Riello RL 28/2 Guide de démarrage rapide

Installation, use and maintenance instructions

Light Oil Burners

RL 28/2 - 38/2 - 50/2

Low - High Operation

C6505050 - 2915758 (4) - 12/2012

CONTENTS

TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3

Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . 6

Choice of nozzles for low and high fire . . . . . . . . . . . . . . . . . . . 6

Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

Final check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Burner operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Switchboard layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Burner firing rates according to air density. . . . . . . . . . . . . . . . . . .20

Start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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.4 = part 1 of figure A, page number 4.

WARNING

Do not store flammable or hazardous materials in the vicinity

of fuel burning appliances.

Improper installation, adjustment, alteration, service or main-

tenance can cause property damage, personal injury or

death. Refer to this manual for instructional or additional in-

formation. Consult a certified installer, service representative

or the gas supplier for further assistance.

Burner shall be installed in accordance with manufacturers

requirements as outlined in this manual, local codes and au-

thorities having jurisdiction.

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 68° F (20° C) - Barometric pressure 394” WC - Altitude 329 ft.

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

(3) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.

Burner models designations

ACCESSORIES (optional):

• Kit for lengthening the combustion head

L = Standard length

L1 = Length obtainable with the kit

COD. 3010250 L = 81/2“ L1 = 1313/16“• RL 28/2

COD. 3010251 L = 81/2“ L1 = 1313/16“• RL 38/2

COD. 3010252 L = 81/2“ L1 = 1313/16“• RL 50/2

MODEL RL 28/2 RL 38/2 RL 38/2 RL 50/2 RL 50/2

Output (1)

Delivery (1)

High

fire MBtu/hr (3) 630 - 1260 896 - 1708 896 - 1708 1120 - 2240 1120 - 2240

GPH 4.5 - 9 6.4 - 12.2 6.4 - 12.2 8 - 16 8 - 16

Low

fire MBtu/hr (3) 364 - 630 448 - 896 448 - 896 560 - 1120 560 - 1120

GPH 2.6 - 4.5 3.2 - 6.4 3.2 - 6.4 4 - 8 4 - 8

Fuel # 2 Fuel oil

Operation Low - high

Nozzles number 2

Standard applications Hot water, steam, thermal oil

Ambient temperature °F 32 - 104 (0 - 40 °C)

Combustion air temperature °F max 140 (60 °C)

Main power supply (+/- 10 %) V/Ph/Hz 120/1/60 208-230 / 460 / 575 / 3 / 60 120-230/1/60

Fan motor rpm

W - HP

3400

370 - 0.5

120

5.2

3400

550 - 0.75

208 - 230 / 460 / 575

3.2 - 1.6 - 1.3

3400

550 - 0.75

120 - 230

9.8 - 4.9

Motor capacitor µF 45 20

Ignition trasformer V1 - V2

I1 - I2 120 V - 2 x 5 kV

3.7 A - 35 mA

Pump delivery (174

PSI) pressure range

GPH

PSI 22

60 - 260

Electrical power consumption W max 550 600 700 750 700

Electrical protection NEMA 1

Noise levels (2) dBA 68.0 70.0 70.0 75.0 75.0

Model Code Voltage Flame safeguard

RL 28/2 C9511200 (3473270) 120/1/60 Burner mounted

RL 38/2

C9512200 (3474170)

C9512250 (3474370)

C9512251 (3474370)

120/1/60

208-230/460/3/60

575/3/60

Burner mounted

RL 50/2

C9513200 (3474670)

C9513201 (3474670)

(3474675)

208-230/460/3/60

575/3/60

120-230/1/60

Burner mounted

Important:

The installer is responsible for the supply and installation of any safety device(s) not indicated in this manual.

BURNER DESCRIPTION (A)

1 Ignition electrodes

2 Combustion head

3 Screw for combustion head adjustment

4 Photocell for flame monitoring

5 Screw for fixing fan to flange

6 Slide bars for opening the burner and inspecting

the combustion head

7 Hydraulic cylinder for regulation ofthe air damper in

low and high fire positions. When the burner is not

operating the air damper is fully closed in order to

reduce heat dispersion from the boiler due to the

flue draught which draws air from the fan suction in-

let.

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 Motor contactor

17 Flame safeguard control

18 Two switches:

- one "burner off - on"

- one for "low and high fire operation"

19 Burner terminal strip

20 Air damper

21 Pump pressure adjustment

22 Low and high fire valve assembly

23 Protection (for RL 50/2 single-phase burner)

Two types of burner failure may occur:

• FLAME SAFEGUARD LOCK-OUT:

if the flame relay 17)(A) pushbutton lights up, it indi-

cates that the burner is in lock-out.

To reset, press the pushbutton.

•MOTOR TRIP

(RL 38/2 - RL 50/2 three phase):

release by pressing the pushbutton on thermal over-

load.

PACKAGING-WEIGHT (B)

Approximate measurements

• The burner is shipped in cardboard box with the

maximum dimensions shown in table (B).

• The weight of the burner complete with packaging is

indicated in table (B).

MAX. DIMENSIONS (C)

Approximate measurements

The maximum dimensions of the burners are given in

(C).

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

1 - Burner head gasket

4 - Screws to secure the burner flange to the boiler:

3/8W x 1”

1 - Instruction booklet

1 - Spare parts list

1 - Adaptor G 1/8” - 1/8” NPT

(A)

(B)

inch A B C lbs

RL 28/2

RL 38/2

RL 50/2 three-phase

RL 50/2 single-phase

3931/32”

2413/16”

1911/16”

2111/16”

(1) Blast tube: short - long (obtainable with the kit)

inch A A1 B C D (1)

RL 28/2 1823/32”-18

21/32”18

13/32”8

1/2”- 1313/16”

RL 38/2 1823/32”-18

21/32”18

13/32”8

1/2”- 1313/16”

RL 50/2 three-phase 1823/32”-18

21/32”18

13/32”8

1/2”- 1313/16”

RL 50/2 single-phase - 213/16”18

21/32”18

13/32”8

1/2”- 1313/16”

inch E F G H (1)

RL 28/2 51/2”13

27/32”2

1/16”26

15/32”- 313/4”

RL 38/2 51/2”13

27/32”2

1/16”26

15/32”- 313/4”

RL 50/2 three-phase 531/32”13

27/32”2

1/16”26

15/32”- 313/4”

RL 50/2 single-phase 531/32”13

27/32”2

1/16”26

15/32”- 313/4”(C)

D2276

D7632

D88

D7631

FIRING RATE (A)

The RL 28/2 - 38/2 - 50/2 Model burners are available

in low-high firing configuration.

LOW FIRE DELIVERY must be selected within area A

of the adjacent diagrams.

HIGH FIRE DELIVERY must be selected within area B.

This area provides the maximum delivery of the burner

in relation to the pressure in the combustion chamber.

The firing rate may be found by plotting a vertical line

from the desired delivery and a horizontal line from

the pressure in the combustion chamber. The inter-

section of these two lines is the firing rate which must

lie within area B.

Important:

the FIRING RATE area values have been obtained

considering a surrounding temperature of 68 °F (20

°C), and an atmospheric pressure of 394” WC above

sea level and with the combustion head adjusted as

shown on page 7.

Note:

The FIRING RATE areas given in figure (A) have been

reduced by 10% with respect to the maximum range that

can be reached.

Consult Appendix on page 20 for operation at different

surrounding temperatures and/or altitudes.

MINIMUM FURNACE DIMENSIONS (B)

The firing rates were set in relation to certified test boil-

ers.

Figure (B) indicates the diameter and length of the test

combustion chamber.

Example:

output 1388 MBtu/hr:

diameter 20 inch - length 4.9 ft.

(A)

Comb. chamb. “ WC Comb. chamb. “ WCL Comb. chamb. “ WC

D2279

D2918

(B)

Diameter (inches)

Length (ft)

Recommended furnace dimensions

INSTALLATION

BOILER PLATE (A)

Drill the combustion chamber mounting plate as

shown in (A). The position of the threaded holes can

be marked using the burner gasket supplied with the

burner.

BLAST TUBE LENGTH (B)

The length of the blast tube must be selected accord-

ing to the indications provided by the manufacturer of

the boiler, and it must be greater than the thickness of

the boiler door complete with its insulation. The range

of lengths available, L (inch), is as follows:

Blast tube 7): RL 28/2 RL 38/2 RL 50/2

• short 81/2“8

1/2“8

1/2“

• long (with the kit) 1313/16“13

13/16“13

13/16“

For boilers with front flue passes 10) or flame inversion

chambers, protective insulation material 8) must be in-

serted between the boiler's refractory 9) and the blast

tube 7).

This protective insulation must not compromise the ex-

traction of the blast tube.

For boilers having a water-cooled front, the insulation

8)-9)(B) is not required unless it is required 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 inserting the

supplied gasket 6). Use the 4 screws provided after

having protected the thread with an anti-seize product

(high-temperature grease, compounds, graphite).

The burner-boiler seal must be airtight.

CHOICE OF NOZZLES FOR 1st AND 2nd STAGE

Both nozzles must be chosen from among those listed

in Table (C).

The first nozzle determines the delivery of the burner

at low fire.

The second nozzle works in combination with the low

fire nozzle to determine the delivery of the burner at

high fire.

The total deliveries of the low and high fire nozzles

must be contained within the value range indicated on

page 3.

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

mended pressure of 174 PSI.

The two nozzles usually have equal deliveries, but the

low fire nozzle may have the following specifications if

required:

• a delivery less than 50% of the total delivery when-

ever the back-pressure peak must be reduced at

the moment of firing;

• a delivery higher than 50% of the total delivery

whenever the combustion during low fire must be

improved.

(A)

inch A B C

RL 28/2 65/16“8

13/16“3/8 W

RL 38/2 65/16“8

13/16“3/8 W

RL 50/2 65/16“8

13/16“3/8 W

Nozzle

size GPH MBtu/hr

174 PSI

145 PSI 174 PSI 203 PSI

RL 28/2

2.00

2.25

2.50

3.00

3.50

2.47

2.75

3.07

3.68

4.32

2.72

3.04

3.39

4.07

4.74

2.95

3.33

3.68

4.42

5.16

381

428

475

570

664

RL 38/2

2.50

3.00

3.50

4.00

4.50

5.00

3.07

3.68

4.32

4.93

5.54

6.15

3.39

4.07

4.74

5.44

6.12

6.79

3.68

4.42

5.16

5.89

6.63

7.36

475

570

664

762

857

951

RL 50/2

3.00

3.50

4.00

4.50

5.00

5.50

6.00

3.68

4.32

4.93

5.54

6.15

6.75

7.40

4.07

4.74

5.44

6.12

6.79

7.46

8.17

4.42

5.16

5.89

6.63

7.36

8.10

8.87

570

664

762

857

951

1044

1144

(B)

(C)

D455

D339

D2280

Example with the RL 38/2 Model

Boiler output = 912 MBTU/hr - efficiency 80 %

Output required by the burner =

912 / 0.8 = 1140 MBTU/hr

1140 / 2 = 570 MBTU/hr per nozzle

therefore, two equal, 60°, 174 PSI nozzles are

required:

1° = 3.00 GPH with 2° = 3.00 GPH,

or the following two different nozzles:

1° = 3.50 GPH with 2° = 2.50 GPH,

or:

1° = 2.50 GPH with 2° = 3.50 GPH.

NOZZLE ASSEMBLY

At this stage of installation the burner is still disassem-

bled from the blast tube; it is now possible to fit two

nozzles, after having removed the plastic plugs 2)(A),

inserting the wrench through the central hole in the

flame stability disk. Do not use any sealing products

such as gaskets, sealing compound, or tape. Be care-

ful to avoid damaging the nozzle sealing seat. The

nozzles must be screwed into place tightly but careful-

ly.

The nozzle for the low fire of operation is the one lying

beneath the firing electrodes Fig. (B).

Make sure that the electrodes are positioned as shown

in Figure (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.6.

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

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

COMBUSTION HEAD SETTING

The setting of the combustion head depends exclu-

sively on the delivery of the burner at high fire - in

other words, the combined delivery of the two nozzles

selected on page 6. Turn screw 4)(E) until the notch

shown in diagram (F) is level with the front surface of

flange 5)(E).

Example:

The RL 38/2 Model with two 3.00 GPH nozzles and

174 PSI pump pressure.

Find the delivery of the two 3.00 GPH nozzles in table

(C), page 6:

4 + 4 = 8 GPH.

Diagram (F) indicates that for a delivery of 8 GPH the

RL 38/2 Model requires the combustion head to be

set to approx. three notches, as shown in Figure (E).

(A)

(C)

(D)

(E)

SETTING THE COMBUSTION HEAD

(F)

N° Notches

Fuel oil delivery at high fire USGPH

(B)

D458

D2281

D460

D461

D462

D2282

HYDRAULIC SYSTEM

FUEL SUPPLY

DOUBLE - PIPE SYSTEM (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 left.

The tank higher than the burner A

The distance "P" must not exceed 33 ft in order to

avoid subjecting the pump's seal to excessive strain;

the distance "V" must not exceed 13 ft in order to per-

mit pump self-priming even when the tank is almost

completely empty.

The tank lower than the burner B

Pump suction values higher than 13 “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 suc-

tion lines enter the burner from the same height; in

this way it will be more improbable that the suction

line fails to prime or stops priming.

LOOP CIRCUIT

A loop circuit consists of a loop of piping supplied

from and returning to the tank with an auxiliary pump

that circulates the fuel under pressure. A branch con-

nection 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 difference are higher than the

values listed in the table.

Key

H = Pump/Foot valve height difference

L = Piping length

Ø = Inside pipe diameter

1=Burner

2=Pump

3=Filter

4 = Manual on/off valve

5 = Suction line

6 = Foot valve

7 = Return line

HYDRAULIC CONNECTIONS (B)

The pumps is equipped with a by-pass that connects

return line and suction line. It is factory set with the

by-pass valve closed by screw 6)(A)p.12.

It is therefore necessary to connect both hoses to the

pump.

The pump seal will be damaged immediately if it is

run with the return line closed and the by-pass

screw inserted.

Remove the plugs from the suction and return con-

nections of the pump.

Insert the hose connectors 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, prefer-

ably 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 section blocking

the two passages 4).

Install the hoses where they cannot be stepped on or

come into contact with hot surfaces of the boiler.

(A)

+ H

- H

(ft)

L (ft)

Ø (inch)

5/16” 3/8” 1/2”

+ 13 115 296 500

+ 10 99 263 500

+ 6.6 86 227 500

+ 3.3 69 194 428

+ 1.6 63 174 391

056158355

- 1.6 49 141 319

- 3.3 43 122 283

- 6.6 30 89 211

- 10 13 53 138

- 13 – 20 66

(B)

D2284

D2283

315/16”

- H + H V

HYDRAULIC CONNECTIONS

PUMP (A)

1 - Suction 1/4” NPT

2 - Return 1/4” NPT

3 - Pressure gauge attachment G 1/8

4 - Vacuum gauge attachment G 1/8

5 - Pressure adjustment screw

A - Min. delivery rate at 174 PSI pressure

B - Delivery pressure range

C - Max. suction pressure

D - Viscosity range

E - Fuel 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 seal 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 loosened in order

to bleed off the air contained in the suction line.

- Start the burner by closing the control circuit and

with switch 1)(B)p.10 in the "ON" position. The pump

must rotate in the direction of the arrow marked on

the cover.

- The pump can be considered to be primed when the

fuel oil starts coming out of the screw 3). Stop the

burner: switch 1)(B)p.10 set to "OFF" and tighten the

screw 3).

The time required for this operation depends upon the

diameter and length of the suction tubing. If the pump

fails to prime at the first starting of the burner and the

burner locks out, wait approx. 15 seconds, reset the

burner, and then repeat the starting operation as often

as required. After 5 or 6 starting operations allow 2 or

3 minutes for the transformer to cool.

Do not illuminate the photocell or the burner will lock

out; the burner should lock out anyway about 10 sec-

onds after it starts.

Important:

the priming operation is possible because the pump is

already full of fuel when it leaves the factory. If the

pump has been drained, fill it with fuel through the

opening on the vacuum gauge connection prior to

starting; otherwise, the pump will seize. Whenever the

length of the suction piping exceeds 66 - 99 ft, the

supply line must be filled using a separate pump.

(A)

PUMP AL 65 C

GPH

PSI

“Hg

cSt

°F - °C

PSI

inch

21.5

58 - 261

2 - 12

140 - 60

174

0.006

D2286

BURNER CALIBRATION

FIRING

Set switch 1)(B) to "ON".

During the first firing, during the switch over from low

to high fire, there is a momentary lowering of the fuel

pressure caused by the filling of the high fire nozzle

tubing. This lowering of the fuel pressure can cause

the burner to lock-out and can sometimes give rise to

pulsations.

Once the following adjustments have been made, the

firing of the burner must generate a noise similar to

the noise generated during operation.

OPERATION

The optimum calibration of the burner requires an

analysis of the flue gases at the boiler outlet and

adjustments on the following points.

• Low and high fire nozzles

See the information listed on page 6.

• Combustion head

The adjustment of the combustion head already

carried out need not be altered unless the high fire

delivery of the burner is changed.

• Pump pressure

174 PSI: This is the pressure calibrated in the factory

which is usually sufficient for most purposes. Some-

times, this pressure must be adjusted to:

145 PSI in order to reduce fuel delivery. This adjust-

ment is possible only if the ambient temperature re-

mains above 0°C;

203 PSI 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 relevant

screw 5)(A) page 9.

• Low fire air damper

Keep the burner operating at low fire by setting the

switch 2)(B) to the low fire. Opening of the air

damper 1)(A) must be adjusted in proportion to the

selected nozzle: the index 7)(A) must be aligned

with the rate specified in table (C). This adjustment

is achieved by turning the hex element 4)(A):

- in rh direction (- sign) the opening is reduced;

- in lh direction (+ sign) the opening increases.

Example RL 38/2 - low fire nozzle 3.00 GPH:

18° notch aligned with index 7(A).

When the adjustment is done lock the hex element

4) with the ring nut 3).

• High fire air damper

Set switch 2)(B) to the high fire position and adjust

the air damper 1)(A) by turning the hex element

6)(A), after having loosened the ring nut 5)(A).

Air pressure at attachment 1)(D) must be approxi-

mately the same as the pressure specified in table

(D) plus the combustion chamber pressure meas-

ured at attachment 2). Refer to the example in the

adjacent figure.

NOTE:

in order to facilitate adjustment of hex elements 4)

and 6)(A), use a 1/8” Allen key 8)(A).

(C)

(A)

(B)

Burner Stage

Off

On 2°

1°

RL 28/2 RL 38/2 RL 50/2

Nozzle

size

GPH

α°Nozzle

size

GPH

α°Nozzle

size

GPH

α°

2.00

2.25

2.50

3.00

3.50

2.50

3.00

3.50

4.00

4.50

5.00

3.00

3.50

4.00

4.50

5.00

5.50

6.00

Low fire

RL 28/2 RL 38/2 RL 50/2

Nozzle

size

GPH “WC Nozzle

size

GPH “WC Nozzle

size

GPH “WC

4.50

5.10

5.80

6.40

7.00

7.70

8.30

9.00

2.40

2.50

2.60

2.70

2.80

3.00

3.30

3.50

6.40

7.00

7.70

8.30

9.30

10.20

11.20

12.10

2.70

3.10

3.70

8.00

9.30

10.60

11.80

13.10

14.40

16.00

2.40

2.50

2.60

3.00

4.00

3.60

High fire

“WC = air pressure in 1) with zero pressure in 2)

D468

D469

D2287

(D)

Ce manuel convient aux modèles suivants

Table des matières

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