Installation, use and maintenance instructions

Dual Fuel Gas / Light Oil Burners

Electronic cam version

RLS 70 - 100 - 130 /E Modulating Gas / Low - High Oil Operation

C65050xx - 2915922 (3) - 10/2008

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

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 maintenance 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 requirements as outlined in this manual, local codes and authorities having jurisdiction.

FUEL OIL Nozzle selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL OIL Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 9 9 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 APPENDIX Procedure to refer burner operating condition in high altitude plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factory wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 17 20 24

TECHNICAL DATA
Model Output (1) Delivery (1) RLS 70/E 1750 - 3094 513 - 907 12.5 - 22.1 854 250 6.1 RLS 100/E RLS 130/E 2646 - 4396 3500 - 5292 775 - 1288 1026 - 1551 18.9 - 31.4 25 - 37.8 1330 1750 390 513 9.5 12.5 #2 Fuel oil Natural gas / Propane gas 3.94 4.29

High

Low

MBtu/hr (4) kW GPH MBtu/hr (4) kW GPH

Fuel Gas pressure at maximum delivery (2) Gas: Natural gas Operation Nozzles Standard applications Ambient temperature Combustion air temperature Main power supply (+/- 10%) Electric motors Fan motor WC 2.44

number F F max V/Ph/Hz rpm V W - HP A V W - HP A V1 - V2 I1 - I2 V1 - V2 I1 - I2 GPH PSI F max W max dBA

Pump motor

Ignition transformer

Oil Gas

delivery (at 174 PSI) pressure range fuel temperature Electrical power consumption Electrical protection Noise levels (3)
(1) (2) (3) (4)

Pump

Low-high light oil Low-high-low / modulating gas 2 Boilers: water, steam, thermal oil 32 - 104 (0 - 40 C) 140 (60 C) 208 - 230 / 460 / 575 /3/60 3400 208 - 230 / 460 / 575 208 - 230 / 460 / 575 208 - 230 / 460 / 575 1100 - 1.5 1800 - 2.5 2200 - 3 4.8 - 2.8 - 2.3 6.7 - 3.9 - 3.2 8.8 - 5.1 - 4.1 208 - 230 / 460 / 575 550 - 0.75 2.6 - 1.5 - 1.2 120 V - 2 x 5 kV 3.7 A - 35 mA 120 V - 1 x 7 kV 1.6 A - 23 mA 54 145 - 290 140 (60 C) 2200 3000 3400 NEMA 1 74 77.5 80

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

Burner model designations:

Model RLS 70/E RLS 100/E RLS 130/E Code C9834000 (3485074) C9834001 (3485074) C9835000 (3485274) C9835001 (3485274) C9836000 (3485474) C9836001 (3485474) Voltage 208-230/460/3/60 575/3/60 208-230/460/3/60 575/3/60 208-230/460/3/60 575/3/60 Auxiliary panel with electronic cam Code

3010348

ACCESSORIES (optional):
Kit for lengthening the combustion head L = Standard length L1 = Length obtainable with the kit Code 3010267 L = 9 27/32 Code 3010268 L = 9 27/32 Code 3010269 L = 9 27/32

L1 = 15 5/32 L1 = 15 5/32 L1 = 15 5/32

RLS 70/E RLS 100/E 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: The installer is responsible for the supply and installation of any required safety device(s) not indicated in this manual.

BURNER DESCRIPTION (A)

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

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

PACKAGING - WEIGHT (B) - Approximate meas(A)

D2985

inch RLS 70/E RLS 100/E RLS 130/E

A 50 50 50

B 2525/32 2525/32 2525/32

C 343/4 343/4 343/4

lbs 159 165 170

D36

urements The burners are skid mounted. Outer dimensions of packaging are indicated in (B). The weight of the burner complete with packaging is indicated in Table (B).

(B)

MAX. DIMENSIONS (C) - Approximate measurements The maximum dimensions of the burners are given in (C). Inspection of the combustion head requires the burner to be opened and the rear part withdrawn on the slide bars. The maximum dimension of the burner when open, without casing, is give in measurement I. STANDARD EQUIPMENT
1 1 4 1 4 Gas train flange Flange gasket Flange fixing screws Burner head gasket Screws to secure the burner flange to the boiler: 1/2 W x 1 3/8 Adaptor G 1/8 / 1/8 NPT Flexible hoses Instruction booklet Spare parts list

D2300

1 2 1 1 N O

RLS 70/E

A
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)

RLS 70/E
Combustion chamber pressure WC

FIRING RATES (A)

MAXIMUM OUTPUT must be selected in area A. In order to increase to area B (RLS 130/E) it is necessary to perform the calibration of the combustion head as explained on page 6.

MINIMUM OUTPUT must not be lower than the minimum 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 considering an ambient temperature of 68 F, and an atmospheric 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 reduced by 10% with respect to the maximum range that can be reached. Consult Procedure on page 16 to refer burner operating condition in high altitude plants.

RLS 100/E
Combustion chamber pressure WC

MINIMUM FURNACE DIMENSIONS (B) A

The firing rates were set in relation to certified test boilers. 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)
Diameter (inches)

D2301

Furnace dimensions Length ft (ft)

(B)
5

D2919

INSTALLATION
inch RLS 70/E A 79/32 1027/32 B 1225/32 1027/32 - 1225/32 1027/32 - 1225/32 C
1/2 1/2 1/2

BOILER PLATE (A)

Drill the combustion chamber mounting plate as shown in (A). The position of the threaded holes can be marked using the gasket supplied with the burner.
D455

W W W

RLS 100/E 721/32 RLS 130/E 721/32

(A)

BLAST TUBE LENGTH (B)

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

(B)

D2986

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 11)-12)(B) is not required unless it is required by the boiler manufacturer.

SECURING THE BURNER TO THE BOILER (B)

Detach the combustion head from the burner, fig. (B): - Disconnect the oil pipes by unscrewing the two connectors 6) - Loosen the 4 screws 3) and remove the cover 1) - Remove the screws 2) from the slide bars 5) - Remove the 2 screws 4) and pull the burner back on slide bars 5) by about 4. - Disconnect the electrode wires and then pull the burner completely off the slide bars. COMBUSTION HEAD CALIBRATION At this point check, on model RLS 130/E, whether the maximum delivery of the burner is contained in area A or in 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 the flange 9)(B) to the boiler plate, inserting the gasket 7)(B) supplied with the burner. Use the 4 screws, also supplied with the unit, after first protecting the thread with an anti-seize product. Tighten the seal between burner and boiler.

(C)
GPH 145 PSI 6.15 6.76 7.4 8.01 8.61 9.22 9.86 10.21 10.47 11.08 11.69 12.3 12.94 13.54 14.76 15.15 16.01 17.0 17.23 18.48 18.83 19.69 20.94 174 PSI 6.79 7.46 8.17 8.84 9.51 10.18 10.86 11.27 11.56 12.23 12.90 13.58 14.28 14.95 16.3 16.71 17.64 18.73 19.02 20.37 20.78 21.74 23.09 203 PSI 7.4 8.13 8.87 9.61 10.34 11.08 11.82 12.26 12.55 13.29 14.03 14.76 15.49 16.23 17.71 18.16 19.18 20.27 20.65 22.16 22.57 23.63 25.1

D1192

Nozzle size 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.30 8.50 9.00 9.50 10.0 10.5 11.0 12.0 12.3 13.0 13.8 14.0 15.0 15.3 16.0 17.0

MBtu/hr 174 PSI 951 1044 1144 1238 1331 1425 1520 1578 1618 1712 1806 1901 1999 2093 2282 2339 2470 2622 2663 2852 2909 3044 3514

NOZZLE SELECTION
Both nozzles must be chosen from among those listed in Table (D). The first nozzle determines the delivery of the burner in low fire. The second nozzle combines together with the 1st nozzle to determine the total firing rate at high fire. The total firing rates of low and high fire must be contained 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.

(D)

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 having 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, sealing compound, or tape. Be careful to avoid damaging 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). Make sure that the electrodes are positioned as shown 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 connectors 6)(B)p.6.
D2539

D1146

D1147

(A)
ELECTRODE POSITION (for OIL operation)

(B)

(C)

Important When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cables until they are slightly stretched.

Ignition pilot Electrode

D1149 D2591

ADJUSTMENTS BEFORE FIRST FIRING (light-oil operation)

Combustion head setting The setting of the combustion head depends exclusively on the maximum delivery of the burner. Turn screw 5)(E) until the notch shown in diagram (F) is level with the front surface of flange 6)(E). Example: Burner RLS 100/E maximum 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, as 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 application of a pressure gauge on the appropriate pump attachment. Air damper adjustment The first time the burner is fired leave the factory setting unchanged for both low and high fire operation. Ignition pilot adjustment Place the pilot and electrode as shown in fig. (D). The pilot works correctly at pressures ranging from 6 12 WC.

(D)

1/32 N Notches

(E)
D2304

(F)

Maximum fuel oil delivery

USGPH

(G)

D2987

PUMP SUNTEC AJ4 CC

PUMP (A)
1 2 3 4 5 Suction Return Pressure gauge attachment Vacuum gauge attachment Pressure regulator 1/4 NPT 1/4 NPT G 1/8 G 1/8

A B CDE F GHD2306

Min. delivery rate at 174 PSI pressure Delivery pressure range Max. suction Viscosity range Max fuel oil temperature Max. suction and return pressure Pressure calibration in the factory Filter mesh width

AJ4 CC A B C D E F G H GPH PSI Hg cSt F - C PSI PSI inch 54 145 - 290 13 2.8 - 75 140 - 60 29 174 0.006

(A)

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. The tank higher than the burner A The distance "P" must not exceed 33 ft in order to avoid subjecting the pump's seal to excessive strain; the distance "V" must not exceed 13 ft in order to permit pump self-priming even when the tank is almost completely empty. The tank lower than the burner B Pump suction pressures higher than 13 Hg must not be exceeded because at higher levels gas is released from the fuel, the pump starts making noise and its working life-span decreases. It is good practice to ensure that the return and suction lines enter the burner from the same height; in this way it will be more improbable that the suction line fails to prime or stops priming. Key H = Pump/Foot valve height difference L = Piping length = Inside pipe diameter 1 = Burner 2 = Pump 3 = Filter 4 = Manual on/off valve 5 = Suction line 6 = Foot valve 7 = Return line

5 V 7

A
P 1

6 315/16 +H

2 4

7 -H

B
D2988

+H -H ft + 13 + 10 + 6.6 + 3.3 + 1.6 0 - 1.6 - 3.3 - 6.6 - 10

L ft RLS 70 - 100 - 130/E inch

3/8 1/2 5/8

HYDRAULIC CONNECTIONS (B)

The pumps are equipped with a by-pass that separates return line and suction line. The pumps are installed on the burner with the by-pass closed by screw 6), see diagram page 15. It is therefore necessary to connect both hoses to the pump. Damage to the pump seal will occur immediately if it is run with the return line closed and the by-pass screw inserted. Remove the plugs from the suction and return connections of the pump. Insert the hose connections with the supplied seals into the connections and screw them down. Take care that the hoses are not stretched or twisted during installation. Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler and where they do not hamper the opening of the burner. Now connect the other end of the hoses to the suction and return lines.

100 88 75 68 52 45 39 26 19 --

210 180 155 140 110 98 85 55 42 13

320 320 320 320 270 240 200 140 104 36

(A)

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 order to bleed off the air contained in the suction line.

(B)

D2989

RLS 70/E p ( WC)

MBtu/hr 1750 1950 2140 2329 2519 2708 2897 3094 1 2.17 2.20 2.24 2.28 2.32 2.36 2.40 2.44

GAS PRESSURE
The adjacent tables are used to calculate manifold pressure taking into account combustion chamber pressure. Column 1 Gas 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 burner as 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 column 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 WC A maximum output of 3616 MBtu/hr shown in Table RLS 100 corresponds to 3.62 WC pressure, column 1, natural gas. This value serves as a rough guide, the effective delivery must be measured at the gas meter.

RLS 100/E p ( WC)

MBtu/hr 2646 2878 3125 3371 3616 3863 4109 4396 1 3.15 3.27 3.39 3.50 3.62 3.70 3.82 3.94

RLS 130/E p ( WC)

MBtu/hr 3500 3825 4128 4431 4734 5037 1 3.66 3.74 3.82 3.90 4.09 4.29

(A) 1

(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 Standards and is supplied separately from the burner.
D2310

(A)
TYPICAL UL SCHEMATIC GAS PIPING

Note See the accompanying instructions for the gas train lay out.

KEY TO LAYOUT (B)

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

GAS PILOT LINE

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 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.

(A)

(B)

(C)

(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 adjustment pressure by slowly turning the relative dial clockwise 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 formation 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, 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 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 pressure switch and the suction inlet of the fan. In such a manner the air pressure switch operates as differential pressure switch.

(A)
HIGH GAS PRESSURE SWITCH

D2548

HIGH GAS PRESSURE SWITCH (B)

Adjust the high gas pressure switch after having performed 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. If the burner locks out again, turn the dial again clockwise by 0.4 WC.

(B)
LOW GAS PRESSURE SWITCH

D2547

LOW GAS PRESSURE SWITCH (C)

Adjust the low gas pressure switch after having performed 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 adjustment 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 analysis 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 from the surroundings and correctly positioned. If in doubt, disassemble the elbow fitting 7)(C).

(A)
UV SCANNER

D484

Nozzles (fuel oil) Do not clean the nozzle orifices. The nozzle filters however may be cleaned or replaced as required. Replace the nozzles every 2-3 years or whenever necessary. 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.
D2992

Flexible hoses (fuel oil) Check to make sure that the flexible hoses are still in good condition and that they are not crushed or otherwise 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. Combustion Adjust the burner if the combustion values found at the beginning of the operation do not comply with the regulations in force, or at any rate, do not correspond to good combustion.

(B)
OPENING THE BURNER

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):

(C)

D2993

- 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 sector. - Reconnect the light-oil pipes.

MEASUREMENT OF DETECTOR CURRENT

Measurement of the detectors signal with a Voltmeter is not normally required since the flame signals intensity is shown on the AZL...display and operating unit.

(D)

D3020

14

OIL HYDRAULIC SYSTEM LAYOUT (A)

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

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. Note Charts are based only on altitude variation (reference temperature = 68F , 20C) To get the combined correction in case of different air temperature, a compensation of 1000 ft each 20F (305 m each 11C) is applicable. Example Rated 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; Burner RLS 100 is OK - the corrected burner air pressure is 1.92.

1
Rated Capacity 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 Average barometric Pressure (20C) Average barometric Pressure (68F)

CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE

m. a.s.l. ft a.s.l 0 0 494 987 1481 1974 2468 2962 3455 3949 4442 4936 5429 5923 6417 6910 7404 7897 8391 8885 9378 9872 1013 399 100 328 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 1000 394 305 1000 512 1023 1535 2046 2558 3069 3581 4092 4604 5116 5627 6139 6650 7162 7673 8185 8697 9208 9720 10231 977,4 385 610 2000 530 1061 1591 2121 2652 3182 3712 4243 4773 5303 5834 6364 6894 7425 7955 8485 9016 9546 10076 10607 942,8 371 Altitude 915 3000 551 1101 1652 2202 2753 3303 3854 4404 4955 5505 6056 6606 7157 7708 8258 8809 9359 9910 10460 11011 908,2 358 1220 4000 571 1142 1713 2284 2855 3425 3996 4567 5138 5709 6280 6851 7422 7993 8564 9135 9705 10276 10847 11418 875,8 345 1525 5000 593 1186 1778 2371 2964 3557 4149 4742 5335 5928 6520 7113 7706 8299 8892 9484 10077 10670 11263 11855 843,5 332 1830 6000 616 1232 1848 2464 3079 3695 4311 4927 5543 6159 6775 7391 8006 8622 9238 9854 10470 11086 11702 12318 811,85 320 2135 7000 641 1282 1924 2565 3206 3847 4488 5130 5771 6412 7053 7694 8335 8977 9618 10259 10900 11541 12183 12824 779,8 307 2440 8000 669 1337 2006 2675 3343 4012 4680 5349 6018 6686 7355 8024 8692 9361 10029 10698 11367 12035 12704 13373 747,8 294

mbar "w.c.

2
Rated Pressure 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,00 8,50 9,00 9,50 10,00 Average barometric Pressure (20C) Average barometric Pressure (68F)

CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE

m. a.s.l. ft a.s.l 0 0 0,49 0,99 1,48 1,97 2,47 2,96 3,46 3,95 4,44 4,94 5,43 5,92 6,42 6,91 7,40 7,90 8,39 8,88 9,38 9,87 1013 399 100 328 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,00 8,50 9,00 9,50 10,00 1000 394 305 1000 0,51 1,02 1,53 2,05 2,56 3,07 3,58 4,09 4,60 5,12 5,63 6,14 6,65 7,16 7,67 8,18 8,70 9,21 9,72 10,23 977,4 385 610 2000 0,53 1,06 1,59 2,12 2,65 3,18 3,71 4,24 4,77 5,30 5,83 6,36 6,89 7,42 7,96 8,49 9,02 9,55 10,08 10,61 942,8 371 Altitude 915 3000 0,55 1,10 1,65 2,20 2,75 3,30 3,85 4,40 4,95 5,51 6,06 6,61 7,16 7,71 8,26 8,81 9,36 9,91 10,46 11,01 908,2 358 1220 4000 0,57 1,14 1,71 2,28 2,85 3,43 4,00 4,57 5,14 5,71 6,28 6,85 7,42 7,99 8,56 9,13 9,71 10,28 10,85 11,42 875,8 345 1525 5000 0,59 1,19 1,78 2,37 2,96 3,56 4,15 4,74 5,33 5,93 6,52 7,11 7,71 8,30 8,89 9,48 10,08 10,67 11,26 11,86 843,5 332 1830 6000 0,62 1,23 1,85 2,46 3,08 3,70 4,31 4,93 5,54 6,16 6,77 7,39 8,01 8,62 9,24 9,85 10,47 11,09 11,70 12,32 811,85 320 2135 7000 0,64 1,28 1,92 2,56 3,21 3,85 4,49 5,13 5,77 6,41 7,05 7,69 8,34 8,98 9,62 10,26 10,90 11,54 12,18 12,82 779,8 307 2440 8000 0,67 1,34 2,01 2,67 3,34 4,01 4,68 5,35 6,02 6,69 7,35 8,02 8,69 9,36 10,03 10,70 11,37 12,04 12,70 13,37 747,8 294

mbar "w.c.

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.) 16

Factory Wiring Diagram RLS 70 - 100 - 130/E

Electrical sheet

Description

Page

1 2

Burner electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . 18 Burner electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . 19

Key to layouts
B7 F1 F2 K1 K2 M1 M2 QRI detector Fan motor thermal overload Pump motor thermal overload Fan motor contactor Pump motor contactor Fan motor Pump motor Servomotor Servomotor Air pressure switch Maximum gas pressure switch Minimum oil pressure switch Gas ignition transformer Oil ignition transformer Burner ground Burner terminal strip 32-pin plug Safety valve 1st stage oil valve 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 208230 V power supply. If 460 V power supply is used, change the fan motor connection from delta to star and change the setting of the thermal overload as well.

SM1 SM2 S10 S12 S14 T1 T2 TB XQ Y20 Y21 Y22 -

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

XMB -

Important note When installing for the first time and after any maintenance work, make sure the gas valves are connected 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 the valves during standby or pre-purging. Burner ignition with the gas valves open during pre-purging may cause the generator to burst.

17

FACTORY WIRING DIAGRAM - Sheet 1

18

FACTORY WIRING DIAGRAM - Sheet 2

19

SPARE PARTS LIST

43 18 73 15 65 25 24 48 37 35 36 38 36 51 52 34 33 35 32 39 56 26 27 28 35 33 35 58 62 20 19 68 12 57 76 1 17 14 2 63 6 8 15 60 61 74 64 66 59 71 72 36 60 33 60 58 58 60 4 61 31 44 53 9 11 23 33 55 34 15 47 50 49 46 45 40 41 42

57

29

20
70 5

22

30 54

21

13 75

67

10

16

N. CODE
C9835001 (3485274) C9836000 (3485474) C9836001 (3485474)
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

DESCRIPTION

DESCRIZIONE

21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 16 16 16 17 18 19 20 20 20 21 22 22 22 22 22 22 23 24 25 26 27 28 29 30 31 32

C5332011

3013258 3003949 3013270 3012384 3012948 3013050 3013268 3013206 3013140 3007627 3013052 3013262 3012938 3013207 3013051 3012935 3012991 3012936 3013124 3012937 3013125 3013205 3012969 3003763 3012939 3012403 3012940 3012934 3012941 3013059 3012942 3013060 3012943 3013061 3012959 3013040 3013041 3012430 3013042 3012042 3003969 3003891 3003481 3012013

AIR DAMPER ASSEMBLY GRID PLUG OIL PRESSURE SWITCH AIR PRESSURE SWITCH BELL PLUG BRACKET H.T. LEAD MEMBRAN PILOT ELECTRODE BRACKET TRANSFORMER SUPPORT DRIVE COUPLING OVERLOAD+CONTACTOR 208-230/460V OVERLOAD+CONTACTOR 575V OVERLOAD+CONTACTOR 208-230/460V OVERLOAD+CONTACTOR 575V OVERLOAD+CONTACTOR 208-230/460V OVERLOAD+CONTACTOR 575V BASE PLATE GAS PRESSURE SWITCH INSPECTION WINDOW FAN FAN FAN COVER MOTOR 208-230/460V MOTOR 575V MOTOR 208-230/460V MOTOR 575V MOTOR 208-230/460V MOTOR 575V H.T. LEAD ELECTROD ELECTROD SUPPORT TUBE ELBOW HALF-SHELL CONNECTOR SCREW BAR

GRUPPO SERRANDA PROTEZIONE SPINA PRESSOSTATO OLIO PRESSOSTATO ARIA CAMPANA SPINA STAFFA COLLEGAMENTO PER ELETTRODO MEMBRANA ELETTRODO PILOTA STAFFA TRASFORMATORE SUPPORTO GRUPPO GIUNZIONE RELE' TERMICO+CONTATTORE 208-230/460V RELE' TERMICO+CONTATTORE 575V RELE' TERMICO+CONTATTORE 208-230/460V RELE' TERMICO+CONTATTORE 575V RELE' TERMICO+CONTATTORE 208-230/460V RELE' TERMICO+CONTATTORE 575V MENSOLA PRESSOSTATO GAS VISORE GIRANTE GIRANTE GIRANTE COFANO MOTORE 208-230/460V MOTORE 575V MOTORE 208-230/460V MOTORE 575V MOTORE 208-230/460V MOTORE 575V COLLEGAMENTO ELETTRODO ELETTRODO SUPPORTO TUBO GOMITO GUSCIO RACCORDO VITE PERNO

N. CODE
C9835001 (3485274) C9836000 (3485474) C9836001 (3485474)

DESCRIPTION

DESCRIZIONE
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

22
O-OVERLOAD+CONTACTOR FOR PUMP MOTOR 208-230/460V

SCREW SEAL CONNECTOR SEAL SCOOP SCOOP SCOOP GAS NOZZLE GAS HEAD SCREW CONTROL DEVICE FRONT PIECE FRONT PIECE SQUARE SQUARE SQUARE COUPLING END CONE END CONE SHUTTER SHUTTER CONNECTOR MANIFOLD CONNECTOR SEAL SEAL FLANGE AND ELBOW BRACKET AIR INTAKE TUBE TUBE SERVOMOTOR NEEDLE VALVE CONNECTOR SEAL BAR CORK MOTOR 208-230/460V MOTOR 575V CONNECTOR PILOT TUBE PUMP FILTER + SEAL
RELE' TERMICO+CONTATTORE MOTORE POMPA 208-230/460V

33 34 35 36 37 37 37 38 39 40 41 42 42 43 43 43 44 45 45 46 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63 64 65 66 67 67

3006721 3007077 3006722 3003381 3013043 3013044 3013045 3012436 3012437 3012049 3003974 3003975 3003976 3012438 3012440 3012442 3013254 3012444 3012446 3003983 3003984 3003322 3013267 3003220 3007166 3005482 3012971 3013264 3013261 3013294 3013295 3013253 3012952 3013524 3007077 3003592 3003681 3013031 3013063 3009087 3013049 3013523 3003936 3012991

PERNO GUARNIZIONE RACCORDO GUARNIZIONE TAZZA TAZZA TAZZA DIFFUSORE DISTRIBUTORE VITE GRUPPO REGOLATORE FRONTONE FRONTONE SQUADRETTA SQUADRETTA SQUADRETTA GIUNTO IMBUTO FIAMMA IMBUTO FIAMMA OTTURATORE OTTURATORE RACCORDO MANICOTTO RACCORDO GUARNIZIONE GUARNIZIONE FLANGIA E GOMITO STAFFA BOCCA D'ASPIRAZIONE TUBO TUBO SERVOMTORE VALVOLA RACCORDO GUARNIZIONE PERNO TAPPO MOTORE MOTORE RACCORDO TUBO PILOTA POMPA FILTRO + GUARNIZIONE

N. CODE
C9835001 (3485274) C9836000 (3485474) C9836001 (3485474)

DESCRIPTION

DESCRIZIONE
BURNER SERIAL NUMBER MATRICOLA BRUCIATORE

C9834000 (3485074)

C9834001 (3485074)

C9835000 (3485274)

67 68 70 71 72 73 74 75 76
RELE' TERMICO+CONTATTORE MOTORE POMPA 575V

3013131 3003952 3012956 3012125 3012003 3013055 3012123 3013132 3013492

FONOASSORBENTE TRASFORMATORE RACCORDO PERNO TUBETTO RACCORDO CONTATTO AUSILIARIO GIUNTO

OVERLOAD+CONTACTOR FOR PUMP MOTOR 575V SOUND DAMPING TRANSFORMER CONNECTOR SCREW TUBE CONNECTOR AUXILIARY CONTACT BLOCK COUPLING

23

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

24

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 Hingham, Massachusetts, U.S.A. 02043 http://www.riello-burners.com Subject to modifications

1-800-4-RIELLO
1-800-474-3556

2165 Meadowpine Blvd. Mississauga, Ontario, Canada L5N 6H6