Riello RDB3 CF 489T50 Quick start guide

2902587 (2)

Installation, use and maintenance instructions

Kerosene and gas oil burners

One stage operation

CODE MODEL TYPE

3748950 RDB3 CF 489T50

3748850 RDB4 CF 488T50

2587

INDEX

1. BURNER DESCRIPTION

1.1 BURNER EQUIPMENT

Flange and gasket . . . . . . . . . . . . No. 1 Screw of by-pass pump . . . . . . . . . . . . . . . . . . . . No. 1

Screw and nuts for flange . . . . . . No. 1 Bolts for flange to be fixed to boiler . . . . . . . . . . . No. 4

Hexagonal key. . . . . . . . . . . . . . . No. 1 Screws and terminal screw for feeding cable . . . . No. 3

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 Working ﬁeld . . . . . . . . . . . . . . . . . . . . . 2

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

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

3.2 Mounting the burner. . . . . . . . . . . . . . . . 3

3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . 4

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . 5

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

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

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

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

4.4 Combustion head setting . . . . . . . . . . . . . 8

4.5 Air damper adjustment . . . . . . . . . . . . . . 8

4.6 Pump pressure . . . . . . . . . . . . . . . . . . . . 8

4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8

5. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9

■One stage kerosene and gas oil burner.

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

■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.

■CE Reg. N: 0036 0275/99 (489 T50) - 0036 0274/99 (488 T50), as 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– Photoresistance

7– Pump pressure adjustment screw

8– Pressure gauge port

D4069

Fig. 1

2587

2. TECHNICAL DATA

2.1 TECHNICAL DATA

◆

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

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD

(as EN 267)

TYPE 489T50 488T50

Output – Thermal power

(with air at 20°C)

3.0 – 5.8 kg/h 4.7 – 9.5 kg/h

35.6 – 68.7 kW 55.7 – 113 kW

(Hi= 11.97 kWh/kg)

Fuel Kerosene, viscosity 1.6 – 6 mm

/s at 20 °C

Gas oil, viscosity 4 – 6 mm

/s at 20 °C

◆

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

Motor Run current 1.3A – 2750 rpm – 288 rad/s

Capacitor 5

Ignition transformer Secondary 8 kV – 16 mA

Pump Kerosene, maximum pressure 10 bar (145 psi)

Gas oil, maximum pressure 15 bar (218 psi)

Absorbed electrical power 0.16 kW

BurnerFlange 167 A 253

204

D1844

83 83

268

163

45°

189

168

140

106

øB

A78 111

ø B88 105

489T50

488T50

0.4

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

Thermal power - kW

D1845

0.2

0.6

0.8

1.0

1.2

3456789

30 40 50 60 70 80 90 100 110

1.4

488T50489T50

2587

3. INSTALLATION

3.1 BOILER FIXING

➤

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

➤

Widen, if necessary, the insulating gasket holes (5), (see fig. 3).

➤

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. 4).

3.2 MOUNTINGTHE BURNER

E1661

Fig. 2

D5012

Fig. 3

E1660

Fig. 4

E1556

1) In case of CF applications, the burner shall not

operate without protection of the suction inlet. 2) In case of BF applications an optional snorkel

and gasket are available replacing (B) with (C).

This item can be supplied separetely.

The combustion air supply is through a flexible

tube connected at the socket.

E1557

2587

3.3 HYDRAULIC SYSTEMS

■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.

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

Fig.5

D5912 2

■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 again the plug (2). (See fig. 5).

■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. 6 it is sufficient to loosen the suction gauge

connection (6, fig. 5) and wait until oil flows out.

On the systems in fig. 7 and 8 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. 8) 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 previous 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

D1560

Fig. 7

D1558

max. 4 m

Fig.8

max. 4 m

min. 0.1 m

D1559

Fig.6

2587 5

3.4 ELECTRICAL WIRING

CONTROL BOX (see fig. 9)

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.

E9154

Fig. 9

Capacitor

~50Hz - 230V

Regulating

Oil valve

D4240

CONTROL BOX

Photoresistance

535SE/LD

thermostat

Limit thermostat

with manual

resetting

Motor

Remote lock-out lamp

(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

2587 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 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.

To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of the

combustion head, 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 fuel and room temperature of 20°C.

4.2 NOZZLES RECOMMENDED: Hago type ES - B ; Delavan type W - B;

Steinen type S ; Danfoss type S.

Nozzle Pump

pressure Burner

output Combustion head

adjustment Air damper

adjustment

GPH Angle bar kg/h ± 4% Set-point Set-point

489T50

GAS OIL

0.75 60° 12 3.0 0.5 1.0

0.85 60° 12 3.4 0.5 1.4

1.00 60° 12 4.0 1.5 2.0

1.10 60° 12 4.4 3.0 2.6

1.25 60° 12 5.0 4.5 3.0

1.35 60° 13 5.6 6.0 4.0

KEROSENE

1.10 60° 7 3.08 0.0 1.1

1.25 60° 8 3.74 0.0 1.4

1.35 60° 8 4.04 0.5 1.9

1.50 60° 8 4.49 1.5 2.2

1.65 60° 8 4.93 3.0 2.5

1.75 60° 8 5.23 4.5 3.1

1.75 60° 10 5.85 6.0 4.0

488T50

GAS OIL

1.10 60° 12 4.4 2.0 2.8

1.25 60° 12 5.0 2.5 3.4

1.35 60° 12 5.4 2.5 3.7

1.50 60° 12 6.0 3.0 4.3

1.65 60° 12 6.6 3.0 5.0

1.75 60° 12 7.0 3.5 5.5

2.00 60° 12 8.0 4.0 7.5

2.25 60° 12 9.0 5.0 8.3

KEROSENE

1.65 60° 7 4.65 2.0 2.8

1.75 60° 8 5.23 2.5 3.1

2.00 60° 8 5.98 2.5 3.9

2.25 60° 8 6.73 3.0 5.1

2.50 60° 8 7.48 3.5 5.9

2.75 60° 8 8.22 4.0 7.4

3.00 60° 9 9.51 5.0 8.5

2587 7

MAINTENANCE POSITION

ACCESS TO THE COMBUSTION HEAD, ELECTRODES AND NOZZLE (see ﬁg. 10).

➤Remove the burner out of the boiler, after loosing the fixing nut to the flange.

➤Hook the burner to the flange (1), by removing the blast tube (2) after loosing the fixing screws (3).

➤Remove the electrodes assembly (5) from the nozzle holder (4) after loosing its fixing screw (A, fig. 11).

➤Screw the nozzle (6).

4.3 ELECTRODES SETTING

E1662 E1663

Fig. 10

Before removing or assembling the

nozzle, loosen the screw (A, ﬁg. 11)

and move the electrodes ahead.

TYPE

489T50 2 – 2.5 mm

488T50 4 ±0.5 mm

ATTENTION

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 AD

Fig. 11

2587 8

4.4 COMBUSTION HEAD SETTING

This is done when ﬁtting the nozzle, with the blast tube removed.It depends on the output of the burner and

is carried out by rotating the regulating rod, till the terminal plane of the blast tube is level with the set-point,

as indicated in the schedule.

4.5 AIR DAMPER ADJUSTMENT

The settings indicated in the schedule refer to the combustion-chamber with “zero” depression.

These regulations are purely indicative. Each installation however, has its own unpredictable working con-

ditions: 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 PUMP PRESSURE:

The pump leaves the factory set for kerosene working.

10 bar: maximum pressure for kerosene.

FOR GAS OIL INCREASE PRESSURE

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

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

4.7 BURNER START-UP CYCLE

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

Combustion head settings indicated in the

schedule are valid for most cases.

The setting of the fan output according to the

installation should normally be done only

through the air damper.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5398

135

In the sketch on the

left, the combustion

head is set for an

output of 1.10 GPH

at 12 bar (

for gas oil

)

or 1.65 GPH at 8 bar

(

for kerosene

489T50

The shutter is level with set-point 3, as required

by the schedule at page 6.

In the sketch on the

left, the combustion

head is set for an

output of 1.50 GPH

at 12 bar (

for gas oil

)

or 2.25 GPH at 8 bar

(

for kerosene

488T50

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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