Riello RL 28/1 Manuel utilisateur

Installation, use and maintenance instructions

Instrucciones de Instalación, Funcionamiento y Mantenimiento

Instruções de Instalação, Funcionamento e Manutenção

Bruciatori di gasolio

Quemadores de gasóleo

Queimadores a gasóleo

One stage operation

Funcionamiento a una llama

Funcionamento a uma chama

2916092 (0)

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3472080 RL 28/1 657 T80

3472081 RL 28/1 657 T80

CONTENTS

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2

Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 5

Choice of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fan gate adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Burner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 13

Resetting the control box and using diagnostics. . . . . . . . . . . 13

Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 14

Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

N.B.

Figures mentioned in the text are identified as follows:

1)(A) = part 1 of figure A, same page as text;

1)(A)p.3 = part 1 of figure A, page number 3.

NOTE

In conformity with Efficiency Directive 92/42/EEC the application

of the burner on the boiler, adjustment and testing must be car-

ried out 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.

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.

(2) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.

VARIANTS

ACCESSORIES (optional):

•STATUS (see page 15): code 3010321

• DEGASSING UNIT

It may occur that a certain amount of air is contained in the light oil sucked up by the pump. This air may originate from the light oil itself as a

consequence of depressurization or air leaking past imperfect seals.

In double-pipe systems, the air returns to the tank from the return pipe; in single-pipe systems, the air remains in circulation causing pressure var-

iations in the pump and burner malfunctions.

For this reason, we advise installing a degassing unit near the burner in single-pipe installations.

Degassing units are provided in two versions:

CODE 3010054 without filter

CODE 3010055 with filter

Degassing unit characteristics

• Burner delivery : 80 kg/h max

• Light oil pressure : 0,7 bar max

• Ambient temperature : 40 °C max

• Light oil temperature : 40 °C max

• Attachment connectors : 1/4 inch

MODEL RL 28/1

TYPE 657 T80

OUTPUT (1)

DELIVERY (1)

kW 178 - 332

153 - 286

15 - 28

Mcal/h

kg/h

FUEL LIGHT OIL

- Net calorific value kWh/kg

Mcal/kg

11.8

10.2 (10200 kcal/kg)

- Density kg/dm30.82 - 0.85

- Viscosity at 20 °C mm2/s max 6 (1.5 °E - 6 cSt)

OPERATION • Intermittent (min. 1 stop in 24 hours).

• Single-stage (all - nothing).

NOZZLES numero 2

STANDARD APPLICATIONS Boilers: water, steam, diathermic oil

AMBIENT TEMPERATURE °C 0 - 40

COMBUSTION AIR TEMPERATURE °C max 60

ELECTRICAL SUPPLY V

220-230 ~ +/-10%

60 - single-phase

ELECTRIC MOTOR rpm

2800

300

220 - 240

2,4

MOTOR CAPACITOR µF/V 12.5/450

IGNITION TRASFORMER V1 - V2

I1 - I2

230 V - 2 x 5 kV

1.9 A - 30 mA

PUMP delivery (at 20 bar)

pressure range

fuel temperature

kg/h

bar

° C max

10 - 18

ELECTRICAL POWER CONSUMPTION W max 370

ELECTRICAL PROTECTION IP 44

IN CONFORMITY WITH EEC DIRECTIVES 89/336 - 73/23 - 92/42 - 89/392

NOISE LEVELS (2) dBA 70.0

Model Code Electrical

supply

Blast tube

lenght mm

RL 28/1 3472080

3472081

single-phase

216

351

BURNER DESCRIPTION (A)

1 Ignition electrodes

2 Combustion head

3 Screw for combustion head adjustment

4 Photocell for flame presence control

5 Screw for fixing fan to flange

6 Indexed selector.

Opens the fan gate to the value necessary at

the burner delivery

7 Slide bars for opening the burner and inspect-

ing the combustion head

8 Valve assembly

9 Pump

10 Plate prearranged to drill 4 holes for the pas-

sage 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 7)

17 Motor capacitor

18 Control box with lock-out pilot light and lock-

out reset button

19 Plugs for electrical connections

20 Air gate valve

21 Pump pressure adjustment

N.B.

If the control box 18)(A) pushbutton (red led)

lights up, it indicates that the burner is in lock-

out.

To reset, hold the pushbutton down for between

1 and 3 seconds.

PACKAGING-WEIGHT (B)

Approximate measurements

• The burner is shipped in cardboard boxe with

the maximum dimensions shown in table (B).

• The weight of the burner complete with pack-

aging is indicated in table (B).

MAX. DIMENSIONS (C)

Approximate measurements.

The maximum dimensions of the burner are giv-

en in (C).

Bear in mind that inspection of the combustion

head requires the burner to be opened and the

rear part withdrawn on the slide bars.

The maximum dimension of the burner, without

casing, when open is give by measurement H.

STANDARD EQUIPMENT

2 - Flexible hoses

2 - Gaskets for flexible hoses

2 - Nipples for flexible hoses

1 - Thermal insulation screen

2 - Extensions 16)(A) for slide bars 7)(A)

(for model with 351 mm blast tube)

4 - Screws to secure the burner flange to the

boiler: M 8 x 25

2 - Fairleads for electrical connections

1 - Instruction booklet

1 - Spare parts lis

(A)

(B)

mm A B C kg

RL 28 /1 1010 620 495 35

(1) Blast tube: short-lang

mm A B C D (1) EFG H(1)

RL 28 /1 476 474 468 216 - 351 140 352 52 672 - 807

(C)

D452

D88

D3261

D3260

D583

FIRING RATES (A)

The burner delivery must be selected within area

of the adjacent diagram.

This area is called firing rate and provides the

delivery of the burner in relation to the pressure

in the combustion chamber.

The work point may be found by plotting a verti-

cal line from the desired delivery and a horizontal

line from the pressure in the combustion cham-

ber. The intersection of these two lines is the

work point which must lie within firing rate.

Important

The FIRING RATE area values have been ob-

tained considering a surrounding temperature of

20 °C, and an atmospheric pressure of 1000

mbar (approx. 100 m above sea level) and with

the combustion head adjusted as shown on page

TEST BOILER (B)

The firing rate was set in relation to special test

boilers in accordance with the methods defined

in EN 267 standards.

Figure (B) indicates the diameter and length of

the test combustion chamber.

Example:

delivery 25 kg/hour:

diameter = 50 cm; length = 1,25 m.

Whenever the burner is operated in a much

smaller commercially-available combustion

chamber, a preliminary test should be per-

formed.

(A)

(B)

D585

D586

pressure mbar

Combustion chamber

length m

INSTALLATION

BOILER PLATE (A)

Drill the combustion chamber locking plate as

shown in (A).

The position of the threaded holes can be

marked using the thermal screen supplied with

the burner.

BLAST TUBE LENGTH (B)

The length of the blast tube must be selected ac-

cording to the indications provided by the manu-

facturer of the boiler, and in any case it must be

greater than the thickness of the boiler door com-

plete with its fettling. The range of lengths avail-

able, L, is as follows:

Blast tube 7): • short 216 mm

• long 351 mm

For boilers with front flue passes 10) or flame in-

version chambers, protective fettling in refractory

material 8) must be inserted between the boiler's

fettling 9) and the blast tube 7).

This protective fettling must not compromise the

extraction of the blast tube.

For boilers having a water-cooled front the refrac-

tory fettling 8)-9)(B) is not required unless it is ex-

pressly requested by the boiler manufacturer.

SECURING THE BURNER TO THE BOILER (B)

Disassemble the blast tube 7) from the burner 4)

by proceeding as follows:

- Remove the screws 2) from the two 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).

Secure flange 5)(B) to the boiler plate interpos-

ing the supplied gasket 6). Use the 4 supplied

screws provided after having protected the

thread with antiscruffing products (high-tempera-

ture grease, compounds, graphite). The burner-

boiler seal must be airtight.

CHOICE OF NOZZLES

Choose the couple of nozzles among those giv-

en in table (C).

Use nozzles with a 60° spray angle at the recom-

mended pressure of 12 bar.

When the burner fires only the first nozzle works.

Its delivery is higher than that of the second noz-

zle in order to assure a good flame stabilisation

to the stability disk, though the fan delivery has

been adjusted for both working nozzles.

Whenever ignition takes place with unusual

noise or pulsations, you should reduce the first

nozzle delivery making sure that the flame stabi-

lisation is still satisfactory.

Subsequently also the second nozzle starts

working.

The burner»s operating delivery consists of the

sum of the two nozzles deliveries.

Example

Boiler output = 230 kW

Efficiency 90 %

Output required by the burner =

230 : 0,9 = 255 kW

In table (C) the following nozzles are recom-

mended:

1° = 3,0 GPH + 2° = 2,0 GPH - 60° - 12 bar.

(A)

(B)

(C)

(1) We get the indicated delivery when both nozzles are working and light

oil has the following characteristics:

Density 0,84 kg/dm3- Viscosity 4,2 cSt/20 °C - Temperature 10 °C.

GPH kg/h (1) kW

12 bar

1° 2° 10 bar 12 bar 14 bar

2,25

2,50

2,75

3,00

3,50

4,00

1,50

1,75

2,00

2,25

2,50

2,75

3,00

14,4

16,3

17,3

19,2

20,2

22,1

23,0

25,9

26,9

15,9

18,0

19,1

21,2

22,3

24,4

25,4

28,6

29,7

17,3

19,6

20,7

23,0

24,2

26,5

27,7

31,1

32,3

189

213

226

251

264

289

301

339

352

D587

D588

NOZZLE ASSEMBLY

At this stage of installation the burner is still dis-

assembled from the blast tube; it is therefore

possible to fit two nozzles with the box spanner

1)(A) (16 mm), after having removed the plastic

plugs 2)(A), fitting the spanner through the cen-

tral hole in the flame stability disk. Do not use any

sealing products such as gaskets, sealing com-

pound, or tape. Be careful to avoid damaging the

nozzle sealing seat. The nozzles must be

screwed into place tightly but not to the maxi-

mum torque value provided by the wrench.

The firing nozzle is the one lying beneath the fir-

ing electrodes fig. (B).

Make sure that the electrodes are positioned as

shown in fig. (B).

Finally remount the burner 4)(C) to the slide bars

3) and slide it up to the flange 5), keeping it

slightly raised to prevent the flame stability disk

from pressing against the blast tube.

Tighten the screws 2) on the slide bars 3) and

screw 1) that attaches the burner to the flange.

If it proves necessary to change a nozzle with the

burner already fitted to the boiler, proceed as

outlined below:

- Retract the burner on its slide bars as shown

in fig. (B)p.5.

- Remove the nuts 1)(D) and the disk 2).

- Use spanner 3)(D) to change the nozzles.

COMBUSTION HEAD SETTING

The setting of the combustion head depends ex-

clusively on the delivery of the burner, in other

words, the combined delivery of the two nozzles

selected on page 5.

Turn screw 4)(E) until the notch shown in dia-

gram (F) is level with the front surface of flange

5)(E).

Example RL 28/1:

with nozzles:

1° = 2.75 GPH + 2° = 1.75 GPH and 14 bar pump

pressure.

Find the delivery of the two nozzles in Table

(C)p.5 , 20.7 kg/h.

Diagram (F) indicates that for a delivery of 20.7

kg/h the RL 28/1 Model requires the combustion

head to be set to approx. three notches, as

shown in fig. (E).

FAN GATE ADJUSTMENT

The fan gate is set using the indexed selector

1)(G), after having loosened the nut 2)(G).

The first time the burner is fired, this setting

should be left as originally set by the manufactur-

er: notch 2, see fig. (G).

2mm

÷4 mm3.5

(A)

(C)

COMBUSTION HEAD SETTING

(G)

(E)

Notches nr.

Light oil delivery kg/h

(D)

(F)

(B)

D460

D591

D462

D592

D593

D3263

D589

HYDRAULIC SYSTEM

FUEL SUPPLY

Double-pipe circuit (A)

The burner is equipped with a self-priming pump

which is capable of feeding itself within the limits

listed in the table at the side.

The tank higer than the burner A

The distance "P" must not exceed 10 meters in

order to avoid subjecting the pump's seal to ex-

cessive strain; the distance "V" must not exceed

4 meters in order to permit pump self-priming

even when the tank is almost completely empty.

The tank lower than the burner B

Pump depression values higher than 0.45 bar

(35 cm Hg) must not be exceeded because at

higher levels gas is released from the fuel, the

pump starts making noise and its working life-

span decreases.

It is good practice to ensure that the return and

suction lines enter the burner from the same

height; in this way it will be less probable that the

suction line fails to prime or stops priming.

The loop circuit

A loop circuit consists of a loop of piping departing

from and returning to the tank with an auxiliary

pump that circulates the fuel under pressure. A

branch connection from the loop goes to feed the

burner. This circuit is extremely useful whenever

the burner pump does not succeed in self-priming

because the tank distance and/or height differ-

ence are higher than the values listed in the table.

Key (A)

Pump/Foot valve height difference

L=Piping length

Æ=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 con-

trolled (only Italy)

8 = On/off solenoid valve (only Italy)

Return line

10 = Check valve (only Italy)

HYDRAULIC CONNECTIONS (B)

The pumps are equipped with a by-pass that

connects return line with suction line. The pumps

are installed on the burner with the by-pass

closed by screw 6)(B)p.11.

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 bj-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 connections and screw them

down.

Take care that the hoses are not stretched or

twisted during installation.

Route the hoses through the holes in the plate,

preferably using those on the rh side, fig. (B):

unscrew the screws 1), now divide the insert

piece into its two parts 2) and 3) and remove the

thin diaphragm blocking the two passages 4).

Install the hoses where they cannot be stepped

on or come into contact with hot surfaces of the

boiler.

Now connect the other end of the hoses to the

supplied nipples, using two wrenches, one to

hold the nipple steady while using the other one

to turn the rotary union on the hose.

(A)

(B)

10 cm

+ H V

- H

+ H

- H

(m)

L (m)

Æ (mm)

81012

+ 4,0 52 134 160

+ 3,0 46 119 160

+ 2,0 39 104 160

+ 1,0 33 89 160

+ 0,5 30 80 160

0 27 73 160

- 0,5 24 66 144

- 1,0 21 58 128

-2,0 194396

-3,0 152865

- 4,0 - 12 33

D3264

D3265

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM as set up by the manu-

facturer

LAYOUT (A)

Burner RL 28/1 (single-phase)

Key to layout (A)

C - Capacitor

RMO88.53A2 - Control box

F - Photocell

MV - Fan motor

TA - Ignition transformer

TB - Burner ground

VA - 1st nozzle solenoid valve

VF - 2nd nozzle solenoid valve

XP1 - Connector for STATUS

XP7 - 7 pole socket

NOTE

For remote-reset, connect a push-button switch

(NO) between terminal 3 and neutral of the con-

trol box (terminals 15, 16, 17 and 18).

ELECTRICAL CONNECTIONS (B)

set by installer

All the wires to connect to the burner plugs 3)(B)

must be routed through the fairleads, supplied by

the manufacturer for insertion into the holes in

the plate, preferably those on the left side, after

having removed the thin diaphragm effectively

closing the aperture, as already explained

above.

1 - Pg 11 Single-phase power supply

2 - Pg 9 Control deviceTL

LAYOUT (C)

RL 28/1 burner electrical connection

Cable section not indicated: 1,5 mm2

Key to layout (C)

h1 - Hourcounter

IN - Manual burner stop switch

S - Remote lock-out signal

TL - Limit control device system: this shuts

down the burner when the boiler tempera-

ture or pressure exceeds the setpoint

value.

TS - Safety control device system: this oper-

ates when TL is faulty.

X7 - 7 pole plug

NOTE

The RL 28/1 burner has been type-approved for

intermittent operation. This means it should

compulsorily be stopped at least once every 24

hours to enable the control box to check its own

efficiency at start-up. Burner halts are normally

provided for automatically by the boiler load

control system.

If this is not the case, a time switch should be fit-

ted in series to IN to provide for burner shut-

down at least once every 24 hours.

WARNING

Do not invert the neutral with the phase

wire in the electricity supply line.

ELECTRICAL EQUIPMENT FACTORY-SET

(A)

(B)

(C)

ELECTRICAL CONNECTION

D3225

D3282

D3266

Black

White

Blue

PUMP (A)

1 - Suction G 1/4"

2 - Return G 1/4"

3 - Pressure gauge attachment G 1/8"

4 - Vacuum meter attachment G 1/8"

5 - Pressure adjustment screw

A - Min. delivery rate at 12 bar pressure

B - Delivery pressure range

C - Max. suction depression

D - Viscosity range

E - Light oil max. temperature

F - Max. suction and return pressure

G - Pressure calibration in the factory

H - Filter mesh width

PUMP PRIMING

- Before starting the burner, make sure that

the tank return line is not clogged.

Obstructions in the line could cause the

sealing organ located on the pump shaft to

break. (The pump leaves the factory with the

by-pass closed).

- In order for self-priming to take place, one of

the screws 3)(A) of the pump must be loos-

ened in order to bleed off the air contained in

the suction line.

- Start the burner by closing the control devices

and the electrical network switch. The pump

must rotate in the direction of the arrow

marked on the cover.

- The pump can be considered to be primed

when the light oil starts coming out of the

screw 3). Stop immediately the burner and

tighten the screw 3).

The time required for this operation depends

upon the diameter and length of the suction tub-

ing. If the pump fails to prime at the first starting

of the burner and the burner locks out, wait ap-

prox. 15 seconds, reset the burner, and then re-

peat the starting operation as often as required.

After 5 or 6 starting operations allow 2 or 3 min-

utes for the transformer 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.

Important:

The a.m. operation is possible because the

pump is already full of fuel when it leaves the fac-

tory. If the pump has been drained, fill it with fuel

through the opening on the vacuum meter prior

to starting; otherwise, the pump will seize. When-

ever the length of the suction piping exceeds 20-

30 meters, the supply line must be filled using a

separate pump.

(A)

AN 57 C

kg/h

bar

cSt

°C

bar

10 - 18

0,45

2 - 75

0,150

PUMP SUNTEC AN 57 C

D602

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