Riello Burners RDB1 70-90 Quick start guide

2902458 (10)

Installation, use and maintenance instructions

CODE MODEL TYPE

3748357 RDB1 70 - 90 483T50

3748557 RDB1 50 - 70 485T50

3513007 RDB1 WM 50/70 501T2K

3748757 RDB2 90 - 120 487T50

KEROSENE BURNER

KEROSENE AND LIGHT OIL

BURNER

2458

INDEX

1. BURNER DESCRIPTION

1.1 BURNER EQUIPMENT

Flange with insulating gasket. . . . . .No. 1 Screws and terminal screw for feeding cable . . . No. 3

Screw and nuts for flange . . . . . . . .No. 1 Screw of by-pass pump . . . . . . . . . . . . . . . . . . . No. 1

Hexagonal key. . . . . . . . . . . . . . . . .No. 1 Nuts for flange to be fixed to boiler. . . . . . . . . . . No. 2

Flexible oil pipe with nipple . . . . . . .No. 1

1. BURNER DESCRIPTION. . . . . . . . . . . . 1

1.1 Burner equipment. . . . . . . . . . . . . . . . . . 1

2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2

2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2

2.2 Overall dimensions. . . . . . . . . . . . . . . . . 2

2.3 Firing rates . . . . . . . . . . . . . . . . . . . . . . 2

3. INSTALLATION. . . . . . . . . . . . . . . . . . . 3

3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Burner assembly . . . . . . . . . . . . . . . . . . 3

3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 5

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 6

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 7

4.1 Combustion adjustment. . . . . . . . . . . . . . 7

4.2 Nozzles recommended . . . . . . . . . . . . . . 7

4.3 Electrodes setting . . . . . . . . . . . . . . . . . 7

4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7

4.5 Air damper adjustment . . . . . . . . . . . . . . 7

4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8

6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9

One stage kerosene and light oil burner.

■In case of BF applications the intake air temperature must not be over 70°C.

■CE Certification No.: 0036 0326/01 (483T50) – 0036 0316/01 (501T2K), as 92/42/EEC.

■The burner meets protection level of IP 40, EN 60529.

■Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,

Machines 98/37/EEC and Efficiency 92/42/EEC.

1– Pump

2– Control-box

3– Reset button with lock-out lamp

4– Flange with insulating gasket

5– Air damper adjustment screw

6– Pump pressure adjustment screw

7– Pressure gauge port

8– Photoresistance

D6115

Fig. 1

2458

2. TECHNICAL DATA

2.1 TECHNICAL DATA

◆

Light oil is not permitted on low level discharge of flue gas products.

2.2 OVERALL DIMENSIONS

2.3 FIRING RATES,

(as EN 267)

TYPE 483T50 485T50 501T2K 487T50

Output – Thermal power

(with air at 20°C)

kg/h 1.8 – 3.4 1.5 – 2.5 1.8 – 2.8 2.3 – 3.9

kW 21.6 – 40.6 18 – 29.9 21.6 – 33.5 27.6 – 46.6

Fuel Kerosene, viscosity 1.6 – 6 mm

/s at 20 °C

(Hi= 11.97 kWh/kg)

Light oil, viscosity 4 – 6 mm

/s at 20 °C

◆

(Hi= 11.86 kWh/kg)

Electrical supply Single phase,

50Hz 230V

10%

Motor Run current 0.7A – 2700 rpm – 283 rad/s

Capacitor 4.5

Ignition transformer Secondary 8 kV – 16 mA

Pump Kerosene, maximum pressure 10 bar (145 psi)

Light oil, maximum pressure 15 bar (218 psi)

Absorbed electrical power kW 0.115 0.125

Flange Burner

140 A 202

130

45°

øB

223.5

168

D6114

180

72 72

150

45°

136

TYPE A Ø B

483T50 96 90

485T50 90 84

501T2K 50 85

487T50 96 90

1.4

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

Thermal power - kW

0.8

1.0

1.2

0.4

0.2

0.6

D4503

15 20 4025 30 35 45

22.5 33.5

1.5 4

487T50483T50501T2K485T50

2458

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

3.1 BOILER FIXING

➤

Put on the flange (1) the screw and two nuts, (see fig. 2).

➤

Fix the flange (1) to the boiler door (4) using screws (2) and

(if necessary)

the nuts (3)

interposing the

insulating gasket (5)

, (see fig. 3).

3.2 BURNER ASSEMBLY

In case of

applications, the burner shall not operate without pro-

tection

(A)

of the suction inlet.

FOR CORRECT BF APPLICATION, THE BURNER MUST BE

INSTALLED ON AN APPROPRIATE BF BOILER.

In case of

applications an optional snorkel and gasket are availa-

ble replacing

(A)

with

(B)

. This item can be supplied separately.

The combustion air supply is through a flexible or rigid pipe connect-

ed to the air intake.

Consequently, you must comply with the following requirements and

instructions:

➤

The combustion air intake tube must be:

- fastened securely to the burner;

- made of a suitable material, with temperature characteristics in

the range - 30 °C to 80 °C;

- in compliance with all requirements of applicable regulations in

force in the country of destination.

RESET

TWICE

ONLY

E9149

Fig. 2

Fig. 3

E9148

D5884

D5883

CF APPLICATION

BF APPLICATION

2458

➤

The intake-tube / burner system must not allow a loss of over 2 m

/h at 0.5 mbar:

for instance, the above requirements will be met if you use flues for pressure exhaust of flue gases (the

condensation kind).

➤

Make sure the air intake tube’s inlet is positioned so that it is not likely to be obstructed by foreign matter

and, where necessary, use suitable screens.

➤

The temperature of the incoming air must not exceed 40 °C;

➤

The inside diameter of the hose must be at least 80 mm.

➤

The intake tube can be up to 6 metres in length.

Warning

: length is reduced if there are bends in the intake section.

For instance, using a tube with a smooth inside surface, you must allow for the following losses:

- for each 45° bend, tube length is reduced by 0.5 m;

- for each 90° bend, tube length is reduced by 0.8 m.

BURNER INSTALLATION MUST COMPLY WITH ONE OF THE INSTALLATIONS ILLUSTRATED IN THE

FIGURES BELOW.

➤

Under no circumstances should the air’s entry in the hose intake area be obstructed.

➤

The hose must not be blocked in any way or feature a shutting device (valves, membranes etc.).

➤

Coaxial tubes must not be installed for any reason.

ATTENTION

S7851

S7853

S7876

2458

3.3 HYDRAULIC SYSTEMS

H= difference of level L= Max. lenght of the suction line I.D. = Interminal diameter of the oil pipes.

Fig.4

D5912 2

➤Check periodically the flexible pipes conditions.

Using kerosene, they have to be replaced at least every 2 years.

➤A metal bowl filter with replaceable micronic filter must be fitted in the

oil supply pipe.

➤The pump is designed to allow working with one pipe.

In order to obtain two pipes working it is necessary to unscrew the

return plug (2), screw the by-pass screw (3) and then screw the

return flexible oil pipe. (See fig. 4).

➤In the two pipes systems, before starting the burner make sure that

the return pipe-line is not clogged. An excessive back pressure

would cause the damage of the pump seal.

WARNING:

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

3.5

100

1- Suction line

2- Return line

3- By-pass screw

4- Gauge connection

5- Pressure adjuster

6- Suction gauge connection

7- Valve

8- Auxiliary pressure test point

PRIMING PUMP

On the system in ﬁg. 5 it is sufﬁcient to loosen the suction gauge

connection (6, ﬁg. 4) and wait until oil ﬂows out.

On the systems in fig. 6 and 7 start the burner and wait for the priming.

Should lock-out occur prior to the arrival of the fuel, await at least 20 sec-

onds before repeating the operation.

The pump suction should not exceed a maximum of 0,4 bar (30 cm Hg).

Beyond this limit gas is released from the oil. Oil pipes must be completely

tight.

In the vacuum systems (fig. 7) the return line should terminate within the oil

tank at the same level as the suction line. In this case a non-return valve is

not required. Should however the return line arrive over the fuel level, a

non-return valve is required. This solution however is less safe than previ-

ous one, due to the possibility of leakage of the valve.

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

100

max. 4 m

min. 0.1 m

Fig.5

D5741

Fig.6 Fig.7

D5740

max. 4 m

D1842

2458 6

3.4 ELECTRICAL WIRING

E9153

CONTROL BOX (see fig. 8)

To remove the control box from the burner follow of the istruction:

➤Loosen the screw (1), open the protection (2) and remove all

components.

➤Remove the coil (3).

➤Loosen the two screws (4).

➤Move a little the control box and remove the high voltage leads.

Fig. 8

Capacitor

~50Hz - 230V

Limit

Oil valve

D4240

CONTROL BOX

Photoresistance

535SE/LD

thermostat

Safety

thermostat

Motor

Remote lock-out signal

(230V - 0.5A max.)

Main switch

T6A

Blue

White

Black

Ignition

electrodes

TESTING:

Check the shut-down of the burner by opening

the thermostats and the lock-out by darkening

the photoresistance.

Burner-earth

NOTES:

– Wires of min. 1 mm2section.

(Unless requested otherwise by local stand-

ards and legislation).

– The electrical wiring carried out by the install-

er must be in compliance with the rules in

force in the Country.

DO NOT EXCHANGE NEUTRAL WITH PHASE

WARNING

2458 7

4. WORKING

4.1 COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and

testing must be carried out observing the instruction manual of the boiler, including verification of the CO and

CO2concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.

4.2 NOZZLES RECOMMENDED : Delavan type W; Steinen type Q - S; Danfoss type H - S.

Angle : 60° - In most cases.

80° - In case of ﬂame detachment, during ignitions at low

temperatures.

4.3 ELECTRODES SETTING

4.4 PUMP PRESSURE

The pump leaves the factory set for kerosene working.

10 bar: maximum pressure for kerosene.

FOR LIGHT OIL INCREASE PRESSURE

12 bar: pressure suitable for light oil in most cases.

14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.

4.5 AIR DAMPER ADJUSTMENT

The air damper is set in factory. This regulation is purely indicative. Each installation however, has its

own unpredictable working conditions: actual nozzle output; positive or negative pressure in the combus-

tion-chamber, the need of excess air, etc. All these conditions may require a different air damper setting.

Before removing or assembling the

nozzle, loosen the screw (A, fig. 9)

and move the electrodes ahead.

TYPE

483T50 3 – 3.5 mm

485T50 2 – 2.5 mm

501 T2K 2 – 2.5 mm

487T50 3 – 3.5 mm

ATTENTION

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 AB

Fig. 9

2458 8

4.6 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).

5. MAINTENANCE

The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity

with legislation and local standards.

Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and

consequent pollution.

Before carrying out any cleaning or control always first switch off the electrical supply to the

burner acting on the main switch of the system.

THE BASIC CHECK ARE:

➤Check that there are not obstructions or dents in the supply or return oil pipes.

➤Clean the filter in the oil suction line and in the pump.

➤Clean the photoresistance,(8, fig. 1, page 1).

➤Check for correct fuel consumption.

➤Replace the nozzle and check the correct position of electrodes (fig. 9, page 7).

➤Clean the combustion head in the fuel exit area, on the diffuser disc.

➤Leave the burner working without interruptions for 10 min. and set rightly all the components stated in

this manual. Then carry out a combustion check verifying:

●Smoke temperature at the chimney; ●Contentof CO2(%); ●ContentofCO(ppm);

●Smoke value according to opacity smokes index according to Bacharach scale.

Normal

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

Lock-out due to failure to light

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