit the nozzle with the box spanner, fitting the spanner through
the central hole in the flame stability disk.
Do not use any sealing products such as gaskets, sealing com-
pound, 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.
4.7 Electrode positioning
Place the electrode on the ignition pilot observing the
dimensions specified in Fig. 13.
kg/h
Delivery
pressure
PSI
Return
pressure
PSI
kg/h GPH
375 290 166.8 147 45.7 Low fire
290 246.5 295 78 High fire
550 290 145 170 52.8 Low fire
290 246.5 421 130.7 High fire
650 290 116 180 56 Low fire
290 239.3 565 175.6 High fire
700 290 87 160 49.7 Low fire
290 232 630 195.7 High fire
750 290 108 180 55.9 Low fire
290 230 660 205 High fire
kg/h
Delivery
pressure
PSI
Return
pressure
PSI
kg/h GPH
375 290 174 147 45.7 Low fire
290 268.3 295 78 High fire
550 290 101.5 170 52.8 Low fire
290 232 421 130.7 High fire
650 290 87 180 56 Low fire
290 246.5 565 175.6 High fire
WARNING
2" 13/16
11/16"
Diffuser
Electrode
D10019
Fig. 13

Installation
15 20020804
4.8 Combustion head setting
In addition to varying air flow depending on the output request-
ed, the air gate valve servomotor 4) (Fig. 5) by means of a lifting
assembly - varies the setting of the combustion head.
This system allows an optimal setting even at a minimum firing
rate.
For the same servomotor rotation, combustion head opening
can be varied by moving the tie rod onto holes 1-2-3, Fig. 14.
The choice of the hole (1-2-3) to be used is decided on the basis
of diagram (Fig. 16) against the required maximum output.
Setting is pre-arranged in the plant for the maximum run (hole 3)
(Fig. 14).
When dealing with boilers featuring a strong back pressure, if air
delivery is insufficient even with the damper fully open, you can
use a different setting to that illustrated in diagram (Fig. 16) do
this by moving the tie rod onto the next highest index, thus in-
creasing the combustion head’s opening and hence air delivery.
If combustion requirements require you to move spacer 1) (Fig.
15) onto the 1st or 2nd hole of the gear and, at the same time,
the hinge is on the right, you need to fit the spacers 4) (Fig. 15)
supplied with the burner.
Proceed as follows:
first unscrew nuts 2), remove tie rod 3), unscrew spacer 1)
and position it on the hole you want,
screw the spacers 4) onto spacer 1) and screw 5) respec-
tively,
once done, refit the tie rod and nuts.
0
1
2
3
4
6
3
2
1
4
D3093 Fig. 14
D3409
Fig. 15
MBtu/hr
3
2
1
0
9090 10605 12120 13634 15149 16664 18179 19694 21209 272682575322723 24238 28782 302984545 6060 7575
3030
Fig. 16
D10023
Max burner output
RLS 800/E US1
N° Hole

20020804 16
Installation
4.9 Fuel supply
4.9.1 Double-pipe circuit
The burner is equipped with a self-priming pump which is capa-
ble 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 33 ft in order to avoid subject-
ing the pump's seal to excessive strain; the distance "V" must
not exceed 4 meters in order to permit pump self-priming even
when the tank is almost completely empty.
The tank lower than the burner B
Pump depression 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 en-
ter the burner from the same height; in this way it will be more
improbable that the suction line fails to prime or stops priming.
4.9.2 The loop circuit
A loop circuit consists of a loop of piping departing from and re-
turning to the tank with an auxiliary pump that circulates the fuel
under pressure. A branch connection from the loop goes to feed
the burner. This circuit is extremely useful whenever the burner
pump does not succeed in self-priming because the tank dis-
tance and/or height difference are higher than the values listed
in the Table.
Tab. 7
Key
H = Pump/Foot valve height difference
L = Piping length
Ø = Inside pipe diameter
1 = Burner
2=Pump
3=Filter
4 = Manual on/off valve
5 = Suction line
6 = Foot valve
7 = Rapid closing manual valve remote controlled (only Italy)
8 = On/off solenoid valve (only Italy). See layout of electric panel
board. Electrical connections set by installer (SV)
9 = Return line
10 = Check valve (only Italy)
1
2
4
8
5
9
10
7
6
6
7
A
B
3
5
9
10 cm
VH+H-
P
D3513
Fig. 17
+ H
- H
(ft)
L (ft)
Ø (inch)
1/2” 5/8”
+ 13 197 263
+ 10 164 230
+ 6.6 132 197
+ 4.8 115 181
+ 3.3 99 164
+ 1.6 82 148
066132
- 1.6 59 115
- 3.3 49 99
- 4.8 43 82
- 6.6 33 66
- 10 16 33
- 13 - 20

Installation
17 20020804
4.10 Pressure variator
Key
1 Nozzle pressure gauge
2 Position indicator (0 ÷ 90) of pressure variator
The pressure variator integrated into the valve unit of the oil cir-
cuit makes it possible to vary the pressure on return of the noz-
zle depending on the flow rate required.
Governing of the pressure on return is obtained with the varia-
tion of a section by rotating the servomotor 23)(A)page 12 which
simultaneously also controls the gas butterfly valve.
Pressure governor at 0° (maximum opening) minimum pressure
on nozzle return.
Pressure governor at 90° (minimum opening) = maximum pres-
sure on nozzle return.
The servomotor is operated by the electronic cam 4)(B) pag. 12;
by means of this device it is possible to set different curves for
oil and gas on the same servomotor (the air gate valve servomo-
tor 4)(A) pag. 12 may be operated in the same way.
• In adjusting with gas it is advisable to set the servomotor at 90°
in order to reduce losses from the gas butterfly valve.
• In regulating with oil, setting is made depending on the type of
nozzle used and on the modulation required. Under the condi-
tions of minimum firing rate, 20° rotation may be sufficient.
4.11 Hydraulic system layout
1 Pump suction
2 Pump and nozzle return
3 By-pass screw in pump
4 Pump pressure governor
5 Safety valve
6 Safety valve
7 Nozzle delivery
8 Nozzle without interception pin
9 Nozzle return
10 Pressure variator on nozzle return
11 Servomotor for pressure variator
12 Check valve (no dripping function)
13 Check valve (no dripping function)
14 Check valve
15 Pressure switch on pump delivery
16 Strainer
17 Security relief valve
M Pressure gauge
V Vacuometer
OPERATION
Pre-purging phase of closed valves 5), 6), 13) and 14).
Firing phase and operation of opened valves 5), 6), 13) and 14).
Halt: All the valves closed.
1 2
D9975 Fig. 18
11
10
M
M
1
2
M
4
V
M
3
P
15
9
8
7
M
12 13
16
14
65
17
D10024 Fig. 19

20020804 18
Installation
4.12 Hydraulic connections
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 3), see diagram Fig. 19.
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 con-
nections and screw them down.
Take care that the hoses are not stretched or twisted during in-
stallation.
Install the hoses where they cannot be stepped on or come into
contact with hot surfaces of the boiler and where they do not
hamper the opening of the burner.
Now connect the other end of the hoses to the suction and return
lines by using the supplied nipples.
4.13 Rotation of fan motor
The correct motor rotation direction is indicated by the phase se-
quence relay 16) (Fig. 6).
After turning the power on to the burner, check the green led
lights up on the phase sequence relay.
If the phase sequence is not correct, the burner does not fire.
4.14 Gas train
4.14.1 Gas train assembly
The gas train is to be connected on the right of the burner, by
flange 1) (Fig. 20).
If necessary:
connect it on the left of the burner;
loosen nuts and screws 3) and 4);
remove blind flange 2) together with its gasket;
fit them to flange 1) tightening the nuts and screws.
Note
Once assembled the gas train, check for leaks.
Fig. 20
D3095 P1 P4