Installation, use and maintenance instructions

Dual Fuel Gas / Light Oil BurnersElectronic cam version

RLS 70 - 100 - 130 /E

Modulating Gas / Low - High Oil Operation

C65050xx - 2915922 (3) - 10/2008

2CONTENTS

FUEL OIL / GASTechnical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUEL OILNozzle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUEL OILPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Pump priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GASGas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Adjustment before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUEL OIL / GASMaintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Oil hydraulic system layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

APPENDIX Procedure to refer burner operating condition in high altitude plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Factory wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

WARNING

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 main-tenance can cause property damage, personal injury or death. Refer to this manual for instructional or additional in-formation. Consult a certified installer, service representative or the gas supplier for further assistance.

Burner shall be installed in accordance with manufacturers requirements as outlined in this manual, local codes and au-thorities having jurisdiction.

3TECHNICAL DATA

(1) Reference conditions: Ambient temperature 68 F (20C) - Barometric pressure 394 WC - Altitude 329 ft.(2) Pressure at test point 18)(A)p.4 with zero pressure in the combustion chamber and maximum burner output.(3) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.(4) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.

Burner model designations:

ACCESSORIES (optional): Kit for lengthening the combustion head

L =Standard lengthL1 =Length obtainable with the kitCode 3010267 L = 9 27/32 L1 = 15 5/32 RLS 70/ECode 3010268 L = 9 27/32 L1 = 15 5/32 RLS 100/ECode 3010269 L = 9 27/32 L1 = 15 5/32 RLS 130/E

Kit for LPG operation - Code 3010305: The kit allows the RLS 70-100-130/E burners to operate on LPG.

Gas train according to UL standards: see page 11.

Model RLS 70/E RLS 100/E RLS 130/EOutput (1)Delivery (1)

High MBtu/hr (4) 1750 - 3094 2646 - 4396 3500 - 5292kW 513 - 907

12.5 - 22.1775 - 128818.9 - 31.4

1026 - 155125 - 37.8GPH

Low MBtu/hr (4) 854 1330 1750kW 250

6.13909.5

51312.5GPH

Fuel #2 Fuel oil Natural gas / Propane gas

Gas pressure at maximum delivery (2)Gas: Natural gas

WC 2.44 3.94 4.29

Operation Low-high light oil Low-high-low / modulating gas

Nozzles number 2Standard applications Boilers: water, steam, thermal oilAmbient temperature F 32 - 104 (0 - 40 C)Combustion air temperature F max 140 (60 C)Main power supply (+/- 10%) V/Ph/Hz 208 - 230 / 460 / 575 /3/60Electric motors rpm 3400Fan motor V

W - HPA

208 - 230 / 460 / 5751100 - 1.5

4.8 - 2.8 - 2.3

208 - 230 / 460 / 5751800 - 2.5

6.7 - 3.9 - 3.2

208 - 230 / 460 / 5752200 - 3

8.8 - 5.1 - 4.1Pump motor V

W - HPA

208 - 230 / 460 / 575550 - 0.75

2.6 - 1.5 - 1.2Ignition transformer Oil V1 - V2

I1 - I2120 V - 2 x 5 kV3.7 A - 35 mA

Gas V1 - V2I1 - I2

120 V - 1 x 7 kV1.6 A - 23 mA

Pump delivery (at 174 PSI)pressure rangefuel temperature

GPHPSI

F max

54145 - 290

140 (60 C)Electrical power consumption W max 2200 3000 3400Electrical protection NEMA 1Noise levels (3) dBA 74 77.5 80

Model Code VoltageAuxiliary panel with

electronic camCode

RLS 70/E C9834000 (3485074)C9834001 (3485074)208-230/460/3/60

575/3/60

3010348RLS 100/E C9835000 (3485274)C9835001 (3485274)208-230/460/3/60

575/3/60

RLS 130/E C9836000 (3485474)C9836001 (3485474)208-230/460/3/60

575/3/60

Important:The installer is responsible for the supply and installation of any required safety device(s) not indicated in this manual.

4BURNER DESCRIPTION (A)1 Combustion head2 Ignition electrodes3 Screw for combustion head adjustment4 Sleeve5 Cover6 Fan motor7 Motors contactors and thermal cut-out with reset but-

ton8 UV scanner9 Terminal strip10 Knockouts for electrical connections by installer11 Servomotor controlling gas butterfly valve12 Screw securing fan to sleeve13 Flame inspection window14 Low air pressure switch

(differential operating type)15 Slide bars for opening the burner and inspecting the

combustion head16 Safety solenoid valve17 Low and high fire oil valves18 Gas pressure test point and head fixing screw19 Air pressure test point20 Servomotor controlling the air damper21 Pump motor22 Low oil pressure switch23 Pilot attachment24 Pump25 Gas input connection26 Boiler mounting flange27 Flame stability disk

Motor trip: release by pressing the pushbutton on thethermal overload 7)(A).

PACKAGING - WEIGHT (B) - Approximate meas-urements The burners are skid mounted. Outer dimensions ofpackaging are indicated in (B). The weight of the burner complete with packaging isindicated in Table (B).

MAX. DIMENSIONS (C) - Approximate measure-mentsThe maximum dimensions of the burners are given in(C).Inspection of the combustion head requires the burnerto be opened and the rear part withdrawn on the slidebars.The maximum dimension of the burner when open, with-out casing, is give in measurement I.

STANDARD EQUIPMENT1 - Gas train flange1 - Flange gasket4 - Flange fixing screws1 - Burner head gasket4 - Screws to secure the burner flange to the boiler:

1/2 W x 1 3/81 - Adaptor G 1/8 / 1/8 NPT2 - Flexible hoses1 - Instruction booklet1 - Spare parts list

(A)

inch A B C lbsRLS 70/E 50 2525/32 343/4 159RLS 100/E 50 2525/32 343/4 165RLS 130/E 50 2525/32 343/4 170

(B)

RLS A B C D E F G H I L M N O

70/E 271/2 113/8 161/8 2127/32 333/32 927/32 71/16 1615/16 4523/32 87/16 59/32 823/32 2100/E 287/8 1225/32 161/8 2127/32 333/32 927/32 71/16 1615/16 4523/32 87/16 59/32 823/32 2130/E 287/8 1225/32 161/8 2127/32 333/32 927/32 77/16 1615/16 4523/32 87/16 59/32 823/32 2

(C)

D2985

D36

D2300

5FIRING RATES (A)MAXIMUM OUTPUT must be selected in area A.In order to increase to area B (RLS 130/E) it is neces-sary to perform the calibration of the combustion headas explained on page 6.

MINIMUM OUTPUT must not be lower than the mini-mum limit shown in the diagram:

RLS 70/E = 854 MBtu/hr = 6.1 GPHRLS 100/E = 1330 MBtu/hr = 9.5 GPHRLS 130/E = 1750 MBtu/hr = 12.5 GPH

Important: The FIRING RATE area values have been obtained con-sidering an ambient temperature of 68 F, and an atmos-pheric pressure of 394 WC and with the combustionhead adjusted as shown on page 7.

Note: The FIRING RATE areas given in figure (A) have beenreduced by 10% with respect to the maximum range thatcan be reached.

Consult Procedure on page 16 to refer burner operatingcondition in high altitude plants.

MINIMUM FURNACE DIMENSIONS (B)The firing rates were set in relation to certified test boil-ers. Figure (B) indicates the diameter and length of the testcombustion chamber.

ExampleOutput 2579 MBtu/hr:diameter 24 inch - length 6.6 ft.

(A)

RLS 70/E

RLS 100/E

RLS 130/E

Com

bust

ion

cham

ber p

ress

ure

WC

C

ombu

stio

n ch

ambe

r pre

ssur

eW

C

Com

bust

ion

cham

ber p

ress

ure

WC

A B

D2301

(B) D2919

A

A

ft

Diameter (inches)

Leng

th (f

t)Fu

rnac

e di

men

sion

s

6INSTALLATION

BOILER PLATE (A)Drill the combustion chamber mounting plate as shownin (A). The position of the threaded holes can be markedusing the gasket supplied with the burner.

BLAST TUBE LENGTH (B)The length of the blast tube must be selected accordingto the indications provided by the manufacturer of theboiler, it must be greater than the thickness of the boilerdoor complete with its insulation. The range of lengthsavailable, L (inch), is as follows:

Blast tube 10): RLS 70/E RLS 100/E RLS 130/E short 927/32 927/32 927/32 long 155/32 155/32 155/32

For boilers with front flue passes 13) or flame inversionchambers, insulation material 11) must be insertedbetween the refractory 12) and the blast tube 10).This protective insulation must not compromise theextraction of the blast tube.For boilers having a water-cooled front, the insulation11)-12)(B) is not required unless it is required by theboiler manufacturer.

SECURING THE BURNER TO THE BOILER (B)Detach the combustion head from the burner, fig. (B):- Disconnect the oil pipes by unscrewing the two con-

nectors 6)- Loosen the 4 screws 3) and remove the cover 1)- Remove the screws 2) from the slide bars 5)- Remove the 2 screws 4) and pull the burner back on

slide bars 5) by about 4.- Disconnect the electrode wires and then pull the

burner completely off the slide bars.

COMBUSTION HEAD CALIBRATIONAt this point check, on model RLS 130/E, whether themaximum delivery of the burner is contained in area A orin area B of the firing rate. See page 5.If it is in area A then no adjustment is required.If it is in area B:- Unscrew the screws 1)(C) and disassemble the blast

tube 2).- Move the fixing of the rod 3)(C) from position A to

position B, thereby causing the shutter 4) to retract.- Now refit the blast tube 2)(C) and the screws 1).

Once this operation has been carried out, secure theflange 9)(B) to the boiler plate, inserting the gasket 7)(B)supplied with the burner. Use the 4 screws, also sup-plied with the unit, after first protecting the thread with ananti-seize product. Tighten the seal between burner andboiler.

NOZZLE SELECTIONBoth nozzles must be chosen from among those listed inTable (D).The first nozzle determines the delivery of the burner inlow fire.The second nozzle combines together with the 1st noz-zle to determine the total firing rate at high fire.The total firing rates of low and high fire must be con-tained within the value range indicated on page 3.Use nozzles with a 60 spray angle at the recommendedpressure of 174 PSI.The two nozzles have equal deliveries rates.

(D)

inch A B C

RLS 70/E 79/32 1027/32 - 1225/32 1/2 WRLS 100/E 721/32 1027/32 - 1225/32 1/2 WRLS 130/E 721/32 1027/32 - 1225/32 1/2 W

D455(A)

(B)

(E)

D2986

Nozzlesize

GPH MBtu/hr174 PSI145 PSI 174 PSI 203 PSI

5.005.506.006.507.007.508.008.308.509.009.5010.010.511.012.012.313.013.814.015.015.316.017.0

6.156.767.48.018.619.229.86

10.2110.4711.0811.6912.3

12.9413.5414.7615.1516.0117.0

17.2318.4818.8319.6920.94

6.797.468.178.849.5110.1810.8611.2711.5612.2312.9013.5814.2814.9516.316.7117.6418.7319.0220.3720.7821.7423.09

7.48.138.879.6110.3411.0811.8212.2612.5513.2914.0314.7615.4916.2317.7118.1619.1820.2720.6522.1622.5723.6325.1

9511044114412381331142515201578161817121806190119992093228223392470262226632852290930443514

D1122

(C) D1192

7NOZZLE ASSEMBLYRemove screw 1)(E) and extract the nozzle assembly2)(E) (see page 6). Install both nozzles 1)(A), after hav-ing removed the plastic plugs 2)(A), fitting the wrenchthrough the central hole in the flame stability disk orloosen screws 1)(B), remove disk 2)(B) and replace thenozzles using the wrench 3)(B).Do not use any sealing products such as gaskets, seal-ing compound, or tape. Be careful to avoid damagingthe nozzle sealing seat. The nozzles must be screwedinto place tightly but carefully.The nozzle for low fire operation is the one lying beneaththe firing electrodes Fig. (C).

Make sure that the electrodes are positioned as shownin Figure (C).Refit the burner to the slide bars 3)(G) at approximately4 from the sleeve 4) - burner positioned as shown in fig.(B)p. 6 - insert the ignition electrode cables and thenslide the burner up to the sleeve so that it is positionedas shown in fig. (G).Refit screws 2)(G) on slide bars 3).Secure the burner to the sleeve by tightening screws 1).Connect the oil pipes again by screwing on the two con-nectors 6)(B)p.6.

ImportantWhen fitting the burner on the two slide bars, it is advis-able to gently draw out the high tension cables until theyare slightly stretched.

ADJUSTMENTS BEFORE FIRST FIRING(light-oil operation) Combustion head settingThe setting of the combustion head depends exclusivelyon the maximum delivery of the burner.Turn screw 5)(E) until the notch shown in diagram (F) islevel with the front surface of flange 6)(E).

Example: Burner RLS 100/Emaximum burner delivery = 23.1 GPH.If diagram (F) is consulted it is clear that for this delivery,the combustion head must be adjusted using notch 3, asshown in fig. (E).

Pump adjustmentNo settings are required for the pump, which is set to174 PSI by the manufacturer. This pressure must bechecked and adjusted (if required) after the burner hasbeen ignited.The only operation required in this phase is the applica-tion of a pressure gauge on the appropriate pumpattachment.

Air damper adjustmentThe first time the burner is fired leave the factory settingunchanged for both low and high fire operation.

Ignition pilot adjustmentPlace the pilot and electrode as shown in fig. (D). The pilot works correctly at pressures ranging from 6 -12 WC.

(A)

(D)

D1146 D1147

D2539

D1149

N Notches

Maximum fuel oil delivery USGPH

D2304

(B)

D2987

ELECTRODE POSITION (for OIL operation)

(G)

(F)

(C)

(E)

Ignition pilot

Electrode

D2591

1/32

8PUMP (A)1 - Suction 1/4 NPT2 - Return 1/4 NPT3 - Pressure gauge attachment G 1/84 - Vacuum gauge attachment G 1/85 - Pressure regulator

A - Min. delivery rate at 174 PSI pressureB - Delivery pressure rangeC - Max. suctionD - Viscosity rangeE - Max fuel oil temperatureF - Max. suction and return pressureG - Pressure calibration in the factoryH - Filter mesh width

(A)

PUMPSUNTEC AJ4 CC

AJ4 CC

ABCDEFGH

GPHPSIHgcSt

F - CPSIPSIinch

54145 - 290

132.8 - 75140 - 60

29174

0.006

D2306

9FUEL SUPPLY (A)The burner is equipped with a self-priming pump whichis capable of feeding itself within the limits listed in thetable at the left.The tank higher than the burner AThe distance "P" must not exceed 33 ft in order to avoidsubjecting the pump's seal to excessive strain; the dis-tance "V" must not exceed 13 ft in order to permit pumpself-priming even when the tank is almost completelyempty.The tank lower than the burner BPump suction pressures higher than 13 Hg must not beexceeded because at higher levels gas is released fromthe fuel, the pump starts making noise and its workinglife-span decreases.It is good practice to ensure that the return and suctionlines enter the burner from the same height; in this way itwill be more improbable that the suction line fails toprime or stops priming.

KeyH =Pump/Foot valve height differenceL =Piping length =Inside pipe diameter1 =Burner2 =Pump3 =Filter4 =Manual on/off valve5 =Suction line6 =Foot valve7 =Return line

HYDRAULIC CONNECTIONS (B)The pumps are equipped with a by-pass that separatesreturn line and suction line. The pumps are installed onthe burner with the by-pass closed by screw 6), see dia-gram page 15.It is therefore necessary to connect both hoses to thepump.Damage to the pump seal will occur immediately if itis run with the return line closed and the by-passscrew inserted.Remove the plugs from the suction and return connec-tions of the pump.Insert the hose connections with the supplied seals intothe connections and screw them down. Take care that the hoses are not stretched or twistedduring installation.Install the hoses where they cannot be stepped on orcome into contact with hot surfaces of the boiler andwhere they do not hamper the opening of the burner.Now connect the other end of the hoses to the suctionand return lines.

PUMP PRIMING- Before starting the burner, make sure that the

tank return line is not clogged. Obstructions inthe line could cause damage to the pump seal.(The pump leaves the factory with the by-passclosed).

- Also check to make sure that the valves located onthe suction line are open and that there is sufficientfuel in the tank.

- For self-priming to take place, one of the screws 3) ofthe pump (See fig.(A) page 8) must be loosened inorder to bleed off the air contained in the suction line.

(A)

6

7

5 3

2

1

4

- H

315 /

16 + H

V

P

57

A

B

6

D2988

+ H- Hft

L ftRLS 70 - 100 - 130/E

inch3/8 1/2 5/8

+ 13+ 10+ 6.6+ 3.3+ 1.6

100 88 75 68 52

210180155140110

320320320320270

0 45 98 240- 1.6- 3.3- 6.6- 10

392619--

85 55 42 13

200140104 36

D2989(B)

10

GAS PRESSUREThe adjacent tables are used to calculate manifold pres-sure taking into account combustion chamber pressure.

Column 1Gas manifold pressure measured at test point 1)(B),with: Combustion chamber at 0 WC Burner operating at maximum output Natural gas

Calculate the approximate high fire output of the burneras follows:- subtract the combustion chamber pressure from the

gas pressure measured at test point 1)(B).- Find the nearest pressure value to your result in col-

umn 1 of the table for the burner in question.- Read off the corresponding output on the left.

Example - RLS 100/E Maximum output operation Natural gas Gas pressure at test point 1)(B) = 4.41 WC Pressure in combustion chamber = 0.79 WC

4.41 - 0.79 = 3.62 WCA maximum output of 3616 MBtu/hr shown in Table RLS100 corresponds to 3.62 WC pressure, column 1, natu-ral gas.This value serves as a rough guide, the effective deliv-ery must be measured at the gas meter.

(A)

(B)

RLS 70/E p ( WC)

RLS 100/Ep ( WC)

RLS 130/Ep ( WC)

MBtu/hr 1

1750 2.171950 2.202140 2.242329 2.282519 2.322708 2.362897 2.403094 2.44

MBtu/hr 1

2646 3.152878 3.273125 3.393371 3.503616 3.623863 3.704109 3.824396 3.94

MBtu/hr 1

3500 3.663825 3.744128 3.824431 3.904734 4.095037 4.29

D2990

1

2

11

GAS LINE The main gas train must be connected to the gas

attachment 1)(A), using flange 2), gasket 3) andscrews 4) supplied with the burner.

The main gas train can enter the burner from theright or left side, see fig. (A).

Gas safety shut-off valves 5)-6)(B) must be as closeas possible to the burner to ensure gas reaches thecombustion head within the safety time range.

The pilot gas train must be connected to the gasattachment 5)(A) and can enter the burner from theright or left side.

GAS TRAIN (B)It must be type-approved according to required Stand-ards and is supplied separately from the burner.

NoteSee the accompanying instructions for the gas train layout.

KEY TO LAYOUT (B)1 - Gas input pipe2 - Manual valve3 - Pressure regulator4 - Low gas pressure switch5 - 1st safety shut off valve6 - 2nd safety shut off valve 7 - Standard issue burner gasket with flange8 - Gas butterfly valve9 - Burner

(A)

(B)

D2310

D2311

TYPICAL UL SCHEMATIC GAS PIPING

GAS PILOT LINE

MAIN GAS LINE

12

ADJUSTMENTS BEFORE FIRST FIRINGAdjustment of the combustion head has been illustratedon page 7. In addition, the following adjustments must also bemade: - Open manual valves up-stream from the gas train.- Adjust the low gas pressure switch to the start of the

scale (A).- Adjust the high gas pressure switch to the upper limit

of the scale (B).- Adjust the air pressure switch to the zero position of

the scale (C).- Purge the air from the gas line.- Fit a U-type manometer (D) to the gas pressure test

point on the sleeve.The manometer readings are used to calculate MAX.burner power using the tables on page 10.

Before starting up the burner it is good practice to adjustthe gas train so that ignition takes place in conditions ofmaximum safety, i.e. with gas delivery at the minimum.

(A)

(D)

LOW GAS PRESSURE SWITCH AIR PRESSURE SWITCHHIGH GAS PRESSURE SWITCH

(B) (C)

D2991

13

AIR PRESSURE SWITCH (A)Adjust the air pressure switch after having performed allother burner adjustments with the air pressure switch setto the start of the scale (A).With the burner operating at min. output, increase adjust-ment pressure by slowly turning the relative dial clock-wise until the burner locks out.Then turn the dial anti-clockwise by about 20% of the setpoint and repeat burner starting to ensure it is correct.If the burner locks out again, turn the dial anti-clockwisea little bit more.

Attention:as a rule, the air pressure switch must prevent the forma-tion of CO.To check this, insert a combustion analyser into thechimney, slowly close the fan suction inlet (for examplewith cardboard) and check that the burner locks out,before the CO in the fumes exceeds 400 ppm.

The air pressure switch may operate in "differential"operation in two pipe system. If a negative pressure inthe combustion chamber during pre-purging preventsthe air pressure switch from switching, switching may beobtained by fitting a second pipe between the air pres-sure switch and the suction inlet of the fan. In such amanner the air pressure switch operates as differentialpressure switch.

HIGH GAS PRESSURE SWITCH (B)Adjust the high gas pressure switch after having per-formed all other burner adjustments with the maximumgas pressure switch set to the end of the scale (B).With the burner operating at MAX output, reduce theadjustment pressure by slowly turning the adjustmentdial anticlockwise until the burner locks out.Then turn the dial clockwise by 0.8 WC and repeatburner firing.If the burner locks out again, turn the dial again clock-wise by 0.4 WC.

LOW GAS PRESSURE SWITCH (C)Adjust the low gas pressure switch after having per-formed all the other burner adjustments with the pressureswitch set at the start of the scale (C).With the burner operating at MAX output, increase ad-justment pressure by slowly turning the relative dialclockwise until the burner locks out.Then turn the dial anti-clockwise by 0.8 WC and repeatburner starting to ensure it is uniform.If the burner locks out again, turn the dial anti-clockwiseagain by 0.4 WC.

(A)

(B)

AIR PRESSURE SWITCH

(C)

HIGH GAS PRESSURE SWITCH

LOW GAS PRESSURE SWITCH

D2548

D2547

D2547

14

MAINTENANCECombustionThe optimum calibration of the burner requires an analy-sis of the flue gases. Significant differences with respectto the previous measurements indicate the points wheremore care should be exercised during maintenance.

Gas leaksMake sure that there are no gas leaks on the pipeworkbetween the gas meter and the burner.

Flame inspection windowClean the flame inspection window (A).

Combustion headOpen the burner and make sure that all components ofthe combustion head are in good condition, notdeformed by the high temperatures, free of impuritiesfrom the surroundings and correctly positioned. If indoubt, disassemble the elbow fitting 7)(C).

Nozzles (fuel oil)Do not clean the nozzle orifices. The nozzle filters how-ever may be cleaned or replaced as required.Replace the nozzles every 2-3 years or whenever nec-essary. Combustion must be checked after the nozzleshave been changed.

UV scannerClean the glass cover from any dust that may haveaccumulated. The scanner 1)(B) is held in position by apressure fit and can therefore be removed by pulling itoutward forcefully.

Flexible hoses (fuel oil)Check to make sure that the flexible hoses are still ingood condition and that they are not crushed or other-wise deformed.

BurnerCheck for excess wear or loose screws. Also make surethat the screws securing the electrical leads in theburner connections are fully tightened.Clean the outside of the burner.

CombustionAdjust the burner if the combustion values found at thebeginning of the operation do not comply with the regu-lations in force, or at any rate, do not correspond togood combustion.

TO OPEN THE BURNER (C):- Switch off the electrical power- Loosen screws 1) and withdraw the cover 2)- Disengage the swivel coupling 7) from the graduated

sector.- Disconnect the light-oil pipes.- Remove screws 3) and pull the burner back by about

4 on the slide bars. Disconnect the electrode leadsand then pull the burner fully back.

Now extract the internal part 5) after having removed thescrew 6).

TO CLOSE THE BURNER (C):- Push the burner until it is about 4 from the sleeve.- Re-connect the leads and slide in the burner until it

comes to a stop. - Refit screws 3) and pull the leads gently out until they

are slightly stretched. - Re-couple the swivel coupling 7) to the graduated sec-

tor. - Reconnect the light-oil pipes.

MEASUREMENT OF DETECTOR CURRENTMeasurement of the detectors signal with a Voltmeter isnot normally required since the flame signals intensity isshown on the AZL...display and operating unit.

(A)

(B)

(C)

FLAME INSPECTION WINDOW

D484

UV SCANNER

OPENING THE BURNER

D2992

D2993

1

(D) D3020

15

OIL HYDRAULIC SYSTEM LAYOUT (A)1 Pump suction2 Filter3 Pump4 Pressure regulator5 Return pipe6 By-pass screw7 Pump return8 Safety solenoid9 Low fire valve10 High fire valve11 FilterM Pressure gaugeP low oil pressure switchV Vacuum gauge

OIL PRESSURE SWITCHThe oil pressure switch 22)(A) page 4 is factory set to145 PSI (10 bar). If the oil pressure goes down to thisvalue, the pressure switch stops the burner.

(A) D2592

16

PROCEDURE TO REFER BURNER OPERATING CONDITION IN HIGH ALTITUDE PLANTS- Find the corrected burner capacity for the plants altitude in chart 1 and the corrected pressure in chart 2.- Check in the firing rate graph of the burner (page 5), if the working point defined by the values above is within the range limits.

If not, higher burner size is needed.

Reference conditions (Charts 1-2): Ambient temperature 68 F (20 C) - Barometric pressure 394 WC (1000 mbar) - Altitude 328 ft a.s.l. (100 m a.s.l.)

NoteCharts are based only on altitude variation(reference temperature = 68F , 20C)

To get the combined correction in case of differentair temperature, a compensation of 1000 ft each20F (305 m each 11C) is applicable.

ExampleRated capacity = 3000 MBtu/hr - Rated air pressure = 1.5w.c.Real altitude = 5000 ft - Real temperature = 108F = 108F - 68F (reference temp.) = 40F (equivalent 2000 ft variation)Proceeding as descripted above and considering a virtual altitude of (5000 + 2000) ft:- the corrected capacity is 3847 MBtu/hr;- the corrected burner air pressure is 1.92. Burner RLS 100 is OK

m. a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000

500 494 500 512 530 551 571 593 616 641 6691000 987 1000 1023 1061 1101 1142 1186 1232 1282 13371500 1481 1500 1535 1591 1652 1713 1778 1848 1924 20062000 1974 2000 2046 2121 2202 2284 2371 2464 2565 26752500 2468 2500 2558 2652 2753 2855 2964 3079 3206 33433000 2962 3000 3069 3182 3303 3425 3557 3695 3847 40123500 3455 3500 3581 3712 3854 3996 4149 4311 4488 46804000 3949 4000 4092 4243 4404 4567 4742 4927 5130 53494500 4442 4500 4604 4773 4955 5138 5335 5543 5771 60185000 4936 5000 5116 5303 5505 5709 5928 6159 6412 66865500 5429 5500 5627 5834 6056 6280 6520 6775 7053 73556000 5923 6000 6139 6364 6606 6851 7113 7391 7694 80246500 6417 6500 6650 6894 7157 7422 7706 8006 8335 86927000 6910 7000 7162 7425 7708 7993 8299 8622 8977 93617500 7404 7500 7673 7955 8258 8564 8892 9238 9618 100298000 7897 8000 8185 8485 8809 9135 9484 9854 10259 106988500 8391 8500 8697 9016 9359 9705 10077 10470 10900 113679000 8885 9000 9208 9546 9910 10276 10670 11086 11541 120359500 9378 9500 9720 10076 10460 10847 11263 11702 12183 1270410000 9872 10000 10231 10607 11011 11418 11855 12318 12824 13373

Average barometric Pressure (20C) mbar 1013 1000 977,4 942,8 908,2 875,8 843,5 811,85 779,8 747,8

Average barometric Pressure (68F) "w.c. 399 394 385 371 358 345 332 320 307 294

Rated Capacity

Altitude

CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE1

m. a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000

0,50 0,49 0,50 0,51 0,53 0,55 0,57 0,59 0,62 0,64 0,671,00 0,99 1,00 1,02 1,06 1,10 1,14 1,19 1,23 1,28 1,341,50 1,48 1,50 1,53 1,59 1,65 1,71 1,78 1,85 1,92 2,012,00 1,97 2,00 2,05 2,12 2,20 2,28 2,37 2,46 2,56 2,672,50 2,47 2,50 2,56 2,65 2,75 2,85 2,96 3,08 3,21 3,343,00 2,96 3,00 3,07 3,18 3,30 3,43 3,56 3,70 3,85 4,013,50 3,46 3,50 3,58 3,71 3,85 4,00 4,15 4,31 4,49 4,684,00 3,95 4,00 4,09 4,24 4,40 4,57 4,74 4,93 5,13 5,354,50 4,44 4,50 4,60 4,77 4,95 5,14 5,33 5,54 5,77 6,025,00 4,94 5,00 5,12 5,30 5,51 5,71 5,93 6,16 6,41 6,695,50 5,43 5,50 5,63 5,83 6,06 6,28 6,52 6,77 7,05 7,356,00 5,92 6,00 6,14 6,36 6,61 6,85 7,11 7,39 7,69 8,026,50 6,42 6,50 6,65 6,89 7,16 7,42 7,71 8,01 8,34 8,697,00 6,91 7,00 7,16 7,42 7,71 7,99 8,30 8,62 8,98 9,367,50 7,40 7,50 7,67 7,96 8,26 8,56 8,89 9,24 9,62 10,038,00 7,90 8,00 8,18 8,49 8,81 9,13 9,48 9,85 10,26 10,708,50 8,39 8,50 8,70 9,02 9,36 9,71 10,08 10,47 10,90 11,379,00 8,88 9,00 9,21 9,55 9,91 10,28 10,67 11,09 11,54 12,049,50 9,38 9,50 9,72 10,08 10,46 10,85 11,26 11,70 12,18 12,70

10,00 9,87 10,00 10,23 10,61 11,01 11,42 11,86 12,32 12,82 13,37Average barometric

Pressure (20C) mbar 1013 1000 977,4 942,8 908,2 875,8 843,5 811,85 779,8 747,8

Average barometric Pressure (68F) "w.c. 399 394 385 371 358 345 332 320 307 294

Rated Pressure

Altitude

CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE2

17

Factory Wiring Diagram RLS 70 - 100 - 130/E

Key to layoutsB7 - QRI detectorF1 - Fan motor thermal overloadF2 - Pump motor thermal overloadK1 - Fan motor contactorK2 - Pump motor contactorM1 - Fan motorM2 - Pump motorSM1 - ServomotorSM2 - ServomotorS10 - Air pressure switchS12 - Maximum gas pressure switchS14 - Minimum oil pressure switchT1 - Gas ignition transformerT2 - Oil ignition transformerTB - Burner groundXMB - Burner terminal stripXQ - 32-pin plugY20 - Safety valveY21 - 1st stage oil valveY22 - 2nd stage oil valve

NOTES The setting of the thermal overload must be according to the total

burner amperage draw.

The RLS 70-100-130/E burners leave the factory preset for 208-230 V power supply. If 460 V power supply is used, change thefan motor connection from delta to star and change the setting ofthe thermal overload as well.

For the installation, electrical connections, start-up and setting of the LMV51... electronic cam, see the instructions supplied with the auxiliary panel.

Important noteWhen installing for the first time and after anymaintenance work, make sure the gas valves areconnected properly to the orange terminals before

proceeding to ignite the burner. Insert auxiliary lamps or check,with the aid of a tester, that power is not being supplied to thevalves during standby or pre-purging. Burner ignition with thegas valves open during pre-purging may cause the generator toburst.

Burner electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . 18

Burner electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . 19

DescriptionElectricalsheet

Page

1

2

18

F

A

C

T

O

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74

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481165

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15

23

2728

26

24

3334

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3334363837

1873

4950

51 52

32

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55

56

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63

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384

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262

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011

3012

969

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2030

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059

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TOR

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2330

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9

H

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CO

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AMEN

TO24

3013

040

ELE

CTR

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3013

041

ELE

CTR

OD

ELE

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O26

3012

430

SUP

POR

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2730

1304

2

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3012

042

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DE

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ON

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NE

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

C9835001 (3485274)

C9836000 (3485474)

C9836001 (3485474)

22

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RN

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7

SE

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ION

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CO

NN

EC

TOR

RAC

CO

RD

O36

3003

381

SEAL

GU

ARN

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NE

3730

1304

3

SC

OO

PTA

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3730

1304

4

SC

OO

PTA

ZZA

3730

1304

5

SC

OO

PTA

ZZA

3830

1243

6

G

AS N

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LED

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437

GAS

HE

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4030

1204

9

SC

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4130

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4

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4330

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8

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4330

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END

CO

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4530

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6

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CO

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267

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2

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681

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3013

031

M

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3013

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6630

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MP

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PA67

3003

936

FILT

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SEA

LFI

LTR

O +

GU

ARN

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NE

6730

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FOR

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P M

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8-23

0/46

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LE' T

ERM

ICO

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MO

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V

N.

CO

DE

DES

CR

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ON

DES

CR

IZIO

NE

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

C9835001 (3485274)

C9836000 (3485474)

C9836001 (3485474)

23

N.

CO

DE

DES

CR

IPTI

ON

DES

CR

IZIO

NE

BU

RN

ER

SER

IAL

NU

MBE

RM

ATR

ICO

LA B

RU

CIA

TOR

E

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

C9835001 (3485274)

C9836000 (3485474)

C9836001 (3485474)

6730

1313

1

OVE

RLO

AD+C

ON

TAC

TOR

FO

R P

UM

P M

OTO

R 5

75V

REL

E' T

ERM

ICO

+CO

NTA

TTO

RE

MO

TOR

E PO

MPA

575

V68

3003

952

SOU

ND

DA

MP

ING

FON

OA

SSO

RB

ENTE

7030

1295

6

TR

ANS

FOR

MER

TRA

SFO

RM

ATO

RE

7130

1212

5

C

ON

NEC

TOR

RAC

CO

RD

O72

3012

003

SCR

EWPE

RN

O73

3013

055

TUBE

TUBE

TTO

7430

1212

3

C

ON

NEC

TOR

RAC

CO

RD

O75

3013

132

AUX

ILIA

RY

CO

NTA

CT

BLO

CK

CO

NTA

TTO

AU

SIL

IAR

IO76

3013

492

CO

UPL

ING

GIU

NTO

24

BURNER START UP REPORT

Model number:

Project name:

Installing contractor:

Serial number:

Start-up date:

Phone number:

GAS OPERATION

Gas Supply Pressure:

Main Power Supply:

Control Power Supply:

Burner Firing Rate:

Manifold Pressure:

Pilot Flame Signal:

Low Fire Flame Signal:

High Fire Flame Signal:

CO2: Low Fire

O2: Low Fire

CO: Low Fire

NOX: Low Fire

Net Stack Temp - Low Fire:

Comb. Efficiency - Low Fire:

Overfire Draft:

High Fire

High Fire

High Fire

High Fire

High Fire:

High Fire:

OIL OPERATION

Oil supply pressure:

Oil suction pressure:

Control Power Supply:

Burner Firing Rate:

Low Fire Flame Signal:

High Fire Flame Signal:

Low Fire Nozzle Size:

High Fire Nozzle Size:

CO2: Low Fire

O2: Low Fire

CO: Low Fire

NOX: Low Fire

Net Stack Temp - Low Fire:

Comb. Efficiency - Low Fire:

Overfire Draft:

Smoke number:

High Fire

High Fire

High Fire

High Fire

High Fire:

High Fire:

CONTROL SETTINGS

Operating Setpoint:

High Limit Setpoint:

Low Gas Pressure:

High Gas Pressure:

Low Oil Pressure:

High Oil Pressure:

Flame Safeguard Model Number:

Modulating Signal Type:

NOTES

RIELLO S.p.A.Via degli Alpini 1I - 37045 Legnago (VR)Tel.: +39.0442.630111 Fax: +39.0442.630375http:// www.rielloburners.com

RIELLO BURNERS NORTH AMERICA35 Pond Park Road 1-800-4-RIELLO 2165 Meadowpine Blvd.Hingham, Massachusetts, 1-800-474-3556 Mississauga, Ontario, U.S.A. 02043 Canada L5N 6H6

http://www.riello-burners.com

Subject to modifications