Riello Burners RDB1R CF 26 Quick start guide

2902661 (3) - 06/2009

Installation, use and maintenance instructions

Light oil burners

One stage operation

CODE MODEL TYPE

3510225 RDB1 CF 38 501 T3

3510050 RDB1R CF 26 501 T1R

3510150 RDB1R CF 33 501 T2R

3510250 RDB1R CF 38 501 T3R

3510650 RDB2R CF 38 502 T3R

3510750 RDB2R CF 46 502 T5R

2661 1

CONTENTS

1. BURNER DESCRIPTION

One stage gas oil burner.

1.1 BURNER EQUIPMENT

Flange with insulating gasket. . . . No. 1 Screws for flange to be fixed to boiler. . . . . . . . No. 4

Screw and nuts for flange . . . . . . No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . No. 2

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

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

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

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

2.2 Working fields . . . . . . . . . . . . . . . . . . . . 2

2.3 Overall dimensions . . . . . . . . . . . . . . . . 3

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

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

3.2 Hydraulic systems . . . . . . . . . . . . . . . . . 4

3.3 Electrical wiring . . . . . . . . . . . . . . . . . . . 5

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Combustion adjustment. . . . . . . . . . . . . . 6

4.2 Nozzles recommended . . . . . . . . . . . . . . 6

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

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

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

4.6 Fuel heating . . . . . . . . . . . . . . . . . . . . . . 7

4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 7

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

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

OThe burner meets protection level of IP 40, EN 60529.

OBurner with CE marking in conformity with EEC Directives: EMC 89/336/EEC - 2004/108/CE, Low Voltage

73/23/EEC - 2006/95/CE, Machines 98/37/EEC and Efficiency 92/42/EEC.

OCE Certification No.: 0036 0316/01 as 92/42/EEC.

1– Pump

2– Flange with insulating gasket

3– Air damper adjustment screw

4– Reset button with lock-out lamp

5– Photoresistance

6– Control-box

7– Pump pressure adjustment screw

8– Pressure gauge port

D4044

Fig. 1

2661 2

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 WORKING FIELDS (as EN 267)

TYPE 501T3 501T1R 501T2R 501T3R 502T3R 502T5R

Output kg/h 2 – 3.2 1.4 – 2.2 1.8 –2.8 2 –3.2 2 –3.2 2.8 – 3.9

Thermal power kW 23.8 - 37.9 16.6 - 26 21.4 - 33.2 23.8 - 37.9 23.8 - 37.9 33.2 - 46.2

(with air at 20°C) (Hi= 11.86 kWh/kg)

Fuel Gas oil, viscosity 4 – 6 mm2/s at 20°C

Electrical supply Single phase, ~50Hz 230V ±10%

Motor Run current 0.7A – 2850 rpm – 298 rad/s

Capacitor 4.5 µF

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.115 kW 0.170 kW 0.180 kW

0.4

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

18 Thermal power - kW

D6270

0.2

0.6

0.8

1.0

1.2

16 20 22 24 28

501T1R 501T2R 501T3

1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.21.2

30 32 34 36 38

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

0.4

0.2

0.6

0.8

1.0

1.2

D6271

Thermal power - kW2624 28

2 2.2 2.4 2.6 2.8 3 3.2

30 32 34 36 38

3.4 3.6 3.8 4

40 42 44 46

1.4

502T3R 502T5R

1.8

22 48

501T3R

2661 3

2.3 OVERALL DIMENSIONS

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL

STANDARDS.

3.1 BOILER FIXING

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

yFix 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).

Flange Burner

140 86 202

130

223.5

168

D4049

180

72 72

150

136

ø89

D4085

E9149

Fig. 2

Fig. 3

E9148

2661 4

3.2 HYDRAULIC SYSTEMS

The pump is designed to allow working with two pipes.

In order to obtain one pipe working it is necessary to unscrew the return

plug (2) (fig. 4), remove the by-pass screw (3) and then screw again the

plug (2).

³In 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.

³A metal bowl filter with replaceable micronic filter must be fitted in the

oil supply pipe.

³Check periodically the flexible pipes conditions.

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.

The suction plug (1) is made of plastic. Once removed,

it must not be used again.

In single-pipe installations, the plug in the return line (2)

must be totally in steel.

WARNING

Fig. 4

D9630

max. 4 m

min. 0.1 m

D5741

Fig. 5

meters

L meters

I.D.

8 mm I.D.

10 mm

0.5

1.5

100

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 seconds before repeating the operation.

In the vacuum systems (fig. 7) the return line should terminate within the oil tank at the same level as the suc-

tion 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 how-

ever is less safe than previous one, due to the possibility of leakage of the valve.

The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg). Beyond this limit gas is re-

leased from the oil.

Oil pipes must be completely tight.

WARNING

1 Suction line

2 Return line

3 By-pass screw

4 Gauge connection

5 Pressure adjuster

6 Suction gauge connection

7Valve

8 Auxiliary pressure test point

D5740

max. 4 m

D1842

Fig. 6 Fig. 7 H

meters

L meters

I.D.

8 mm I.D.

10 mm

0.5

1.5

3.5

100

H= difference of level;

L= max. lenght of the suction line;

I.D. = interminal diameter of the oil pipes

2661 5

3.3 ELECTRICAL WIRING

NOTES:

yWires of min. 1 mm2section. (Unless requested otherwise by local standards and legislation).

yThe electrical wiring carried out by the installer must be in compliance with the rules in force in the Country.

TESTING:

Check the shut-down of the burner by opening the thermostats

and the lock-out by darkening the photoresistance.

Start

White

Black

Neutral

Capacitor

50Hz - 230V

Oil valve

D6072

CONTROL BOX

Photoresistanc

535RSE/LD

Motor

Main switch

T6A

Blue

White

Black

DO NOT EXCHANGE NEUTRAL WITH PHASE

WARNING

Resistance

thermostat

Ignition

electrodes

Neutral

Capacitor

50Hz - 230V

Oil valve

D6041

CONTROL BOX

Photoresistance

535SE/LD

Limit thermostat

Motor

Remote lock-out signal

(230V - 0.5A max.)

Main switch

T6A

Blue

White

Black

Ignition

electrodes

CONTROL BOX (see fig. 8)

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

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

components.

yRemove the coil (3).

yLoosen the two screws (4).

yMove a little the control box and remove the high voltage leads.

E9150

Fig. 8

501T3 501T1R-2R-3R - 502T3R-5R

Safety thermostat Safety thermostat

Limit thermostat

Remote lock-out signal

(230V - 0.5A max.)

2661 6

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 ofthe boiler, including verification of the CO and CO2

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

To suit the required appliance output, fit the proper nozzle, then adjust the pump pressure and the air damper

opening in accordance with the following schedule.

The values shown in the table are measured on a CEN boiler (as per EN 267).

They refer to 12.5% CO2at sea level and with gas oil and room temperature of 20 °C.

4.2 NOZZLES RECOMMENDED : Delavan type W - E; Monarch type R - NS

Steinen type Q - H ; Danfoss type S - H.

TYPE

Nozzle Pump

pressure Burner output Air damper adjustment

GPH Angle bar kg/h ±4% Set-point

501T3

0.50 60° 12 2.0 3.3

0.55 60° 12 2.2 4.5

0.60 60° 12 2.4 4.8

0.65 60° 12 2.6 5.5

0.75 60° 12 3.0 6.5

0.75 60° 13.5 3.2 7.5

501T1R

0.40 60° 10.5 1.4 0.8

0.50 60° 12 1.9 2.8

0.55 60° 12 2.1 3.8

0.55 60° 13 2.2 5

501T2R

0.50 60° 11 1.8 3.3

0.50 60° 12 1.9 3.5

0.55 60° 12 2.1 4.3

0.60 60° 12 2.3 4.7

0.65 60° 12 2.5 5.2

0.75 60° 11 2.8 6

501T3R

0.55 60° 11 2.0 3.1

0.60 60° 12 2.3 4.1

0.65 60° 12 2.5 4.8

0.75 60° 12 2.9 6.3

0.85 60° 11.5 3.2 7.5

502T3R

0.55 60° 11 2.0 3.4

0.60 60° 12 2.3 4

0.65 60° 12 2.5 4.6

0.75 60° 12 2.9 5.4

0.85 60° 11.5 3.2 6.5

502T5R

0.75 80° 11 2.8 1.5

0.85 60° 12 3.3 2.2

1.00 60° 12 3.8 3.6

1.00 60° 12.5 3.9 3.8

2661 7

4.3 ELECTRODES SETTING

4.4 PUMP PRESSURE:

12 bar: The pump leaves the factory set at this value.

14 bar: (Only for type 501T3).

Improves flame retention; it is therefore suitable for ignitions at low temperatures.

4.5 AIR DAMPER ADJUSTMENT

The settings indicated in the schedule are purely indicative. Each installation however, has its own

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

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

4.6 FUEL HEATING (for type 501T1R-2R-3R - 502T3R-5R)

In order to assure regular ignition and working also at low temperatures the burner has an oil pre-heater fitted in

combustion head. The pre-heater starts when thermostats close and it is indicated by the ignition of an orange

led placed on the control box. When the required temperature for ignition is reached the thermostat fitted on the

nozzle holder starts the burner the orange led switches off, the green led switches on and the motor starts. The

pre heater remains energised during working and cuts out when burner shuts-down.

4.7 BURNER START-UP CYCLE

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

Before removing or assembling the

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

and move the electrodes ahead.

ATTENTION 4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 A2 –2.5 mm

Fig. 9

Thermostat

Motor

Ignition transformer

Flame

Lock-out lamp

150s

D5329

150s

12s

Resistance

Valve

Thermostat

Motor

Ignition transformer

Oil valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

Lock-out due to failure to light

Normal 501T3

Lock-out due to failure to light

Normal 501T1R-2R-3R - 502T3R-5R

2661 8

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:

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

yClean the filter in the oil suction line and in the pump.

yClean the photoresistance, (5, fig. 1, page 1).

yCheck for correct fuel consumption.

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

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

yLeave 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.

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