Riello Burners RG2 Guide de démarrage rapide

2903260 (0)

Installation, use and maintenance instructions

Light oil burner

One stage operation

CODE MODEL TYPE

3737754 RG2 377 T1

3260

1GB

INDEX

1. BURNER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4. BURNER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.2 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

4.5 Maintenance position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.6 Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.7 Air damper adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.8 Operating programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.8.1 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.8.2 Lockout due to firing failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.8.3 Lockout due to extraneous light during pre-purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.8.4 Lockout types and triggering times in case of burner malfunction. . . . . . . . . . . . . . . . . . . . . . . . 12

4.8.5 Control box reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.8.6 Recycle function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.8.7 Logging of burner operation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.9 Additional, programmable control box functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.9.1 Post-purging function (t6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.9.2 Continuous purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.9.3 Long pre-purging function (t7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.9.4 Function setting procedure using reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.1 Control box visual diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 Start-up problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.2 Operating irregularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7. WARNINGS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.1 Burner identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.2 Basic safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3260

2GB

1. BURNER DESCRIPTION

One stage light oil burner.

1.1 BURNER EQUIPMENT

Flange with insulating gasket No. 1 Screws 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

Remote reset connection . . . . . . . . . . No. 1

1.2 ACCESSORIES

DIAGNOSTIC SOFTWARE KIT

A special kit is available that detects the life of the burner through optical connections with a PC showing

the duty hours, number and types of lockout, control box serial number etc...

Do the following to display the diagnostic:

³Connect the kit supplied separately to the appropriate socket on the control box.

The information is read after the software program in the kit is booted.

REMOTE RESET KIT

The burner is fitted with a remote reset kit (RS)consisting of a connection to which a button can be con-

nected up to a distance of 20 meters.

For the installation, remove the protection block installed in the factory and install the block that is supplied

with the burner (see wiring diagram on page 6).

1– Oil pump

2– Control-box

3– Reset button with lockout lamp

4– Flange with insulating gasket

5– Air damper adjustment assembly

³Burner with CE marking in conformity with EEC Directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,

Machines 98/37/EEC and Yield 92/42/EEC.

³CE Certification No.: 0036 0344/03 in accordance with 92/42/EEC.

³The burner meets protection level IP X0D (IP 40), as per EN 60529.

³The burner is approved for intermittent operation as per Directive EN 267.

6– Nozzle holder assembly

7– Flame detector

8– Flame tube

9– Motor

Fig. 1

7 56

D4681

3260

3GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 FIRING RATE, (as per EN 267)

TYPE 377T1

Output – Thermal power 4 −10kg/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 0.8A – 2750 rpm. – 288 rad/s

Capacitor 4 µF

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

3 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

3260

4GB

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

3.1 WORKING POSITION

The burner is designed to work only in the positions, 1and 2.

Installation 1is preferable, as it is the only one that allows performing maintenance operations as de-

scribed in this manual.

Installations 2allow working operations but not maintenance with hooking to the boiler.

Any other position could compromise the correct working of the appliance.

Installations 3, 4 and 5are forbidden for safety reasons.

3.2 BOILER FIXING

To install the burner on the boiler, do the following:

³Put on the flange (1) the screw and two nuts (see fig. 3).

³Widen, if necessary, the insulating gasket holes (5 fig.).

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

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

D7088

1 2 3 4 5

Fig. 2

Fig. 3

S7209

3260

5GB

3.3 HYDRAULIC SYSTEMS

ONLY FOR ITALY: Automatic cut-off device as per Ministry of Internal Affairs’ regulation n° 73 dated 7/29/71.

H= difference of level; L= max. length of the suction line; øi= internal diameter.

PRIMING PUMP

On the system in fig. 5 it is sufficient to loosen the suction gauge connection

(5, fig. 4) and wait until oil flows out.

On the systems in fig. 6 and 7 start the burner and wait for the priming.

Should lockout occur prior to the arrival of the fuel, await at least 20 seconds be-

fore 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. 7) 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

required. 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

øi

8 mm

øi

10 mm

0.5

1.5

100

meters

L meters

øi

8 mm

øi

10 mm

0.5

1.5

3.5

100

³The burner is designed to accomodate the installation of

light oil supply pipes on either side of the burner.

³It is necessary to install a filter on the fuel supply line.

³The pump is designed for use with a two-pipe system.

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 the plug (2) up again, (see fig. 4).

³Before 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.

ATTENTION:

max. 4 m

D5710



max. 4 m

D5711

Fig. 6 Fig. 7



1- Suction line

2- Return line

3- By-pass screw

4- Gauge connection

5- Pressure adjuster

6- Vacuometer connection

7- Valve

8- Auxiliary pressure socket

SYSTEM

NOT ALLOWED

IN GERMANY

Fig. 5

324

D5487

Fig. 4

3260

6GB

3.4 ELECTRICAL WIRING

WARNING:

³Do not swap neutral and phase over, follow the dia-

gram shown carefully and carry out a good earth con-

nection.

³The cross section of the wires must be at least 1 sq. mm.

(Unless requested otherwise by local standards and legis-

lation).

³The electrical wiring carried out by the installer must com-

ply with the rules in force in the country.

CONTROL BOX, (see fig. 8)

To extract the control box from the burner it is necessary:

³to disconnect all the connectors connected to it, the 7 pin plug, and

the earth wire (TB);

³undo the screw (A) and pull out the control box in the direction of

the arrow.

For the installation of the control box it is necessary:

³to tighten up the screw (A) with a torque of 1 to 1.2 Nm;

³connect all the connectors that were previously connected.

NOTE:

The burners have been approved for intermittent operation.

This means that they must stop once every twenty four hours to permit

the electrical control box to check its efficiency at start up.

Normally the boiler's limit thermostat (TL) ensures the stopping of the

burner. If this is not the case, it is necessary to apply in series with

(TL) a timer switch that turns off the burner at least once every twenty-

four hours.

AE9275

KEY TO LAY-OUT:

C– Capacitor

E– Electrode

F– Flame detector

h1 – Hour counter

MV – Motor

P– Bridge socket

RS – Remote reset

SER – Safety lockout device

S3 – Remote lockout signal

T6A –Fuse

TB – Burner earth

TL – Limit thermostat

TS – Safety thermostat

V1 – Oil valve

V2 – Safety lockout device

X7 – 7 pin plug

XP7 – 7 pole socket

TESTING

³Check the burner has stopped by opening

the thermostats.

³Check the burner's lockout during opera-

tion by interrupting the flame detector.

CONTROL BOX

MO550

D4684

Main switch

230V ~ 50Hz

Fig. 8

TO BE DONE BY

THE INSTALLER

CARRIED-OUT

IN THE FACTORY

3260

7GB

4. BURNER OPERATION

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 by observing the instruction manual of the boiler, including verification of the CO

and CO2concentration 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), and they refer to 12.5% CO2

at sea level and with light oil and room temperature of 20 °C.

4.2 RECOMMENDED NOZZLES

Delavan W - B type; Danfoss S - B type;

Monarch R type; Steinen S - Q type.

For nozzles of 1.75 - 2.00 - 2.25 GPH, it is advisable to use full cones.

4.3 PUMP PRESSURE

It leaves the factory set at 12 bar. To change it act on pump pressure screw (4, fig. 4, page 5).

4.4 ELECTRODE ADJUSTMENT, (see fig. 9)

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

QUALIFIED PERSONNEL WITH THE RIGHT INSTRUMENTS MUST HANDLE THE BURNER'S

START-UP.

ATTENTION

MEASURES MUST BE RESPECTED

Lean the diffuser disc-holder assem-

bly (1) on the nozzle-holder (2) and

lock it by screw (3).

For prospective adjustments loosen

screw (4) and move the electrode as-

sembly (5).

To access the electrodes do the follow-

ing described in chapter “4.5 MAINTE-

NANCE POSITION” (page 8).

ATTENTION

4 to 5 mm

4.5 – 0.5 mm

123

D5537

Fig. 9

3260

8GB

4.5 MAINTENANCE POSITION, (fig. 10 and 11)

ACCESSIBILITY TO THE NOZZLE, THE DIFFUSER DISC AND THE ELECTRODES IS MADE EASY IN 2 WAYS:

³Unscrew and remove the fixing nuts to the

flange and remove the burner from the boiler.

³Hook the burner onto flange (1), loosen the

screws (3) and remove the nozzle (2).

³Remove the small cables (4) from the elec-

trodes, loosen the screw (3 fig. 9 page 7) and

remove the diffuser disc-holder assembly (5)

from the nozzle-holder assembly (7).

³Screw up the nozzle (6) holding the nozzle sup-

port with a spanner.

³Refit following the operations in the reverse

order to the one described above.

³Undo the wires (4) from the control box, the

flame detector (8) and undo the nut (9) from the

pump.

³Loosen the screws (10) and extract the nozzle

holder assembly (7) by turning to the right.

³Remove the small cables (4) from the elec-

trodes, loosen the screw (3 fig. 9 page 7) and

remove the diffuser disc-holder assembly (5)

from the nozzle-holder assembly (7).

³Screw up the nozzle (6) holding the nozzle sup-

port with a spanner.

³Refit following the operations in the reverse

order to the one described above.

E9315

Fig. 10

E9316

Fig. 11

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

Fig. 12

ATTENTION

During the reassembly of the nozzle-holder assembly

screw the nut (9) as shown in fig. 12.

410

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