Riello RDB3 Manual

38/52 kW

56/70 kW

Please read these instructions carefully

before commissioning and using this appliance.

To be retained by the householder

Burner Setup Details

Riello RDB3

HEALTH AND SAFETY

INFORMATION FOR THE USER, INSTALLER AND SERVICE ENGINEER

Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a

requirement to provide information on substances hazardous to health (COSHH Regulations

1998).

TR Engineering takes every reasonable care to ensure that its products are designed and

constructed to meet these safety requirements when the products are properly installed and

used. To fulfil the requirements, products are comprehensively tested and examined before

despatch.

When working on the appliance, it is the responsibility of the user or engineer to ensure that

personal protective clothing or equipment—appropriate to parts that could be considered

hazardous or harmful—is worn.

This appliance may contain some of the items below:

Insulation and Seals

Glass rope, mineral wool, insulation pads, ceramic fibre, glass insulation.

When handling, avoid inhalation and contact with eyes. These may be harmful and cause

irritation to the skin, eyes, nose or throat. Use disposable gloves, facemasks and eye protection.

After handling, wash hands and other exposed areas. When disposing of materials, limit dust and

the risk of inhalation by using a water spray. Ensure materials are securely wrapped.

Seek urgent medical attention if inhaled or ingested. Exposure to eyes and skin should be

followed by immediate cleansing of the affected areas and medical attention if necessary.

Glues, Sealants and Paints

The glues, sealants and paints used present no known hazards when the appliance is used in the

manner for which it is intended.

Mineral Oils

The appliance is designed to run on 28 sec. kerosene class C2. The effects of mineral oils on the

skin will vary depending on the length of exposure.

Avoid any skin contact with oil or clothing contaminated with oil. Kerosene will remove the

protective grease normally present on the surface of the skin, rendering it dry, liable to cracking

and more prone to damage caused by cuts and abrasions. Seek immediate medical attention for

any rash, wart or sore that develops on any part of the body.

Barrier cream that contains lanolin, such as Rosalex Antisolv is recommended together with a

strict regime of personal cleaning.

Do not breathe oil vapours. Do not fire the burner in the open (i.e. out of the boiler), as a misfire

will produce unburned oil vapours. Under no circumstances should mineral oils be taken

internally.

CONTENTS

Page no.

Technical specifications

Burner set-up

Combustion air / adjustment

Oil pump

Nozzle replacement

Electrode positions

Burner removal

Control box wiring / removal

Fault-finding

10–11

Spares

12–13

Model

Riello RDB3

Ignition

8 kV / 16 mA

Electrical supply

230/280 V –50 Hz fused at 5A

Control box

RBL 535 SE/LD analogue

Motor

RBL 150W

Pump

RBL

Rpm

2,750

Fuel

Kerosene C2

Capacitor

5 uF

Power

0.16 kW

Output

Input

Nozzle

Oil pressure

Air damper

CO2

38.1 kW

130,000 Btu/h

39.8 kW

135,797 Btu/h

1.25 x 60º S

100 psi

6.9 bar

2.0

11.0%

45.4 kW

155,000 Btu/h

47.4 kW

161,729 Btu/h

1.35 x 60º S

110 psi

7.6 bar

4.0

11.5%

52.7 kW

180,000 Btu/h

54.4 kW

185,619 Btu/h

1.65 x 60º S

105 psi

7.2 bar

5.5

11.5%

55.5 kW

190,000 Btu/h

**.* kW

***,*** Btu/h

**.* x **º *

*** psi

*.* bar

*.*

**.*%

63.0 kW

215,000 Btu/h

**.* kW

***,*** Btu/h

**.* x **º *

*** psi

*.* bar

*.*

**.*%

70.3 kW

240,000 Btu/h

**.* kW

***,*** Btu/h

**.* x **º *

*** psi

*.* bar

*.*

**.*%

Note 1 The air damper settings are for guidance only; individual site conditions may compel deviation from the

recommended positions. See fig 3 for air damper adjustment instructions.

Note 2 The CO2ratio is correct for a combustion air temperature of 20°C; see fig 2 for other temperatures.

Note 3 The *indicates factory settings. To attain different outputs, changes to the nozzle specification pump

pressure and air setting may be required. The boiler should be set to match the heat requirements of the

system. Incorrect matching may impede the boiler's correct operation and invalidate its warranty.

BURNER SETUP

TECHNICAL SPECIFICATIONS

Fig 1

To set the primary air damper (A), remove the secondary air damper (B) by loosening the screws (1).

Loosen the primary air wheel screw (2) and rotate the primary damper to the required position. Retighten the

screw and replace the secondary damper.

To set the secondary air damper (B), turn the adjustment screw (3) either clockwise (+) or anti-clockwise (–)

using the Allen key provided. The air setting will be indicated in the display window.

COMBUSTION AIR

AIR DAMPER ADJUSTMENT

To conform to Efficiency Directive

92/42/EEC, the concentrations of

CO and CO2in the flue gases must

be verified. As combustion air can

be taken from the room in which the

boiler is situated or from outside,

there may be variations in the ratio

depending on the combustion air

temperature. Use the graph

adjacent to set the correct level.

Example: a 29/36 kW boiler taking

in combustion air at 20°C will

require a CO2ratio of 12%

Fig 2

Fig 3

OIL PUMP

If the burner goes to a lockout state due to a lack of oil pressure, the pump may require priming. Remove

the pressure gauge bleed port plug until oil is seen to be present and replace the plug.

Single-pipe systems

Where the lowermost part of the tank is above the level of the oil pump, a single-pipe gravity system can

be used. The supply pipe should be connected to the suction port on the burner pump via the flexible hose

(supplied). The pump is pre-set to run on single-pipe oil supplies the bypass screw (3) must not be present

in the return line (see fig 4).

Two-pipe systems

Where the lowermost part of the tank is below the level of the burner, a two-pipe suction lift is necessary. A

second flexible hose will be required, and the oil pump must first be converted for use. Remove the return

line plug (2), insert the bypass screw (3) and connect a second flexible oil line (not supplied).

Single pipe oil supplies with a de-aerator

Where a two-pipe suction lift is required, but it is not feasible to fit a return pipe, an oil de-aerator can be

used. The burner should be piped and the pump converted as for a two-pipe system, up to the de-aerator,

at which point a single pipe can be taken to the storage tank. The de-aerator should be fitted as close to

the boiler as possible though externally to the premises at a height no lower than the oil pump.

Fig 4

1 –Suction line

2 –Return line

3 –Bypass screw

4 –Pressure gauge connection /

air bleed point

5 –Pressure adjustment

6 –Suction gauge connection

7 –Solenoid valve

8 –Auxiliary pressure test point

1. Switch off the electrical supply to the burner

and isolate the oil supply.

2. Remove the burner plug from the boiler

control box.

3. Remove the burner from the boiler (fig 8).

4. Remove the blast tube (fig 5), exposing the

nozzle holder assembly.

5. Taking care not to damage the electrodes,

remove the nozzle with an appropriate

socket or box spanner (fig 6)

6. Fit a new nozzle of the same specification.

7. Replace the flame ring in the same position,

check the electrode positions (fig 7) and

tighten.

8. Refit the blast tube.

Fig 5

Fig 6

NOZZLE REPLACEMENT

1 –Blast tube retaining screws (x2)

2 –Oil pump

3 –Control box

4 –Reset button / light

5 –Mounting flange / gasket

6 –Air damper fine tuning

7 –Pump pressure adjustment

8 –Pressure gauge connection

9 –Photocell

Fig 8

ELECTRODE POSITIONS

BURNER REMOVAL

Fixed Head

Important:

Before removing or assembling

the nozzle, loosen the screw (B)

and move the electrodes ahead.

Fig 7

To remove the burner (2), unscrew the nut that holds it to the mounting flange (1) and pull

away, leaving the mounting flange and gasket (5) attached to the boiler (4). To remove /

replace the flange and gasket, undo the retaining nuts (3).

CONTROL BOX WIRING

Fig 9 RBL 535 SE/LD Analogue

CONTROL BOX REMOVAL

HS –Mains switch

ST –Limit thermostat

RT –Control thermostat

Fig 10

To remove the control box:

1 –Loosen the screw (1) and open lid (2).

2 –Remove all components.

3 –Remove the solenoid valve (3).

4 –Loosen the two retaining screws (4).

5 –Disconnect the ignition leads and

remove the control box.

Note: before making any electrical checks or modifications, ensure the mains supply to the boiler is switched off.

Fault

Possible cause

Action

Burner will not start

Control box locked out

Press red reset button on burner

High limit thermostat tripped

Press red reset button on rear of control panel;

check function of boiler thermostat

System controls satisfied

Ensure that all controls are calling for heat

Blown fuse

Fit new fuse (5A); if problem persists, look for short

circuits in the wiring

Motor or pump seized

Check for rotation; replace as necessary

Burner starts but flame will not

establish

No oil supply

Check oil levels in storage tank; check for

adequate flow through the oil supply pipes

Air trapped in pump or oil line

Bleed excess air from the pump via the pressure

gauge connection

Solenoid coil not opening

Check coil for continuity; replace as necessary

Blocked nozzle

Replace the nozzle

Electrodes incorrectly set

Reset gap and position to dimensions given

Electrode insulation cracked

Replace as necessary

Faulty ignition leads

Replace as necessary

Low oil pressure

Check pump pressure and adjust to level given

Flame establishes but cuts out after

a few seconds

Oil contaminated with water

Run oil from drain cock at tank until free of water

Oil filter partially blocked

Wash filter clean with kerosene

Faulty photocell or photocell not seeing

flame

Clean photocell; check for damage; ensure it is

fully inserted; replace as necessary

Low oil pressure

Check pump pressure and adjust

Morning start lock-out

Faulty non-return valve or air leak

Replace non-return valve; repair leak

Low voltage to the boiler

Check with electricity supplier to remedy

Incorrect combustion settings

Check combustion under normal running

conditions; set air intake and oil pressure

Oil in storage tank below level of burner

Raise tank or fit two-pipe oil supply

Delayed ignition (burner pulsates)

Nozzle partially blocked

Replace nozzle

Low oil pressure

Check pump pressure and adjust

Flue blocked or damaged

Check flue; replace/repair as necessary

Fan slipping on shaft

Check fan; replace/repair as necessary

Pump coupling loose or worn

Check coupling; replace/repair as necessary

Burner starts violently

Electrodes incorrectly set

Reset electrode gap and position to dimensions

given in burner details leaflet

Electrodes damaged

Replace as necessary

Faulty ignition leads

Replace as necessary

Burner repeatedly attempts to fire

(balanced-flue only)

Exhaust gas in combustion air

Repair/replace leaking flue sections as necessary;

check for obstructions close to the terminal

Combustion fumes smell

Combustion chamber access cover not

secure

Tighten nuts; replace seal as necessary

Burner incorrectly fitted or gasket

damaged

Tighten burner to boiler; replace seal as necessary

Flue incorrectly fitted or gasket damaged

Tighten mounting nuts; replace seal as necessary

BURNER FAULT-FINDING

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