Riello 3433823 Quick start guide

2916192 (0)

Montage und Bedienungs Anleitung

Manuel d’entretien

Installation, use and maintenance instructions

Istruzioni per installazione, uso e manutenzione

Bruciatore di nafta

Heizölbrenner

Heavy oil burner

Brûleur à fioul lourd

CODICE

CODE

MODELLO - MODELL

MODELE - MODEL TIPO - TYP

TYPE

3433823 PRESS 30 N/ECO 626 T

3433824 PRESS 30 N/ECO 626 T

Funzionamento bistadio

Zweistufiger Betrieb

Two-stage operation

Fonctionnement à deux allures

6192 1 GB

INDEX

1. BURNER DESCRIPTION

Two-stage operation fuel-oil burner.

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

1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2

2.3 Field of operation . . . . . . . . . . . . . . . . . . . . 2

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

3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 3

3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 4

3.3 Electrical connections . . . . . . . . . . . . . . . . 5

4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 6

4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6

4.3 Combustion head adjustment . . . . . . . . . . . . 6

4.4 Air damper motor adjustment . . . . . . . . . . . . 6

4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . . .7

4.6 Atomisation temperature adjustment . . . . . . . 7

4.7 Start-up programme. . . . . . . . . . . . . . . . . . . . 9

4.8 Ecological oil burners . . . . . . . . . . . . . . . . . . 9

4.9 Emulsified fuel oil operation . . . . . . . . . . . . . 9

4.10 Start-up programme diagnostic . . . . . . . . . . 10

4.11 Operating fault diagnostic . . . . . . . . . . . . . . 10

2893

OThe burner corresponds with IP 40 grade of protection in accordance with EN 60529.

OBurner with CE marking in conformity with EEC directives: CEM 89/336/EEC, Low Voltage 73/23

CEE, Machines 98/37/EEC and Yield 92/42/EEC.

OIn conformity with the Yield Directive 92/42/EEC, the application of the burner to the boiler, adjustmen

and testing must be carried out in compliance with the said boiler's instruction manual, including the

checking of the CO and CO2concentration in the fumes, their temperature and the average temperature

of the boiler water.

1 - Suction fitting

2 - Return fitting

3 - Pump pressure adjustment screw

4 - Manometer fitting (G1/8)

5 - Vacuometer fitting (G1/2)

6 - Air damper opening motor

7 - Control box reset button and lock-out indicator

8 - Fan overload cutout reset

9 - Regulating screw for combustion head

10 - Double filter

11 - Valve group

12 - Manometer with protection valve

13 - Adjustment thermostat

14 - Pre-heater contact maker

15 - Transformer

16 - Terminal board

17 - Cable glands

18 - Antigas valve

19 - Thermometer

20 - Pump motor starter with reset

21 - Air pressure switch

Fig. 1

1.1 EQUIPMENT

Flexible tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples . . . . . . . . . . . . . . . . . . . . . . . No. 2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Screws. . . . . . . . . . . . . . . . . . . . . . . . . . No. 4

Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . No. 2

Guide extensions (for the lengthened

head version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Fitting for emulsified fuel oil

emulsified (see page 9) . . . . . . . . . . . . . . . . . . . . . No. 1

6192 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 DIMENSIONS

2.3 FIELD OF OPERATION (2 functioning nozzles)

TYPE 626 T

Thermal power - Capacity 85/171 - 342 kW – 7.5/15 - 30 kg/h

Fuel Oil with max. viscosity at 50° C 115 sq.mm (15° E)

Power supply Three-phase, 230 V ±10% ~50Hz without neutral

400V ±10% ~50Hz with neutral

Motor 230V - 400V Fan: 2.4A - 1.4A

Pump: 2.1A - 1.2A

Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA

Heaters 2.8 kW

Intake electrical power 4.1 kW

Pump 60 kg/h at 20 bar

D2715

D2628

BurnerBoiler plate

NOTE

The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised

to hold the burner while it is being extracted so as not damage the flame disc and the said guides.

For elongated - head version.

Use the pin extensions provided as accessories when pulling the burner back.

783 185

320

625

290

Diam. 161

305

Thermal power

Pressure in combustion

chamber – mbar

D2627

When the burner operates with only one nozzle, the pressurisation conditions are better and no problems

arise. Minimal flow rate with one only nozzle: 7.5 kg/h - 85 kW.

kg/h

6192 3 GB

3. INSTALLATION

3.1 FUEL OIL SUPPLY SYSTEMS

GRAVITY SYSTEM

SUCTION SYSTEM

LOOP SYSTEM (max loop system pressure 3 bar)

metres

L metres

Diam.

3/4”

Diam.

1” gas

0510

0.5 8 15

11120

1.5 14 25

21730

Pump priming:

loosen the tap from the vacuometer fitting

(5, fig. 1) and wait for the fuel to flow out.

H: Difference in height

L: Length of the suction tube

For light oil with max. viscosity 7°E at 50°C.

D2720

max. 30m

metres

L metres

diam.

1” gas

diam. 1

1/4”

02445

0.5 21 40

11835

1.5 15 30

21225

2.5 9 20

3615

Not advised. To be used only in case of

previously existing system.

Never exceed the max. vaccum of 0.5 bar

(38 cm Hg) measured at the vacuometer

fitting (5, fig. 1).

The pipes should be perfectly airtight.

When the tank is placed below of the burn-

er level, the return pipe should arrive at the

same level as the suction pipe.

In this case the foot valve is not required.

For light oil with max viscosity 7°E at 50°C.

D2721

max. 30m

1- Tank (heated for heavy oil) 5- Transfer pump

2- Filter (with resistor for oil > 7°E / 50°C) 6- Control manometer

3- Burner 7- Burner pump

4- Burner cut-out gate valves (coupled) 8- Pressure adjuster

For heavy oil with viscosity up to 20°E / 50°C.

Important note: to allow the fuel to flow properly, all the pipes have to be properly sized, insulated and heat-

ed (electrically or by means of steam or hot water).

Warning: before using the burner, make sure that there is no obstruction in the return pipe,

any obstruction may damage the sealing of the pump.

D2631

6192 4GB

3.2 BURNER ELECTRICAL SYSTEM (made in the factory)

RMO88.53A2

PMP

246 96

135

13 A1

RT1

1512 16

171318 9 5 8114

ST2

ST1

ST0

HS1

MV2

R2 R3

246 95

135

13 A1

531

624

L1R

NL1 L2 L3 LN S3 T1 30T2T6T8

V21

V22

L1P

L2P

L3P

CMP

CMV

CMP Pump motor contact maker

CMV Fan motor contact maker

CR Pre-heater contact maker

FSuppressor

FR photocell

MB Burner terminal strip

MP Pump motor

MV Fan motor

PA Air pressure switch

R1 Spray holder resistor

R2 Pump resistor

R3 Valve assembly resistor

RMO Electrical control box

RT Fan motor thermal relay

RT1 Pump motor thermal relay

SPre-heater tank

SM Servomotor

TA Ignition transformer

TB Burner earth

TE Regulation thermostat and start-up enabling

signal

Tm Minimum contact thermostat

Tm Maximum contact thermostat

V1 First stage valve

V2 Second stage valve

2598

6192 5 GB

3.3 ELECTRICAL CONNECTIONS TO THE TERMINAL STRIP (to be made by the installer)

FASTENING OF THE ELECTRICAL WIRES

All the wires to be connected to the terminal strip (16, fig. 1) shall pass through the appropriate cable entries

(17, fig. 1), see the figure below.

Any other signals or controls can be connected to the burner terminal strip by pushing out the metal disc in the

pre-sheared holes and inserting a common cable entry for the passage and the clamping of the leads. To ensure

the IP 40 degree of protection in compliance with EN 60529 close any unused cable entries with appropriate

discs.

NOTES

- Make a safe earth connection.

- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.

IN Manual switch

MB Burner terminal strip

HLock-out signal

TL Limit remote control

TR Adjustment remote control

TS Safety remote control

NOTE

Wire cross-section: min. 1 sq. mm.

(Unless otherwise required by local standards

and legislation).

TWO STAGE OPERATION

It is achieved by means of the remote control

device connected to terminals 5-6 (removing

the jumper), that controls the second valve. RESISTOR CONNECTIONS

D2634

PRE-HEATER

2610

230V 400V

A Ampere 10 6

B Ampere 6 4

C sq.mm 1.5 1.5

D sq. mm 2.5 1.5

D2635

1- Single phase pre-heated resistor

power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21

2 - Three-phase power supply: . . . . . . . . . . . .cable entry Pg 16

3 - Single phase power supply and

safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

4- Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

5-2

nd stage thermostat:. . . . . . . . . . . . . . . . .cable entry Pg 13.5

6192 6GB

4. OPERATION

4.1 CHOICE OF NOZZLES

Recommended nozzles:

- Monarch F 80 H0.

4.2 PUMP PRESSURE

Recommended pressure:

- Fluid oil: 20 bar

- Heavy oil: 25 bar

Rated deliveries of the nozzles are indicated on the above

list and refer to a light oil (viscosity from 3 to 5°E at 50° C pre-

heated at 100°C). The actual flow rate may vary by ± 5%

compared with the rated flow rate.

In values in between those indicated in the tables are

required, the pump pressure could be changed or the

composition of the nozzles varied.

The pump leaves the factory set at 20 bar.

4.3 COMBUSTION HEAD ADJUSTMENT

Turn the screw A, fig. 2 till the set-point, detected from the dia-

gram, is in the line with the washer B, fig. 2.

4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR

STOP - Blue lever

This lever leaves the factory vertically positioned and corre-

sponds to the air damper fully closed.

A partial opening of the air damper might be obtained by

moving this lever leftwards (+on the plate).

The new position of the air damper is detectable when the

burner stops.

Do not exceed the position of the orange lever for the

1st stage.

1st STAGE - Orange lever

The orange lever controls the air damper position for the first

flame, it is adjustable both for opening and closing.

2nd STAGE - Red and black levers

The red lever controls the air damper position for the second

flame, it is adjustable both on closing and opening.

The black lever controls the opening of the second oil valve

and it must always be slightly before the red lever, but never

the first stage orange one.

Nozzle

GPH (45° - 60°)

20 bar

kg/h

25 bar

kg/h

1.25 + 1.25 15.00 17.00

1.50 + 1.50 18.00 20.30

1.75 + 1.75 21.00 23.80

2.00 + 2.00 24.00 27.10

2.25 + 2.25 27.00 30.50

2.50 + 2.50 30.00 –

D2638

Black lever

Red lever

Orange lever

Blue lever

Opening +–Closing

kg/h

Set-points

D2636

D2637

Set-point 4

Fig. 2

6192 7 GB

4.5 AIR PRESSURE SWITCH

4.6 ATOMISATION TEMPERATURE ADJUSTMENT

Control thermostat - minimum value - maximum value

Adjustment thermostat prevents the burner start up if the fuel temperature has not reached the value required

for a better atomisation as indicated in the diagram below.

Example

Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.

The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob

to get approximately 100°C at the nozzles).

The value has to be read after some minutes of operation and later the necessary adjustments carried out.

Minimum value contact thermostat intervenes by stopping the burner if the fuel temperature falls below

the value necessary for better combustion.

Maximum value contact thermostat switches off the resistors when in case of failure of the adjustment

thermostat, the temperature increases inside the pre-heater. In case of abnormal cut ins ,check the control

thermostat the resistor in contact with the said thermostat probe are operation properly.

D2640

D2719

Thermostat adjustment

knob

Pre-heater

Purge

Atomisation temperature

Viscosity at 50° C

sq. mm/sec °E

°C

Carry out the regulation of the air pressure switch after

carrying out all the other regulations of the burner with

the air pressure switch regulated at the beginning of

the scale.

With the burner operating at the MIN power increase

the pressure of the adjustment by slowly turning the

appropriate knob clockwise until the burner locks out.

Then turn the knob counterclockwise to a value equal

to about 20% of the regulated value and then check

the correct start up of the burner. If the burner locks out

again turn the knob a bit further in a counterclockwise

direction.

D68

D 521

6192 8GB

IMPORTANT NOTES

If the pre-heater thermostat or the resistor in contact with

the probe is to be replaced, the probe has to be positioned

in contact with the resistor and with the pipes of the last

aluminium plate, after loosening of the fixing screws of the

aluminium plate pack. See drawing opposite.

If, during the operation exceptional differences or temper-

atures that peak too high should be detected, verify the

continuity of the resistor, using an ohmmeter, contacting

the temperature probe (value approximately 35 Ohm).

Only use filters marked with a recognizable printing on the screwing hexagon.

NOTES

yThe pre-heater might be fitted with a second thermostat of maximum value.

This thermostat can be used as a switch on an external contact maker to cut off current to the pre-heater in

case of excess temperature (Kit code no. 3000800).

yResistor Ron the nozzle-holder is wired to the supply line of the pre-heater (see pag. 4).

When the burner is off, the pre-heater supply line shall remain fed.

Should the pre-heater line be turned off, the fuel must be pre-heated for approximately 30 minutes before the

burner start-up. On the contrary, the nozzle-holder resistor must be supplied with an independent single-

phase line, protected by a 1A fuse.

This line shall never be switched off, when the burner is off.

yBefore the burner start-up, verify that the pump is filled of fuel in order to avoid it running empty for too long.

yFilter cleaning:

periodically clean the filters in order to avoid malfunctioning in burner operation.

ySupply line filter:

positioned on the suction line, it causes the increase of the vacuum in the pump with the consequent flow of

gas and noise. Do not exceed the vacuum of 38 cm Hg (5 m W.c.) at the vaccumeter attachment (5, fig. 1).

yPre-heater filter (10, fig. 1):

positioned in the delivery line, it causes a decrease of the atomising pressure which can be checked on

the manometer (12, fig. 1).

MANOMETER PROTECTION VALVE

After atomising pressure check, it is recommended to cut off the manometer (12, fig. 1) to avoid pressure shocks

that it might be subjected to at every burner starting.

Close protection valve when the burner is not operation and the manometer indicates 0 bar.

Thermostat probe

Resistor

Plate tubes

Plate

D2751

6192 9 GB

4.7 BURNER START-UP PROGRAMME

Motor lock-out

It is caused by the thermal motor overload relay if there is an overload or no phase.

4.8 ECOLOGICAL OIL BURNERS

WARNING

The transition from normal fuel oil to ecological fuel oil requires:

yThe tank to be emptied of normal fuel oil.

yCleaning of the tank and the pipes that carry the fuel oil to the burner.

yApplication of a filter if there is not one already on the burner fuel line with a filtering grade of 0.3 mm maxi-

mum.

If this is not done, Riello S.p.A. declines all liability if the burner fails to work properly or wears out prematurely.

NOTES

These burners are the result of careful study that allows them to be used with ecological fuels as well; oils, that

in certain temperature and speed conditions, are particularly aggressive for the vital parts of the burner.

The objective has been achieved with the reduction of the transiting speed in some of the parts and an appropri-

ate choice of materials (in particular surface treatments) as well as a redefinition of the backlashes and coupling

tolerances.

The burners for ecological oils are very different from normal fuel oil burners because they have a separate

pump (worked by its own motor at 1400 rpm) and the fact there is double filtration between pump and nozzle.

4.9 EMULSIFIED FUEL OIL OPERATION

Lock-out because of no ignitionNormal

Thermostat

Motors

Ignition transformer

1st flame valve

2nd flame valve

Lock-out indicator

2894

D3435

WARNING

In emulsified fuel oil it is necessary

to change the fitting on the burner

(*) with the one supplied with it.

This manual suits for next models

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