Riello RL 50, Installation, Use And Maintenance Instructions

Page 1: ...2916423 3 04 2011 Installation use and maintenance instructions Gas oil Kerosene burners Two stage operation CODE MODEL TYPE 3470810 3470811 RL 50 979 T GB ...

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Page 3: ...r description 11 4 8 Packaging Weight 12 4 9 Standard equipment 12 5 Installation 13 5 1 Notes on safety for the installation 13 5 2 Handling 13 5 3 Preliminary checks 13 5 4 Installer Servicer notes for the use of Gas oil with Bio blends up to 10 14 5 5 Operating position 14 5 6 Boiler plate 14 5 7 Blast tube length 15 5 8 Securing the burner to the boiler 15 5 8 1 Combustion head calibration 15 ...

Page 4: ...th one control device TR 26 8 4 2 System not equipped with control device TR jumper wire installed 26 8 5 Final checks 26 9 Maintenance 27 9 1 Notes on safety for the maintenance 27 9 2 Maintenance programme 27 9 2 1 Maintenance frequency 27 9 2 2 Checking and cleaning 27 9 3 Opening the burner 28 9 4 Closing the burner 28 9 5 Burner start up cycle diagnostics 29 9 6 Resetting the control box and ...

Page 5: ...ives MD 2006 42 EC Machine Directive LVD 2006 95 EC Low Voltage Directive EMC 2004 108 EC Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BIm SchV release 26 01 2010 Pr...

Page 6: ...ivered to the user by the system manufacturer with the recommendation to keep it in the room where the heat generator is to be installed The instruction manual shows the serial number of the burner the address and telephone number of the nearest Assist ance Centre The system supplier must carefully inform the user about the use of the system any further tests that may be required before activating...

Page 7: ...mp safety value and nozzle The Riello war ranty is dependent upon the use of Riello genuine compo nents including the oil lines being used 3 Riello warranty does not cover defects arising from incorrect commissioning or servicing by non Riello employed service engineers and any issues impacting the burner arising from external site related issues 2 3 Guidance for the use of bio fuel blends up to 1...

Page 8: ...liance applica tion and commissioned checking that all combustion param eters are as recommended in the appliance technical manual Riello recommends that the in line and burner oil pump fil ters are inspected and if required replaced at least every 4 months during burner use before the burner start up follow ing a long period of discontinue operation and even more frequently where contamination ha...

Page 9: ... maintenance errors or to improper use 3 3 Basic safety rules Children or inexpert persons must not use the appliance Under no circumstances must the intake grids dissipation grids and ventilation vents in the installation room be cov ered up with cloths paper or any other material Unauthorised persons must not attempt to repair the appli ance It is dangerous to pull or twist the electric leads Cl...

Page 10: ...50 1 220 230 50 60 Auxiliary voltage 230 50 60 110 50 60 R L 50 TC Emission Class 1 EN267 EN676 MZ Class 2 EN267 Class 2 EN676 BLU Class 3 EN267 EN676 MX Class 2 EN267 Class 3 EN676 FS1 3 230 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 1 230V 50Hz 3 230V 50Hz 230V 50 60Hz 110V 50 60Hz Heavy oil Two stage M Modulating 1 Single stage S L LS N Head TC Standard head TL Extended head 220 23...

Page 11: ...kg Mcal kg kg dm3 mm2 s max 11 86 10 2 10 200 kcal kg 0 82 0 85 6 1 5 E 6 cSt Kerosene net calorific value density viscosity at 20 C kWh kg Mcal kg kg dm3 mm2 s max 11 97 10 3 10 300 kcal kg 0 77 0 83 6 1 5 E 6 cSt Operation Intermittent min 1 stop in 24 hours Two stage high and low flame and single stage all nothing Nozzles number 2 Standard applications Boilers water steam diathermic oil Ambient...

Page 12: ...s the maximum delivery of the burner in relation to the pressure in the combustion chamber The work point may be found by plotting a vertical line from the desired delivery and a horizontal line from the pressure in the combustion chamber The intersection of these two lines is the work point which must lie within area B In order to utilize also area C it is necessary to perform the cali bration of...

Page 13: ...dis persion from the boiler due to the flue draught which draws air from the fan suction inlet 8 Safety solenoid valve 9 Pump 10 Plate prearranged to drill 4 holes for the passage of hoses and electrical cables 11 Air inlet to fan 12 Fan pressure test point 13 Boiler mounting flange 14 Flame stability disk 15 Flame inspection window 16 Extensions for slide bars 6 17 Motor contactor and thermal cut...

Page 14: ...2 Nipples for flexible hoses 1 Thermal insulation screen 2 Extensions 16 Fig 4 for slide bars 6 Fig 4 for model with 351 mm blast tube 4 Screws to secure the burner flange to the boiler M 8 x 25 4 Fairleads for electrical connections 1 Instruction booklet 1 Spare parts list mm A B C kg RL 50 1010 620 495 39 Fig 5 D88 WARNING In case of use with gas oil containing up to 10 Bio blend it will be esse...

Page 15: ...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 adequate escape area i e a free safe area to which you can quick ly move if the burner should fall When han...

Page 16: ...flexible oil lines must be suitable for bio fuel use check with Riello if in doubt Riello have carefully chosen the specification of the bio compatible components including the flexible oil lines to protect the pump safety value and nozzle The Riello war ranty is dependent upon the use of Riello genuine compo nents including the oil lines being used The burner must be commissioned and combustion p...

Page 17: ...o slide bars 3 Remove the screw 1 fixing the burner 4 to the flange 5 Withdraw the blast tube 7 complete with flange 5 and slide bars 3 5 8 1 Combustion head calibration At this point check whether the maximum delivery of the burner in 2nd stage operation is contained in area B or in area C of the firing rate If it is in area B then no operation is required If on the other hand it is in area C uns...

Page 18: ...density 0 84 kg dm3 viscosity 4 2 cSt 20 C temperature 10 C Kerosene 100 Tab F 1 We get the indicated delivery when both nozzles are working and kerosene has the following characteristics density 0 81 kg dm3 viscosity 1 6 cSt 20 C temperature 25 C 5 9 3 Nozzle assembly At this stage of installation the burner is still disassembled from the blast tube it is therefore possible to fit two nozzles wit...

Page 19: ...pends exclusively on the delivery of the burner in the 2nd stage in other words the com bined delivery of the two nozzles selected on page 16 is a partic ularly simple operation Turn screw 4 Fig 15 until the notch shown in diagram Fig 16 is level with the front surface of flange 5 Fig 15 Example gas oil Model with two 3 00 GPH nozzles and 12 bar pump pressure Find the delivery of the two 3 00 GPH ...

Page 20: ... length ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Manual on off valve 5 Suction line 6 Foot valve 7 Rapid closing manual valve remote controlled only Italy 8 On off solenoid valve only Italy 9 Return line 10 Check valve only Italy 11 Tank filter Tab G 6 Hydraulic system WARNING Where gas oil containing bio diesel is in use it is recommended to avoid over oxygenation of the blended fuels Wh...

Page 21: ...closed by screw 6 Fig 29 on page 26 It is therefore necessary to connect both hoses to the pump The pump will break down immediately if it is run with the return line closed and the by pass screw inserted Remove the plugs from the suction and return connections of the pump Insert the hose connections with the supplied seals into the con nections and screw them down Take care that the hoses are not...

Page 22: ...rmer to cool Do not illuminate the photocell or the burner will lock out the burner should lock out anyway about 10 seconds after it starts WARNING In case of use with gas oil containing up to 10 Bio blend it will be essential to use flexible oil lines suitable for bio fuel use Please contact Riello for further information Suntec AL75CK Min delivery rate at 12 bar pressure kg h 88 Delivery pressur...

Page 23: ...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 If this is not the case it is necessary to apply in series with IN a timer switch that turns off the burner at least once every twenty four hours Refer to the wiring diagrams The electrical safety of the device is o...

Page 24: ...f the thermal cut out as well 7 3 Thermal relay calibration This is required to avoid motor burn out in the event of a signifi cant increase in intake power caused by a missing phase If the motor is star powered 400V the cursor should be posi tioned at MIN If the motor is delta powered 230V the cursor should be posi tioned at MAX Even if the scale of the thermal relay does not include rated motor ...

Page 25: ... above 0 C Never calibrate to pressures below 10 bar at which pressures the cylinders may have difficulty in opening 14 bar in order to increase fuel delivery or to ensure firings even at temperatures of less than 0 C In order to adjust pump pressure use the screw 5 Fig 20 Pump pressure kerosene 10 bar maximun pressure for kerosene 1st stage fan air gate valve Keep the burner operating at 1st stag...

Page 26: ...ab K plus the combustion chamber pressure measured at attachment 2 Refer to the example in the figure NOTE in order to facilitate adjustment of hex elements 4 and 6 Fig 25 on page 23 use a 3 mmc Allen key 8 Fig 25 on page 23 2nd STAGE Tab K mbar Air pressure in 1 with zeropressure in 2 1 With shutter 4 Fig 10 on page 15 retracted Fig 26 D8633 Gas oil kerosene GPH mbar GPH mbar 25 6 1 24 8 8 2 29 6...

Page 27: ...hen sprayed out through the nozzle igniting when it comes into contact with the spark This is the 1st stage flame 29 s The ignition transformer switches off 36 s If the control device TR is closed or has been replaced by a jumper wire the 2nd stage solenoid valve 11 is opened and the fuel enters the valve 12 and raises the piston which opens two passages one to piping 13 filter 14 and the 2nd stag...

Page 28: ... damper valve closes completely 8 4 2 System not equipped with control device TR jumper wire installed The burner is fired as described in the case above If the temper ature or pressure increase until control device TL opens the burner shuts down Section A A in the diagram When the solenoid valve 11 Fig 29 de energizes the piston 12 Fig 29 closes the passage to the 2nd stage nozzle and the fuel co...

Page 29: ...s clogged or not Contrarily if the problem lies in the suction line check to make sure that the filter is clean and that air is not enter ing the piping Fan Check to make sure that no dust has accumulated inside the fan or on its blades as this condition will cause a reduction in the air flow rate and provoke polluting combustion Combustion head Check to make sure that all the parts of the combust...

Page 30: ...t how to achieve this then please contact the fuel or oil tank supplier Boiler Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics in tact especially the flue gas temperature and combustion cham ber pressure Fuel pump and or couplings replacement In conformity with Fig 33 9 3 Opening the burner Remove screw 1 and withdraw ...

Page 31: ...tells you the cause of the malfunction accord ing to the coding system indicated in the table on page 30 9 6 3 Software diagnostics Reports burner life by means of an optical link with the PC indi cating hours of operation number and type of lock outs serial number of control box etc To view diagnostics proceed as follows Hold the button down for more than 3 seconds once the red LED burner lockout...

Page 32: ...cted to return line Correct connection 22 Valves up line from pump closed Open 23 Filters dirty line pump nozzle Clean 24 Defective photocell or control box Replace photocell or control box 25 Photocell dirty Clean 26 1st stage operation of cylinder is faulty Change the cylinder 27 Motor protection tripped Reset thermal relay 28 Defective motor command remote control device Substitute it 29 Missin...

Page 33: ... immersed in fuel Bring to same height as suction pipe 60 Air enters suction piping Tighten connectors Pump leaks fuel 61 Leakage from sealing organ Replace pump Smoke in flame dark Bacharach yellow Bacharach 62 Not enough air Adjust head and fan gate see page 17 and page 23 63 Nozzle worn or dirty Replace 64 Nozzle filter clogged Clean or replace 65 Erroneous pump pressure Adjust to between 10 14...

Page 34: ...ble for use where the burner opening on the boiler is of excessive diameter SOUND PROOFING BOX If noise emission needs reducing even further sound proofing boxes is available PC INTERFACE KIT To connect the control box to a personal computer for the trans mission of operation fault signals and detailed service informa tion an interface adapter with PC software IS available STATUS Assembly The burn...

Page 35: ... after stage 5 the code I I I I will appear on the read out this indicates that the starting phase is terminated WITH CONTROL DEVICE TR OPEN 1 Burner off TL open 2 Control device TL closed 3 Motor start seconds count starts on read out V 4 1st stage valve energized 7 30 seconds after stage 4 seconds count stops on read out V 8 10 seconds after stage 7 the code I I I I will appear on the read out t...

Page 36: ...ECTRICAL EQUIPMENT FACTORY SET For remote reset connect a push button switch NO between terminal 3 and neutral of the control box terminals 15 16 17 and 18 TO BE COMPLETED BY THE INSTALLER B Appendix Electrical panel layout D3227 Fig 3 D3228 Fig 4 ...

Page 37: ... the boiler tem perature or pressure exceeds the setpoint value TR High low mode control device system This controls operating stages 1 and 2 and is necessary only for two stage operation TS Safety control device system This operates when TL is faulty V1 1st stage solenoid valve V2 2nd stage solenoid valve VS Safety solenoid valve X4 4 pole plug X5 5 pole plug X7 7 pole plug XP1 Connector for STAT...

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Page 40: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www rielloburners com ...