Riello RDB2.2 GKD, Installation, Use And Maintenance Instructions

Page 1: ...Installation use and maintenance instructions 20063165 3 05 2016 Light oil burner Two stage operation CODE MODEL 20063119 RDB2 2 GKD ...

Page 2: ...Original instructions ...

Page 3: ...p 11 5 7 2 One pipe system 12 5 8 Two pipe system 13 5 9 Pump pressure 13 5 10 Electrical wiring 14 5 10 1 Control box 14 6 Start up calibration and operation of the burner 16 6 1 Notes on safety for the first start up 16 6 2 Combustion adjustment 16 6 3 Combustion check 16 6 4 Accessing the nozzle diffuser disc and electrodes 17 6 5 Electrodes setting 17 6 6 Positionning the optical fibre 18 6 7 ...

Page 4: ...matic pre heating disabling 23 6 16 Programming menu 24 6 16 1 Sequence for enable disable Shutdown test 24 6 16 2 Sequence for enable disable Light diagnosis 24 6 16 3 Sequence for enable disable Intermittent operation 25 6 16 4 Sequence for enable disable Post purging 25 6 16 5 Sequence for enable disable second stage delay 25 6 17 Lockout types 26 7 Maintenance 27 7 1 Notes on safety for the ma...

Page 5: ...ing Technical Standards EN 267 EN 12100 and according to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 UE Low Voltage Directive EMC 2014 30 UE Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Legnago 01 12 2015 Executive General Manager RIELLO S p A Burner Department Research Development Di...

Page 6: ...h risks CAUTION This symbol indicates operations which if not car ried out correctly may cause damage to the ma chine and or injury to people DANGER DANGER LIVE COMPONENTS This symbol indicates operations which if not car ried out correctly lead to electric shocks with le thal consequences DANGER FLAMMABLE MATERIAL This symbol indicates the presence of flammable materials DANGER BURNING This symbo...

Page 7: ...of damage to things or injury to people if such damage injury was due to any of the following causes incorrect installation start up use and maintenance of the burner improper incorrect or unreasonable use of the burner intervention of unqualified personnel carrying out of unauthorised modifications on the equipment use of the burner with safety devices that are faulty incor rectly applied and or ...

Page 8: ...nce Only those parts envisaged by the manufacturer can be replaced 3 2 Personnel training The user is the person body or company that has acquired the machine and intends to use it for the specific purpose He is re sponsible for the machine and for the training of the people work ing around it The user undertakes to entrust the machine exclusively to suitably trained and qualified personnel undert...

Page 9: ... 26 kW Fuel Light oil viscosity 1 6 6 mm2 s at 20 C Hi 11 97 kWh kg Electrical supply Single phase 50Hz 5 230 V 10 Max power supply 1 A Short circuit current 4 A Motor Intensity 0 75 A Output 90 W Velocity 2800 tr min 294 rad s Capacitor 4 5 µF Ignition transformer Secondary 18 kV 25 mA Pump pressure 8 20 bar Absorbed electrical power 0 18 kW Protection level IP 40 Conditions of reference Ambient ...

Page 10: ...justment screw 10 Combustion head 11 Electrical motor 12 1st stage air damper adjustment screw 13 2nd stage air damper adjustment screw 14 Electrical motor start up capacitor 15 Head air pressure test point 16 Light oil suction line 17 Light oil return live vat 18 Air intake BF 19 One stage pump pressure adjustment screw 20 Two stage pump pressure adjustment screw 21 Flange gasket 4 5 Burner equip...

Page 11: ...ent it is highly recommended to carry out cleaning and maintenance more frequently WARNING The handling operations for the burner can be highly dangerous if not carried out with the great est attention keep any unauthorised people at a distance check the integrity and suitableness of the available means of handling Check also that the area in which you are working is empty and that there is an ade...

Page 12: ...e insulat ing gasket 5 WARNING The burner is designed to operate only in the positions 1 and 3 Fig 4 Installation 1 is preferable as it is the only one that allows performing maintenance operations as described in this manual Installations 2 3 and 4 allow working opera tions but not maintenance with hooking to the boiler DANGER Any other position could compromise the correct operation of the appli...

Page 13: ...king attrition sparks and heat Make sure that the fuel interception tap is closed before performing any operation on the burner WARNING The fuel supply line must be installed by qualified personnel in compliance with current standards and laws WARNING Before activating the burner ensure that the re turn line in the vat is not clogged The presence of any obstacle would cause the rupture of the seal...

Page 14: ...ation Tab B Tab C H difference of level L max lenght of the suction line I D interminal diameter of the oil pipes NOTE The Tab B and Tab C show the maximum approximate lengths for the supply line depending on the difference in level length and the diameter of the fuel conduit CAUTION You are advised to use additional filters on the fuel supply line Riello recommends a good quality fuel filter at t...

Page 15: ...ax lenght of the suction line I D interminal diameter of the oil pipes NOTE The Tab D shows the maximum approximate lengths for the sup ply line depending on the difference in level length and the di ameter of the fuel conduit 5 9 Pump pressure The pump is factory set to the values indicated in Tab E on page 16 CAUTION You are advised to use additional filters on the fuel supply line Riello recomm...

Page 16: ... identification label and in this man ual The burners have been set for intermittent operation This means they should compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally the boiler s thermostat pressure switch ensures the stopping of the burner The electrical safety of the device is obtained only when it is correc...

Page 17: ...te reset TR Regulation on demand TS Safety thermostat V1 One stage oil valve V2 Two stage oil valve F Flame detector Fig 14 50Hz 230V CONTROL BOX Fuse Main switch N L PE BURNER MO535 BRSPHF BOILER 20067494 DANGER Do not swap neutral and phase over fol low the diagram shown carefully and carry out a good earth connection The section of the conductors must be at least 1mm2 unless requested otherwise...

Page 18: ...om outside there fore there may be sensitive temperature varia tions which can affect the CO2 percentage value It is recommended to adjust the CO2 based on the graph indicated For example external air temperature equal to 20 C set the CO2 at 12 0 2 External air temperature C CO 2 D7052 Fig 15 Nozzle Pump pressure Burner output Combustion head adjustment One stage air damper adjustment 12 Fig 2 on ...

Page 19: ...ing screw to extract the optical fibre 4 from the diffuser disc holder assembly 6 Remove the wires 5 from the electrodes Replace and correctly screw in the nozzle 8 tightening it as shown in Fig 16 Refit following the procedure in the reverse order to the one described above 6 5 Electrodes setting To access the electrodes perform the operation described in par agraph Accessing the nozzle diffuser ...

Page 20: ...arefully tighten the screw 4 to lock the optical fibre 1 6 7 Combustion head adjustment The combustion head is factory set Check that these settings are consistent with the value indicated in Tab E on page 16 The adjustments according to the power required Fig 18 can be adjusted by turning the adjustment screw 9 Fig 2 on page 8 Distance between two notches 3 mm One full turn 1 mm Fig 17 D4222 4 5 ...

Page 21: ... turning the adjustment screw 1 Set at the required position and then fix the nut 2 by using a 8 spanner Second stage air damper adjustment This damper 4 is used to precisely adjust the flow of 2nd stage air input The device can be adjusted by operating on screw 5 Fig 20 6 9 Fuel heating To ensure proper start up and operation throughout its output range the burner is equipped with an electric res...

Page 22: ... due to flame failure t5i Spark post ignition time TR Regulation on demand ts Safety time 6 10 2 Lock out due to extraneous light during pre purging 6 10 3 Lock out due to ignition failure Loss of flame during operation R ecycle max 3 attempts t1 t3 t4i ts t5i t4l HT FM ID V1 F LED F LED P M t3i POW ERSUPPLY Signal not required R ed fast Blinking Green Green Blinking Orange Blinking Orange Blinkin...

Page 23: ...ail ure during operation the final action at the last attempt following flame failure is a lock out 3 re cycles tpp Post purge time additional purge time at the end of heat demand can be interrupted by a new heat demand 0 default 10s up to120s programma ble Status Reset push button color Seconds Color code OFF OFF Pre heating time GREEN flashing 0 5 2 5 Pre purge ORANGE blinking 0 5 0 5 Safety tim...

Page 24: ...on a new attempt is added By disconnecting power supply when new a heat request occurs power supply is applied to the burner all re ignition attempts are allowed maximum 3 6 13 6 Presence of an extraneous light or parasite flame If the extraneous light or parasite flame signal continues for more than 25 seconds the burner will go into lockout Once the control box has been reset a new firing attemp...

Page 25: ...of re lays of the oil valve in the event of a fault it performs a lockout The lockout is indicated by led flashing see table 6 13 14 EEprom check The control box automatically detects if EEprom memory of mi crocontroller has failed and will perform a lockout The lockout is indicated by the led flashing see table 6 14 Post purging Post purging is a function that maintains air ventilation even after...

Page 26: ...ss the button for 15 sec t 20 sec GREEN led flashing 2 times Release the button GREEN led OFF Press push button 1 time for enable or 2 times for disable function GREEN led ON and OFF at every press and release After 10 sec the GREEN LED will blink for the number of times programmed 0 5 sec ON 0 5 sec OFF Version Button release time LED signal menu page No of pressings of the button LED visualised ...

Page 27: ...Press push button 1 5 times GREEN led ON and OFF every time press and release After 10 sec the GREEN LED will blink for the number of times programmed 0 5 sec ON 0 5 sec OFF Sequence for disable post purging Allowable resetting only during RUNNING operation Press the button for 10 sec t 15 sec GREEN led flashing 1 time Release push button GREEN led OFF Press push button for 6 times After 10 sec GR...

Page 28: ...5 seconds presence of false flame signal during post purging The flame is not detected after the safety time After 5 seconds from oil valve starts RED Steady ON flame detector defective or dirty oil valve defective or dirty faulty ignition transformer badly regulated burner oil fuel not present Flame failure during opera tion After 3 recycles badly adjusted burner oil valve defective or dirty flam...

Page 29: ...operation will need to be more thorough Boiler Clean the boiler according to the instruction booklet so as to be able to find the original combustion data in particular pressure in the combustion chamber and flue gas temperatures 7 Maintenance DANGER The maintenance interventions and the calibration of the burner must only be carried out by qualified authorised personnel in accordance with the con...

Page 30: ...ntify if it is the suction line which is respon sible for the fault or the pump On the contrary if the cause of anomalies is related to the suction line check that there is no clogged filter on the line or air intake on the line Filters Check the line filters and the nozzle present in the system If nec essary clean or replace them If you notice rust or other impurities inside the burner suck up an...

Page 31: ...ing a separate pump Combustion If combustion values recorded at the start of the intervention do not meet the standards in force or do not allow for good combus tion see the table below and contact the after sales service so that any necessary adjustments can be made Allow the burner to work at full speed for about 10 minutes checking all the parameters specified in this manual Then perform a comb...

Page 32: ...he control box are wrongly inserted OFF Check and connect all the plugs and sockets properly The P short circuit socket is not con nected if used Replace them The burner goes into lockout mode before or during the pre purging The pre heater is faulty Eliminate the exstraneous light Burner runs normally in the prepurge and ignition cycle and locks out after 5 seconds ca The flame detector is dirty ...

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Page 36: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...