Riello RG5D Quick start guide

2902312 (5)

Manuel d’entretien

Installation, use and maintenance instructions

Installatie-, gebruiks- en onderhoudsvoorschriften

Montage und Bedienungsanleitung

Οδηγίες εγκατάστασης, χρήσης και συντήρησης

Instrucciones de instalación, uso y mantenimiento

Öl-Gebläsebrenner

Brûleur fioul domestique

Light oil burner

Stookoliebrander

Quemadores de gasóleo

Καυστήρας Πετρελαίου

CODE - CÓDIGO

ΚΩ ΙΚΟΣ

MODELL - MODELE

MODEL - MODELO - ΜΟΝΤΕΛΟ

TYP - TYPE

TIPO - ΤΥΠΟΣ

3739850 RG5D 398T1

Zweistufiger Betrieb

Fonctionnement à 2 allures

Two stage operation

Tweetrapsbranders

Funcionamiento de dos llamas

ιβάθµια λειτουργία

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2312 1GB

INDEX

1. BURNER DESCRIPTION

Two 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 4 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 Working field . . . . . . . . . . . . . . . . . . . . . 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 Combustion head setting. . . . . . . . . . . . . 7

4.4 Electrodes adjustment. . . . . . . . . . . . . . . 7

4.5 Pump pressure and air output . . . . . . . . . 7

4.6 Burner start-up cycle . . . . . . . . . . . . . . . . 8

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

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

1– Pump

2– Electronic start delaying

device

3– Control-box

4– Reset button with lock-out

lamp

5– Flange with insulating

gasket

6– 2nd stage air damper

adjustment assembly

7– Nozzles holder assembly

8– Photoresistance

9– Hydraulic jack

10 – 4 pole socket

11 – 2nd stage valve

12 – 1st stage valve

13 – Valve casing assembly

■CE Certification No.: 0036 0325/01 as 92/42/EEC.

■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.

Fig. 1

S7111

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2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD (as EN 267)

TYPE 398T1

Output - Thermal power 8 / 12 – 25 kg/h – 95 / 142 – 296 kW

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

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

Motor Run current 2.1 A - 2730 rpm - 286 rad/s

Capacitor 8 µF

Ignition transformer Secondary 8 kV - 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.47 kW

247 159 300 213

160

190

12,5

285

345

127

45°

D5390

ø125

8 10 12 14 Fuel output – kg/h

100 Thermal power – kW

2.4

2.0

1.2

0.4

Pressure in combustion

chamber – mbar

D5391 16 18

120

3.2

140 160 180 220 240200

0.8

1.6

2.8

22 24 26

260 280 300

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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 (4), (see fig. 4).

➤Fix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the

insulating gasket (4), (see fig. 2).

➤After installation ensure that burner is lightly inclined as in fig. 5.

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 cable clamp (2) should be reversed, (see fig. 6).

Fig. 5

D5012

Fig. 4

D5025

Fig. 2

Fig. 3

S7112

D5392

Fig. 6

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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. 7 it is

sufficient to loosen the suction gauge

connection (6, fig. 8) and wait until oil flows out.

On the systems in fig. 9 and 10 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. 10) 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.

D5395

Fig. 7

max. 4 m

5 -2

nd stage pressure adjuster

6 - Suction gauge connection

7 -1

st stage valve

8 - Valve casing assembly

9 -2

nd stage valve

10 - Auxiliary pressure test point

SYSTEM NOT PERMITTED

IN GERMANY

■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),

remove the by-pass screw (3) and then screw

again the plug (2), (see fig. 8).

■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:

1 - Suction line

2 - Return line

3 - By-pass screw

4 - Gauge connection

meters

L meters

øi

8 mm

øi

10 mm

0.5

1.5

3.5

100

D5405

Fig. 8

max. 4 m

D5393

Fig. 9 Fig. 10

meters

L meters

øi

8 mm

øi

10 mm

0.5

1.5

100

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3.4 ELECTRICAL WIRING

DO NOT EXCHANGE

NEUTRAL WITH PHASE

WARNING

CONTROL BOX

To remove the control-box from the burner, loosen screw (A, fig. 11) 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.

7 pin plug

7 pole socket

L1 B4S3

Black

White

Blue

Capacitor

Burner-earth

Main switch

T6A

Neutral

CONTROL BOX

552SE

~50Hz 230V

123

Photoresistance

Blue

Ignition

electrodes

Brown

2nd stage oil valve

T6B5 4 pin plug

4 pole socket

Blue

Black

White

Blue

Brown

21 321

ELECTRONIC

DELAYING DEVICE

●2nd stage

Motor

thermostat

12123

CARRIED-OUT IN THE FACTORY

1st stage oil valve

D5336

Limit thermostat Remote lock-out signal

(230V - 0.5A max.)

Safety thermostat

1st stage

hour counter

(230V - 0.1A max.)

2nd stage hour counter

(230V - 0.1A max.)

Brown

Blue

S7120

Fig. 11

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.

●Connect 2nd stage thermostat between clamps T6 - T8

by removing the bridge.

TESTING: Check the shut-down of the burner by opening

the thermostats and the lock-out by darkening

the photoresistance.

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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

Steinen type Q

Danfoss type S

N.B.: If necessary the 1st stage nozzle can

have an output exceeding 50% of the

total output.

TO FIT NOZZLES CARRY OUT THE FOL-

LOWING ACTIONS: (see fig. 12)

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

ing screws (2) and nuts (3), remove the small

cables (4) from the control box and the pho-

toresistance (5).

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

trodes, remove the diffuser disc assembly (8)

from the nozzle-holder assembly (1) after loos-

ing screws (9).

➤Screw the nozzles (10) correctly and tighten

it as shown in figure.

ATTENTION

During the reassembly of the nozzle-holder assem-

bly screw the nuts (3) as shown in the figure below.

Nozzles Pump

pressure

Burner

output

Combustion

head

adjustment

Air damper

adjustment

GPH Angle kg/h ± 4% 1st stage 2nd stage

1st stage 2nd stage bar 1st stage 2nd stage Set-point Set-point Set-point

2.00 1.00 60° 12 8.0 12.4 0 0.25 2.1

2.00 2.00 60° 12 8.0 16.4 3 0.15 3.0

2.50 2.50 60° 12 10.3 20.5 6 0.3 4.4

3.00 3.00 60° 12.5 12.6 25,0 8 0,6 6,0

02468

S7118

Fig. 12

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

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4.3 COMBUSTION HEAD SETTING (see fig. 12, page 6)

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

screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the nozzles-

holder assembly (1).

➤In the sketch the combustion head is set for an output of 2.00 + 2.00 GPH at 12 bar.

The set-point 3of the regulating rod is at the same level with the outside plane of the nozzles-holder as-

sembly as shown in the schedule.

4.4 ELECTRODES ADJUSTMENT

1 1

MEASURES MUST BE RESPECTED.

For prospective adjustments loosen

screws (1) and move the electrodes as-

sembly (2), (see fig. 13).

WARNING

To have access to the electrodes carry

out operation as described in chapter

“4.2 RECOMMENDED NOZZLES”

(page 6).

Fig. 13

4.5

–0.5mm

D5406

4.5 PUMP PRESSURE AND AIR OUTPUT

■1st STAGE ADJUSTMENT

ADJUSTMENT OF AIR SHUTTER

Unloosen the nut (1), turn the screw (2) until the indicator (3)

reaches the position desired. Then lock the nut (1), (see fig. 14).

■2nd STAGE ADJUSTMENT

ADJUSTMENT OF AIR SHUTTER

Unloosen the nut (4), turn the screw

(5) until the indicator (6) reaches the

position desired.

Then lock the nut (4), (see fig. 14).

PRESSURE REGULATION

This is set at 12 bar at the factory.

Should it be necessary to re-set or al-

ter such pressure, this can be done,

by adjusting screw (8).

The pressure gauge must be mount-

ed in place of cap (7), (see fig. 15).

When burner shuts down the air

damper automatically closes till a

max. chimney depressure of

0.5 mbar.

Fig. 15

D5407

Fig. 14

S7119

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2312 8GB

4.6 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (4, 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

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 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, (8, fig. 1, page 1).

➤Check for correct fuel consumption.

➤Replace the nozzles (see fig. 12, page 6) and check the correct position of electrodes (fig. 13, 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 check the right settings at 1st and 2nd

stage of all components stated in this manual. Then carry out a combustion check verifying:

●Smoke temperature at the chimney; ●Content of CO2(%); ●Content of CO (ppm);

●Smoke value according to opacity smokes index according to Bacharach scale.

D6040

Lock-out due to failure to light

Normal

3 –28s ~12s 5s

1st stage thermostat

2nd stage thermostat

Motor

Ignition transformer

1st stage valve

1st stage flame

2nd stage valve

2nd stage flame

Lock-out lamp

~12s

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2312 9GB

6. FAULTS / SOLUTIONS

Here below you can find some causes and the possible solutions for problems that could cause a failure to

start or a bad working of the burner.

A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box

(4, fig. 1, page 1).

When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the

burner functions correctly, the lock-out can be attributed to a temporary fault.

If however the lock out continues the cause must be determined and the solution found.

WARNING

The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error

in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the

technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.

FAULTS POSSIBLE CAUSES SOLUTION

The burner doesn’t

start when the limit

thermostat closes

Lack of electrical supply.

Check presence of voltage in the

L1 - N clamps of the 7 pin plug.

Check the conditions of the fuses.

Check that safety thermostat is not

lock out

The photoresistance sees false light. Eliminate the light.

Thermostats are faulty. Replace them.

The connections in the control box

are wrongly inserted.

Check and connect completely all the

plugs.

Burner runs normal-

ly in the prepurge

and ignition cycle

and locks out after 5

seconds ca.

The photoresistance is dirty. Clear it.

The photoresistance is defective Change it.

Flame moves away or fails.

Check pressure and output of the fuel.

Check air output.

Change nozzle.

Check the coil of solenoid valve

1st stage.

Burner starts with an

ignition delay.

The ignition electrodes are wrongly

positioned.

Adjust them according to the

instructions of this manual.

Air output is too high. Set the air output according to the

instructions of this manual.

Nozzle dirty or worn. Replace it.

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