Riello RG2 Quick start guide

2902613 (4) - 05/2010

Installation, use and maintenance instructions

Montage- og driftsinstruktion

Instruktioner för installation, användning och underhåll

Anvisninger for installasjon, bruk og vedlikehold

Light oil burner

Oliebrænder

Oljebrännare

Oljebrenner

One stage operation

Et-trins funktion

Enstegsfunktion

Ett-trinns brenner

CODE - KODE

KOD MODELL - MODEL TYPE - TYP

3737720 RG2 377T1

2613 GB

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Light oil burner

Model: RG2

These products are in compliance with the following Technical Standards:

EN 267

EN 292

and according to the European Directives:

BED 92/42/EEC Efficiency Directive

MD 2006/42/EC Machine Directive

LVD 73/23/EEC - 2006/95/EC Low Voltage Directive

EMC 89/336/EEC - 2004/108/EC Electromagnetic Compatibility

The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO

9001.

Legnago, 31.03.2010 Mr. G. Conticini

Burners Division Department

RIELLO S.p.A.

2613 1GB

INDEX

1. BURNER DESCRIPTION

One stage light oil burner.

1.1 BURNER EQUIPMENT

Flange with insulating gasket. . . . . . . No. 1 Screw and nuts for flange to be fixed to boiler . . . . . .No. 4

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

7 pin plug . . . . . . . . . . . . . . . . . . . . . . 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 rate . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

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

4.2 Recommended nozzles. . . . . . . . . . . . . . 6

4.3 Electrodes adjustment. . . . . . . . . . . . . . . 7

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

4.5 Combustion head setting. . . . . . . . . . . . . 8

4.6 Air damper adjustment . . . . . . . . . . . . . . 8

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

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

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

1– Oil pump

2– Control-box

3– Reset button with lock-out

lamp

4– Flange with insulating

gasket

5– Air damper adjustment assembly

6– Nozzle holder assembly

7– Photoresistance

CE Certification No.: 0036 0344/03 as 92/42/EEC.

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.

The burner meets protection level of IP X0D (IP 40), EN 60529.

Fig. 1

S7208

2613 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 FIRING RATE, (as EN 267)

TYPE 377T1

Output - Thermal power 4 –10 kg/h - 47 –119 kW

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

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

Motor Run current 0.9A – 2720 rpm – 285 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.18 kW

202 115 189

140

168

230

280

8383

106

45°

D5707

255

ø95

03 4 5 Light oil output – kg/h

35 45 55 Thermal power – kW

1.0

0.8

0.6

0.4

0.2

Pressure in combustion

chamber – mbar

D5416

65 75

891011

1.2

95 105 115 125

2613 3GB

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. 3).

Widen, if necessary, the insulating gasket holes (5).

Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3) interposing the insu-

lating gasket (5), (see fig. 2).

3.2 FUEL SUPPLY

The burner is designed to allow entry of the oil supply pipes on either side.

Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate (1)

and closing plate (2) should be reversed, (see fig. 4).

Fig. 2

Fig. 3 S7209

D5709

Fig. 4

2 21

2613 4GB

3.3 HYDRAULIC SYSTEMS

It is necessary to install a filter on the fuel supply line.

H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.

PRIMING PUMP:

On the system in fig. 6 it is sufficient to loosen the suction gauge

connection (5, 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 seconds

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 re-

quired. 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

3.5

100

Fig. 6

max. 4 m

D5713

max. 4 m

D5714

Fig. 7 Fig. 8

SYSTEM

NOT

PERMITTED

IN GERMANY

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

100

OThe 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), remove the

by-pass screw (3) and then screw again the plug (2).

(See fig. 5).

OBefore 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:

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 gauge

Fig. 5

234567

D5026

2613 5GB

3.4 ELECTRICAL WIRING

D4034

ESEGUITO IN FABBRICA

WARNING

CONTROL BOX

To remove the control-box from the burner, loosen screw (A, fig. 9)

and pull to the arrow direction, after removing all components, the

7 pin plug and earth wire.

In case of disassembly of the control box, retighten the screw

(A) with a torque wrench setting of 1 – 1.2 Nm.

DO NOT EXCHANGE NEUTRAL WITH PHASE

7 pin plug

7 pole socket

Black

White

Capacitor

Main switch

T6A

Motor

Safety

thermostat

Blue

Oil valve

Hour counter

(230V - 0.

max.)

Limit

thermostat Remote lock-out signal

(230V - 0.5A max.)

Ignition

electrodes

Brown

Burner-earth

CARRIED-OUT IN THE FACTORY

553SE/H

CONTROL BOX

Photoresistance

PE L N

50Hz 230V

Blue

Brown

Blue

TESTING

Check the shut-down of the

burner by opening the thermo-

stats and the lock-out by dark-

ening the photoresistance.

NOTES:

– Wires of min. 1 mm2section. (Unless requested

otherwise by local standards and legislation).

– The electrical wiring carried out by the installer

must be in compliance with the rules in force in

the Country.

S7217

Fig. 9

2613 6GB

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 CO2

concentration 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 light oil and room temperature of 20 °C

4.2 RECOMMENDED NOZZLES: Delavan type W - B ; Danfoss type S - B

Monarch type R ; Steinen type S - Q.

For 1.75 - 2.00 - 2.25 GPH nozzles it is advisable to use

full cones.

MAINTENANCE POSITION

THE ACCESSIBILITY TO THE NOZZLE, THE

DIFFUSER DISC AND THE ELECTRODES IS

MADE EASY IN 2 WAYS:

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 small cables (4) from the electrodes

and the diffuser disc-holder assembly (5) from

the nozzle-holder assembly after loosing its fix-

ing screw (3, fig. 12, page 7).

Screw the nozzle (6) correctly and tighten it as

shown in the figure.

Nozzle Pump

pressure Burner

output Combustion head

adjustment Air damper

adjustment

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

1.00 60° 12 4.0 0 0.9

1.10 60° 12 4.4 1 3.1

1.25 60° 12 5.0 2 3.4

1.50 60° 12 6.0 3 3.8

1.75 60° 12 7.0 4 4.5

2.00 60° 12 8.0 5 4.9

2.25 60° 14 9.8 6 6.0

AFig. 10

S7480

2613 7GB

Fig. 11

Remove nozzle-holder assembly (1) after loos-

ing screws (2) and nut (3), remove the small ca-

bles (4) from the control box and the

photoresistance (6).

Withdraw the small cables (4) from the elec-

trodes, remove the diffuser disc-holder assem-

bly (10) from the nozzle-holder assembly (1)

after loosing screw (3, fig. 12).

Screw the nozzle (11) correctly and tighten it

as shown in figure.

ATTENTION

During the reassembly of the nozzle-holder as-

sembly screw the nut (3) as shown in the figure

below.

4.3 ELECTRODES ADJUSTMENTS (see fig. 12)

4.4 PUMP PRESSURE

The pump leaves the factory set at 12 bar.

To change it act on pump pressure adjust screw (4, fig. 5, page 4).

S7210

BFig. 11

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

WARNING

Lean the diffuser disc-holder

assembly (1) on the nozzle-holder

(2) and lock it by screw (3). For

prospective adjustments loosen

screw (4) and move the elec-

trodes assembly (5).

ATTENTION

To have access to the electrodes carry

out operation as described in

chapter

4.2

RECOMMENDED NOZZLES”

(page 6)

Fig. 12

4 – 5

4.5

– 0.5 mm

MEASURES MUST BE

D5537

RESPECTED

2613 8GB

4.5 COMBUSTION HEAD SETTING (see fig. 11, page 7)

It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting

screw (5) until the set-point marked on the regulating rod (9) is level with the outside plane of the nozzle-holder

assembly (1).

In the sketch the combustion head is set for an output of 1.50 GPH at 12 bar.

The set-point 3of the regulating rod (9) is at the same level with the outside plane of the nozzle-holder as-

sembly (1) as shown in the schedule.

4.6AIR DAMPER ADJUSTMENT (see fig. 11, page 7)

To vary the setting adjust the screw (7) after loosing the nut (8).

When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.

4.7 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 conse-

quent 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 CHECKS 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, (7, fig. 1, page 1).

Check for correct fuel consumption.

Replace the nozzle (see fig. 10, page 6) and check the correct position of electrodes (fig. 12, 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.

Lock-out due to failure to light

Normal

D5029

~12s

Thermostat

Motor

Ignition transformer

Oil valve

Flame

Lock-out lamp ~12s 5s

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