Installation, use and maintenance instructions

Dual Fuel Gas / Light Oil Burners

Electronic cam version

11 / 15 / 2002

Preliminary
copy

RLS 70 - 100 - 130 /E

Modulating Gas / Low - High Oil Operation

C65050xx - 2915922 (0)

CONTENTS WARNING
FUEL OIL / GAS
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3 If you smell gas:
Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • Do not touch any electrical items.
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Open all windows.
Packaging - Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Close all gas supply valves.
Max. dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Contact your local gas authority immediately.
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Do not store flammable or hazardous materials in the vicinity
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 of fuel burning appliances.
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Improper installation, adjustment, alteration, service or main-
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6 tenance can cause property damage, personal injury or
death. Refer to this manual for instructional or additional in-
FUEL OIL formation. Consult a certified installer, service representative
Nozzle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 or the gas supplier for further assistance.
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Burner shall be installed in accordance with manufacturers
requirements as outlined in this manual, local codes and au-
FUEL OIL
thorities having jurisdiction.
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

FUEL OIL / GAS

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil hydraulic system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ELECTRICAL WIRING
Factory wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix - Burner firing rates according to air density. . . . . . . . 20
Start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2
TECHNICAL DATA

Model RLS 70/E RLS 100/E RLS 130/E

Output (1) Maximum MBtu/hr (4) 1750 - 3094 2646 - 4396 3500 - 5292
Delivery (1) kW 513 - 907 775 - 1288 1026 - 1551
GPH 12.5 - 22.1 18.9 - 31.4 25 - 37.8
Minimum MBtu/hr (4) 854 1330 1750
kW 250 390 513
GPH 6.1 9.5 12.5
Fuel #2 Fuel oil
Natural gas / Propane gas
Gas pressure at maximum delivery (2)
“ WC 2.44 3.94 4.29
Gas: Natural gas
Operation Low-high light oil
Low-high-low / modulating gas
Nozzles number 2
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%) V/Ph/Hz 208 - 230 / 460 / 575 /3/60
Electric motors rpm 3400
Fan motor V 208 - 230 / 460 / 575 208 - 230 / 460 / 575 208 - 230 / 460 / 575
W - HP 1100 - 1.5 1800 - 2.5 2200 - 3
A 4.8 - 2.8 - 2.3 6.7 - 3.9 - 3.2 8.8 - 5.1 - 4.1
Pump motor V 208 - 230 / 460 / 575
W - HP 550 - 0.75
A 2.6 - 1.5 - 1.2
Ignition transformer Oil V1 - V2 120 V - 2 x 5 kV
I1 - I2 3.7 A - 35 mA
Gas V1 - V2 120 V - 1 x 7 kV
I1 - I2 1.6 A - 23 mA
Pump delivery (at 174 PSI) GPH 52.5
pressure range PSI 145 - 290
fuel temperature ° F max 140 (60 °C)
Electrical power consumption W max 2200 3000 3400
Electrical protection NEMA 1
Noise levels (3) dBA 74 77.5 80

(1) Reference conditions: Ambient temperature 68 °F (20°C) - 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 manufacturer’s 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:

Control panel with
Model Code Voltage electronic cam
Code
Cxxxxxxx (3485074) 208-230/460/3/60
RLS 70/E
Cxxxxxxx (3485074) 575/3/60
Cxxxxxxx (3485274) 208-230/460/3/60
RLS 100/E 301xxxx
Cxxxxxxx (3485274) 575/3/60
Cxxxxxxx (3485474) 208-230/460/3/60
RLS 130/E
Cxxxxxxx (3485474) 575/3/60

ACCESSORIES (optional):
• KIT FOR LENGTHENING THE COMBUSTION HEAD
L = Standard length
L1 = Length obtainable with the kit
Code 3010267 L = 9 27/32” L1 = 15 5/32” • RLS 70/E
Code 3010268 L = 9 27/32” L1 = 15 5/32” • RLS 100/E
Code 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.

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

3
 BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrodes
3 Screw for combustion head adjustment
4 Sleeve
5 Cover
6 Fan motor
7 Motors contactors and thermal cut-out with reset but-
ton
8 UV scanner
9 Terminal strip
10 Knockouts for electrical connections by installer
11 Servomotor controlling gas butterfly valve
12 Screw securing fan to sleeve
13 Flame inspection window
14 Low air pressure switch
(differential operating type)
15 Slide bars for opening the burner and inspecting the
combustion head
16 Safety solenoid valve
17 Low and high fire oil valves
18 Gas pressure test point and head fixing screw
19 Air pressure test point
20 Servomotor controlling air damper
21 Pump motor
22 Low oil pressure switch
23 Pilot attachment
24 Pump
25 Gas input connection
26 Boiler mounting flange
27 Flame stability disk
Motor trip: release by pressing the pushbutton on the
thermal overload 7)(A).

PACKAGING - WEIGHT (B) - Approximate measure-

ments
(A) • The burners are skid mounted. Outer dimensions of
D2985
packaging are indicated in (B).
• The weight of the burner complete with packaging is
indicated in Table (B).
inch A B C lbs
RLS 70/E 50“ 2525/32“ 343/4“ 159 MAX. DIMENSIONS (C) - Approximate measure-
ments
RLS 100/E 50“ 2525/32“ 343/4“ 165
The maximum dimensions of the burners are given in
RLS 130/E 50“ 2525/32“ 343/4“ 170 (C).
Inspection of the combustion head requires the burner
(B) D36 to be opened and the rear part withdrawn on the slide
bars.
The maximum dimension of the burner when open, with-
out casing, is give in measurement I.

STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws
1 - Burner head gasket
4 - Screws to secure the burner flange to the boiler:
1/2 W x 1 3/8”
D2300 1 - Adaptor G 1/8“ / 1/8“ NPT
2 - Flexible hoses
1 - Instruction booklet
1 - Spare parts list

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“ 2“
100/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“ 2“
130/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)

4
 RLS 70/E FIRING RATES (A)
MAXIMUM OUTPUT must be selected in area A.
Combustion chamber pressure

In order to increase to area B (RLS 130/E) it is neces-

sary to perform the calibration of the combustion head
as explained on page 6.
MINIMUM OUTPUT must not be lower than the mini-
“WC

A mum limit shown in the diagram:

RLS 70/E = 854 MBtu/hr = 6.1 GPH
RLS 100/E = 1330 MBtu/hr = 9.5 GPH
RLS 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 combustion
head adjusted as shown on page 7.
Note:
The FIRING RATE areas given in figure (A) have been
RLS 100/E reduced by 10% with respect to the maximum range that
can be reached.
Combustion chamber pressure

Consult Appendix on page 20 for operation at different

ambient temperatures and/or altitudes.
“WC

MINIMUM FURNACE DIMENSIONS (B)

A The firing rates were set in relation to certified test boil-
ers.
Figure (B) indicates the diameter and length of the test
combustion chamber.
Example
Output 2579 MBtu/hr:
diameter 24 inch - length 6.6 ft.

RLS 130/E
Combustion chamber pressure
“WC

A B

(A) D2301

Diameter (inches)
Furnace dimensions
Lengthft (ft)

(B) D2919

5
 INSTALLATION
inch A B C BOILER PLATE (A)
RLS 70/E 79/32“ 1027/32“ - 1225/32“ 1/2 W Drill the combustion chamber mounting plate as shown
in (A). The position of the threaded holes can be marked
RLS 100/E 721/32“ 1027/32“ - 1225/32“ 1/2 W
using the gasket supplied with the burner.
RLS 130/E 721/32“ 1027/32“ - 1225/32“ 1/2 W
BLAST TUBE LENGTH (B)
(A) D455
The length of the blast tube must be selected according
to the indications provided by the manufacturer of the
boiler, it must be greater than the thickness of the boiler
door complete with its insulation. The range of lengths
available, 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 inversion
chambers, insulation material 11) must be inserted
between the refractory 12) and the blast tube 10).
This protective insulation must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front, the insulation
(B) 11)-12)(B) is not required unless it is required by the
D2986
boiler manufacturer.

SECURING THE BURNER TO THE BOILER (B)

Detach the combustion head from the burner, fig. (B):
- Disconnect the oil pipes by unscrewing the two con-
nectors 6)
- Loosen the 4 screws 3) and remove the cover 1)
- Remove the screws 2) from the slide bars 5)
(C) D1192 - 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
GPH burner completely off the slide bars.
Nozzle MBtu/hr
size 174 PSI
145 PSI 174 PSI 203 PSI COMBUSTION HEAD CALIBRATION
At this point check, on model RLS 130/E, whether the
5.00 6.15 6.79 7.4 951 maximum delivery of the burner is contained in area A or
5.50 6.76 7.46 8.13 1044 in area B of the firing rate. See page 5.
6.00 7.4 8.17 8.87 1144
If it is in area A then no adjustment is required.
6.50 8.01 8.84 9.61 1238
7.00 8.61 9.51 10.34 1331 If it is in area B:
7.50 9.22 10.18 11.08 1425 - Unscrew the screws 1)(C) and disassemble the blast
8.00 9.86 10.86 11.82 1520 tube 2).
8.30 10.21 11.27 12.26 1578 - Move the fixing of the rod 3)(C) from position A to
8.50 10.47 11.56 12.55 1618 position B, thereby causing the shutter 4) to retract.
9.00 11.08 12.23 13.29 1712 - Now refit the blast tube 2)(C) and the screws 1).
9.50 11.69 12.90 14.03 1806
10.0 12.3 13.58 14.76 1901 Once this operation has been carried out, secure the
10.5 12.94 14.28 15.49 1999 flange 9)(B) to the boiler plate, inserting the gasket 7)(B)
11.0 13.54 14.95 16.23 2093 supplied with the burner. Use the 4 screws, also sup-
12.0 14.76 16.3 17.71 2282 plied with the unit, after first protecting the thread with an
12.3 15.15 16.71 18.16 2339 anti-seize product. Tighten the seal between burner and
13.0 16.01 17.64 19.18 2470 boiler.
13.8 17.0 18.73 20.27 2622
14.0 17.23 19.02 20.65 2663
15.0 18.48 20.37 22.16 2852 NOZZLE SELECTION
15.3 18.83 20.78 22.57 2909 Both nozzles must be chosen from among those listed
16.0 19.69 21.74 23.63 3044 in Table (D).
17.0 20.94 23.09 25.1 3514 The first nozzle determines the delivery of the burner in
(D) low 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 recommended
pressure of 174 PSI.
The two nozzles have equal deliveries rates

D1122

(E)

6
 NOZZLE ASSEMBLY
Remove screw 1)(E) and extract the nozzle assembly
2)(E) (see page 6). Install both nozzles 1)(A), after hav-
ing removed the plastic plugs 2)(A), fitting the wrench
through the central hole in the flame stability disk or
loosen screws 1)(B), remove disk 2)(B) and replace the
nozzles using the wrench 3)(B).
Do not use any sealing products such as gaskets, seal-
ing compound, or tape. Be careful to avoid damaging
D1146 D1147 the nozzle sealing seat. The nozzles must be screwed
into place tightly but carefully.
The nozzle for low fire operation is the one lying beneath
the firing electrodes Fig. (C).
(A) (B)
Make sure that the electrodes are positioned as shown
ELECTRODE POSITION (for OIL operation)
in Figure (C).
Refit the burner to the slide bars 3)(G) at approximately
4” from the sleeve 4) - burner positioned as shown in fig.
(B)p. 6 - insert the ignition electrode cables and then
slide the burner up to the sleeve so that it is positioned
as shown in fig. (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-
3/32”
nectors 6)(B)p.6.
(C) D2539
Important
When fitting the burner on the two slide bars, it is advis-
able to gently draw out the high tension cables until they
are slightly stretched.

ADJUSTMENTS BEFORE FIRST FIRING

Ignition pilot (light-oil operation)
• Combustion head setting
Electrode The setting of the combustion head depends exclusively
on the maximum delivery of the burner.
D1149
Turn screw 5)(E) until the notch shown in diagram (F) is
D2591 level with the front surface of flange 6)(E).

1/32” Example: Burner RLS 100/E

(D) (E) maximum burner delivery = 23.1 GPH.
If diagram (F) is consulted it is clear that for this delivery,
N° Notches the combustion head must be adjusted using notch 3, as
D2304
shown in fig. (E).
• Pump adjustment
No settings are required for the pump, which is set to
174 PSI by the manufacturer. This pressure must be
checked and adjusted (if required) after the burner has
been ignited.
The only operation required in this phase is the applica-
tion of a pressure gauge on the appropriate pump
attachment.
• Air damper adjustment
The first time the burner is fired leave the factory setting
Maximum fuel oil delivery USGPH unchanged for both low and high fire operation.
(F)
• Ignition pilot adjustment
Place the pilot and electrode as shown in fig. (D).
The pilot works correctly at pressures ranging from 6 -
12” WC.

(G) D2987

7
PUMP PUMP (A)
1 - Suction 1/4” NPT
SUNTEC AJ6 CC 2 - Return 1/4” NPT
3 - Pressure gauge attachment G 1/8”
4 - Vacuum gauge attachment G 1/8”
5 - Pressure regulator
A- Min. delivery rate at 174 PSI pressure
B- Delivery pressure range
C- Max. suction
D- Viscosity range
E- Max fuel oil temperature
F - Max. suction and return pressure
G- Pressure calibration in the factory
H- Filter mesh width
D2306

AJ6 CC

A GPH 52.5
B PSI 145 - 290
C “Hg 13
D cSt 2.8 - 75
E °F - °C 140 - 60
F PSI 29
G PSI 174
H inch 0.006

(A)

8
 FUEL SUPPLY (A)
The burner is equipped with a self-priming pump which
is capable of feeding itself within the limits listed in the
table at the left.
5
The tank higher than the burner A
7
The distance "P" must not exceed 33 ft in order to avoid

V
A subjecting the pump's seal to excessive strain; the dis-
tance "V" must not exceed 13 ft in order to permit pump

P
self-priming even when the tank is almost completely
1 empty.
6 The tank lower than the burner B
Pump suction pressures higher than 13 “Hg must not be
+H

exceeded because at higher levels gas is released from

315/16

2 the fuel, the pump starts making noise and its working
life-span decreases.
It is good practice to ensure that the return and suction
4 lines enter the burner from the same height; in this way it
5 3 will be more improbable that the suction line fails to
prime or stops priming.
Key
H = Pump/Foot valve height difference
7 L = Piping length
Ø = Inside pipe diameter
1 = Burner
-H

2 = Pump
B 3 = Filter
4 = Manual on/off valve
5 = Suction line
6 6 = Foot valve
D2988
7 = Return line

+H L ft HYDRAULIC CONNECTIONS (B)

-H RLS 70 - 100 - 130/E The pumps are equipped with a by-pass that separates
ft Ø inch return line and suction line. The pumps are installed on
the burner with the by-pass closed by screw 6), see dia-
1/2” 9/16” 5/8”
gram page 15.
+ 13 234 454 493 It is therefore necessary to connect both hoses to the
+ 10 204 401 493 pump.
+ 6.6 174 349 493 Damage to the pump seal will occur immediately if it
+ 3.3 145 296 493 is run with the return line closed and the by-pass
+ 1.6 132 270 493 screw inserted.
0 118 243 451 Remove the plugs from the suction and return connec-
tions of the pump.
- 1.6 105 217 405 Insert the hose connections with the supplied seals into
- 3.3 92 191 359 the connections and screw them down.
- 6.6 63 138 266 Take care that the hoses are not stretched or twisted
- 10 33 86 174 during installation.
- 13 - 33 82 Install the hoses where they cannot be stepped on or
(A) 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.

PUMP PRIMING
- Before starting the burner, make sure that the
tank return line is not clogged. Obstructions in
the line could cause damage to the pump seal.
(The pump leaves the factory with the by-pass
closed).
- Also check to make sure that the valves located on
the suction line are open and that there is sufficient
fuel in the tank.
- For self-priming to take place, one of the screws 3) of
the pump (See fig.(A) page 8) must be loosened in
(B) D2989 order to bleed off the air contained in the suction line.

9
 GAS PRESSURE
RLS 70/E ∆p (“ WC)
The adjacent tables show minimum pressure losses
MBtu/hr 1 2 along the gas supply line depending on the maximum
burner output.
1750 2.17 0.08
Column 1
1950 2.20 0.08
Pressure loss at combustion head.
2140 2.24 0.12 Gas pressure measured at test point 1)(B), with:
2329 2.28 0.12 • Combustion chamber at 0” WC
• Burner operating at maximum output
2519 2.32 0.12
• Natural gas
2708 2.36 0.16
Column 2
2897 2.40 0.16
Pressure loss at butterfly valve.
3094 2.44 0.16
Calculate the approximate high fire output of the burner
as follows:
RLS 100/E ∆p (“ WC) - subtract the combustion chamber pressure from the
gas pressure measured at test point 1)(B).
MBtu/hr 1 2 - Find the nearest pressure value to your result in col-
umn 1 of the table for the burner in question.
2646 3.15 0.16
- Read off the corresponding output on the left.
2878 3.27 0.16
Example - RLS 100/E
3125 3.39 0.20
• Maximum output operation
3371 3.50 0.20 • Natural gas
3616 3.62 0.24 • Gas pressure at test point 1)(B) = 4.41” WC
• Pressure in combustion chamber = 0.79” WC
3863 3.70 0.28
4.41 - 0.79 = 3.62” WC
4109 3.82 0.31 A maximum output of 3616 MBtu/hr shown in Table RLS
4396 3.94 0.31 100 corresponds to 3.62” WC pressure, column 1, natu-
ral gas.
This value serves as a rough guide, the effective deliv-
RLS 130/E ∆p (“ WC) ery must be measured at the gas meter.

MBtu/hr 1 2 To calculate the required gas pressure at test point

1)(B), set the maximum output required from the burner:
3500 3.66 0.39 - find the nearest output value in the table for the burner
3825 3.74 0.43 in question.
4128 3.82 0.51 - Read off the pressure at test point 1)(B) on the right in
column 1.
4431 3.90 0.59
- Add this value to the estimated pressure in the com-
4734 4.09 0.67 bustion chamber.
5037 4.29 0.71 Example - RLS 100/E
• Maximum required burner output: 3616 MBtu/hr
(A) • Natural gas
• Gas pressure at burner output of 3616 MBtu/hr, taken
1 from table RLS 100, column 1, natural gas = 3.62” WC
• Pressure in combustion chamber = 0.79” WC
3.62 + 0.79 = 4.41” WC
pressure required at test point 1)(B).

(B) D2990

10
 GAS LINE
• The main gas train must be connected to the gas
attachment 1)(A), using flange 2), gasket 3) and
screws 4) supplied with the burner.
• The main gas train can enter the burner from the
right or left side, see fig. (A).
• Gas safety shut-off valves 5)-6)(B) must be as close
as possible to the burner to ensure gas reaches the
combustion head within the safety time range.
• The pilot gas train must be connected to the gas
attachment 5)(A) and can enter the burner from the
right or left side.

GAS TRAIN (B)

It must be type-approved according to required Stand-
ards and is supplied separately from the burner.
D2310
(A) Note
TYPICAL UL SCHEMATIC GAS PIPING See the accompanying instructions for the gas train lay
out.

KEY TO LAYOUT (B)

1 - Gas input pipe
2 - Manual valve
3 - Pressure regulator
GAS PILOT LINE 4 - Low gas pressure switch
5 - 1st safety shut off valve
6 - 2nd safety shut off valve
7 - Standard issue burner gasket with flange
8 - Gas butterfly valve
9 - Burner

MAIN GAS LINE

(B) D2311

11
LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWITCH AIR PRESSURE SWITCH ADJUSTMENTS BEFORE FIRST FIRING
Adjustment of the combustion head has been illustrated
on page 7.
In addition, the following adjustments must also be
made:
- 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
(A) (B) (C)
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 adjust
the gas train so that ignition takes place in conditions of
maximum safety, i.e. with gas delivery at the minimum.

(D) D2991

12
AIR PRESSURE SWITCH AIR PRESSURE SWITCH (A)
Adjust the air pressure switch after having performed all
other burner adjustments with the air pressure switch set
to 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 set
point and repeat burner starting to ensure it is correct.
If the burner locks out again, turn the dial anti-clockwise
a 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 the
chimney, slowly close the fan suction inlet (for example
with cardboard) and check that the burner locks out,
(A) D2548 before the CO in the fumes exceeds 400 ppm.
HIGH GAS PRESSURE SWITCH The air pressure switch may operate in "differential"
operation in two pipe system. If a negative pressure in
the combustion chamber during pre-purging prevents
the air pressure switch from switching, switching may be
obtained by fitting a second pipe between the air pres-
sure switch and the suction inlet of the fan. In such a
manner the air pressure switch operates as differential
pressure switch.

HIGH GAS PRESSURE SWITCH (B)

Adjust the high gas pressure switch after having per-
formed all other burner adjustments with the maximum
gas pressure switch set to the end of the scale (B).
With the burner operating at MAX output, reduce the
adjustment pressure by slowly turning the adjustment
dial anticlockwise until the burner locks out.
Then turn the dial clockwise by 0.8” WC and repeat
burner firing.
(B) D2547 If the burner locks out again, turn the dial again clock-
LOW GAS PRESSURE SWITCH 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 pressure
switch set at the start of the scale (C).
With the burner operating at MAX output, increase ad-
justment pressure by slowly turning the relative dial
clockwise until the burner locks out.
Then turn the dial anti-clockwise by 0.8” WC and repeat
burner starting to ensure it is uniform.
If the burner locks out again, turn the dial anti-clockwise
again by 0.4” WC.

(C) D2547

13
FLAME INSPECTION WINDOW
MAINTENANCE
Combustion
The optimum calibration of the burner requires an analy-
sis of the flue gases. Significant differences with respect
to the previous measurements indicate the points where
more care should be exercised during maintenance.
Gas leaks
Make sure that there are no gas leaks on the pipework
between the gas meter and the burner.
Flame inspection window
Clean the flame inspection window (A).
Combustion head
Open the burner and make sure that all components of
the combustion head are in good condition, not
deformed by the high temperatures, free of impurities
D484 from the surroundings and correctly positioned. If in
(A) doubt, disassemble the elbow fitting 7)(C).
UV SCANNER Nozzles (fuel oil)
Do not clean the nozzle orifices. The nozzle filters how-
1 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 nozzles
have been changed.
UV scanner
Clean the glass cover from any dust that may have
accumulated. The scanner 1)(B) is held in position by a
pressure fit and can therefore be removed by pulling it
outward forcefully.
Flexible hoses (fuel oil)
Check to make sure that the flexible hoses are still in
good condition and that they are not crushed or other-
wise deformed.
Burner
Check for excess wear or loose screws. Also make sure
that the screws securing the electrical leads in the
burner connections are fully tightened.
Clean the outside of the burner.
(B) D2992 Combustion
Adjust the burner if the combustion values found at the
OPENING THE BURNER beginning of the operation do not comply with the regu-
lations in force, or at any rate, do not correspond to good
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 leads
and then pull the burner fully back.
Now extract the internal part 5) after having removed the
screw 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.
(C) D2993
FLAME SIGNAL MEASUREMENT
Min value for a good signal: 70 µA.
If the value is lower, it can be due to:
• Worn scanner;
• Low current;
• Bad set up of the burner.
In order to measure the current, use a microammeter of
100 µA c.c., connected to the scanner, as in the dia-
(D) D1143 gram, with a capacitor of 100 µF - 1V c.c. at the same
level of the instrument. See fig. (A).

14
 OIL HYDRAULIC SYSTEM LAYOUT (A)
1 Pump suction
2 Filter
3 Pump
4 Pressure regulator
5 Return pipe
6 By-pass screw
7 Pump return
8 Safety solenoid
9 Low fire valve
10 High fire valve
11 Filter
M Pressure gauge
P low oil pressure switch
V Vacuum gauge

OIL PRESSURE SWITCH

The oil pressure switch 22)(A) page 4 is factory set to
145 PSI (10 bar). If the oil pressure goes down to this
value, the pressure switch stops the burner.

(A) D2592

15
 Factory Wiring Diagram RLS 70 - 100 - 130/E

Layout of electric panel board

1 CONTENTS

2 References layout

3 Functional diagram

4 Functional diagram

5 Functional diagram

Key to layouts NOTES

B7 - QRI detector • The setting of the thermal overload must be according to the total
F1 - Fan motor thermal overload burner amperage draw.
F2 - Pump motor thermal overload
• The RLS 70-100-130/E burners leave the factory preset for 208-
K1 - Fan motor contactor
230 V power supply. If 460 V power supply is used, change the
K2 - Pump motor contactor
fan motor connection from delta to star and change the setting of
M1 - Fan motor
the thermal overload as well.
M2 - Pump motor
SM1 - Servomotor
SM2 - Servomotor
S10 - Air pressure switch For the installation, electrical connections, start-up and set-
S12 - Maximum gas pressure switch ting of the LMV51... electronic cam, see the instructions
S14 - Minimum oil pressure switch supplied with the control panel.
T1 - Gas ignition transformer
T2 - Oil ignition transformer
T8 - Burner ground
XMB - Burner terminal strip
XQ - 32-pin plug
Y20 - Safety valve
Y21 - 1st stage oil valve
Y22 - 2nd stage oil valve

2 References layout

/1. A1
N. Page

Coordinates

16
17
18
19
APPENDIX - Burner firing rates according to air density

CORRECTION FACTOR F
average barom.
above sea level Air temperature
pressure
°F (°C)

ft m “ W.C. mbar 0 (0°C) 41 (5°C) 50 (10°C) 59 (15°C) 68 (20°C) 77 (25°C) 86 (30°C) 104 (40°F)

0 0 399 1013 1,087 1,068 1,049 1,031 1,013 0,996 0,980 0,948
329 100 394 1000 1,073 1,054 1,035 1,017 1,000 0,983 0,967 0,936
658 200 389 989 1,061 1,042 1,024 1,006 0,989 0,972 0,956 0,926
987 300 385 978 1,050 1,031 1,013 0,995 0,978 0,962 0,946 0,916
1316 400 380 966 1,037 1,018 1,000 0,983 0,966 0,950 0,934 0,904
1645 500 376 955 1,025 1,007 0,989 0,972 0,955 0,939 0,923 0,894
1974 600 372 944 1,013 0,995 0,977 0,960 0,944 0,928 0,913 0,884
2303 700 367 932 1,000 0,982 0,965 0,948 0,932 0,916 0,901 0,872
2632 800 363 921 0,988 0,971 0,954 0,937 0,921 0,906 0,891 0,862
2961 900 358 910 0,977 0,959 0,942 0,926 0,910 0,895 0,880 0,852
3290 1000 354 898 0,964 0,946 0,930 0,914 0,898 0,883 0,868 0,841
3947 1200 346 878 0,942 0,925 0,909 0,893 0,878 0,863 0,849 0,822
4605 1400 337 856 0,919 0,902 0,886 0,871 0,856 0,842 0,828 0,801
5263 1600 329 836 0,897 0,881 0,866 0,851 0,836 0,822 0,808 0,783
5921 1800 321 815 0,875 0,859 0,844 0,829 0,815 0,801 0,788 0,763
6579 2000 313 794 0,852 0,837 0,822 0,808 0,794 0,781 0,768 0,743

(A)

The FIRING RATE area values have been obtained considering a surround-
ing temperature of 68°F (20°C), and an atmospheric pressure of 398” W.C. “ W.C.
and with the combustion head adjusted as shown on page 7.
H2
The burner may be required to operate with combustion air at a higher tem-
H3
perature and/or at higher altitudes. H1 A
Heating of air and increase in altitude produce the same effect: the expan-
sion of the air volume, i.e. the reduction of air density.
D2617 Qe
The burner fan's delivery remains substantially the same, but the oxygen MBTU/h
content per cubic meter and the fan's head are reduced. (B)
It is therefore important to know if the maximum output required of the burner
at a given combustion chamber pressure remains within the burner's firing rate range even at different temperature and altitude con-
ditions. Proceed as follows to check the above:
1 -Find the correction factor F in the Table (A) for the plant's air temperature and altitude.
2 -Divide the burner's delivery Q by F in order to obtain the equivalent delivery Qe:

Qe = Q : F (MBtu/hr)

3 -In the firing rate range of the burner, Fig. (B), indicate the work point defined by:
Qe = equivalent delivery
H1 = combustion chamber pressure
The resulting point A must remain within the firing rate range.
4 -Plot a vertical line from Point A as shown in Figure (B) and find the maximum pressure H2 of the firing rate.
5 -Multiply H2 by F to obtain the maximum reduced pressure H3 of the firing rate.

H3 = H 2 x F (“ W.C.)

If H3 is greater than H1, as shown in Fig. (B), the burner delivers the output required.
If H3 is lower than H1, the burner's delivery must be reduced. A reduction in delivery is accompanied by a reduction of the pressure in
the combustion chamber:
Qr = reduced delivery
H1r = reduced pressure

H1r = H1 x ( QrQ ) 2

Example, a 5% delivery reduction:

Qr = Q x 0.95
H1r = H1 x (0.95)2
Steps 2 - 5 must now be repeated using the new Qr and H1r values.
Important: the combustion head must be adjusted in respect to the equivalent delivery Qe.

20
 BURNER START UP REPORT

Model number: Serial number:

Project name: Start-up date:
Installing contractor: Phone number:

GAS OPERATION

Gas Supply Pressure: CO2: Low Fire High Fire

Main Power Supply: O2: Low Fire High Fire

Control Power Supply: CO: Low Fire High Fire

Burner Firing Rate: NOX: Low Fire High Fire

Manifold Pressure: Net Stack Temp - Low Fire: High Fire:

Pilot Flame Signal: Comb. Efficiency - Low Fire: High Fire:

Low Fire Flame Signal: Overfire Draft:

High Fire Flame Signal:

OIL OPERATION

Oil supply pressure: CO2: Low Fire High Fire

Oil suction pressure: O2: Low Fire High Fire

Control Power Supply: CO: Low Fire High Fire

Burner Firing Rate: NOX: Low Fire High Fire

Low Fire Flame Signal: Net Stack Temp - Low Fire: High Fire:

High Fire Flame Signal: Comb. Efficiency - Low Fire: High Fire:

Low Fire Nozzle Size: Overfire Draft:

High Fire Nozzle Size: Smoke number:

CONTROL SETTINGS
Operating Setpoint: Low Oil Pressure:
High Limit Setpoint: High Oil Pressure:
Low Gas Pressure: Flame Safeguard Model Number:
High Gas Pressure: Modulating Signal Type:

NOTES

21
RIELLO S.p.A.
Via degli Alpini 1
I - 37045 Legnago (VR)
Tel.: +39.0442.630111 Fax: +39.0442.630375
http:// www.rielloburners.com

RIELLO BURNERS NORTH AMERICA

35 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