Riello Burners RDB1 70-90 Quick start guide

2902458 (10)
Installation, use and maintenance instructions
CODE MODEL TYPE
3748357 RDB1 70 - 90 483T50
3748557 RDB1 50 - 70 485T50
3513007 RDB1 WM 50/70 501T2K
3748757 RDB2 90 - 120 487T50
KEROSENE BURNER
KEROSENE AND LIGHT OIL
BURNER

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1
INDEX
1. BURNER DESCRIPTION
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . . . .No. 1 Screws and terminal screw for feeding cable . . . No. 3
Screw and nuts for flange . . . . . . . .No. 1 Screw of by-pass pump . . . . . . . . . . . . . . . . . . . No. 1
Hexagonal key. . . . . . . . . . . . . . . . .No. 1 Nuts for flange to be fixed to boiler. . . . . . . . . . . No. 2
Flexible oil pipe with nipple . . . . . . .No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment. . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions. . . . . . . . . . . . . . . . . 2
2.3 Firing rates . . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION. . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Burner assembly . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 5
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 6
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Combustion adjustment. . . . . . . . . . . . . . 7
4.2 Nozzles recommended . . . . . . . . . . . . . . 7
4.3 Electrodes setting . . . . . . . . . . . . . . . . . 7
4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7
4.5 Air damper adjustment . . . . . . . . . . . . . . 7
4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
One stage kerosene and light oil burner.
■In case of BF applications the intake air temperature must not be over 70°C.
■CE Certification No.: 0036 0326/01 (483T50) – 0036 0316/01 (501T2K), as 92/42/EEC.
■The burner meets protection level of IP 40, EN 60529.
■Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
1– Pump
2– Control-box
3– Reset button with lock-out lamp
4– Flange with insulating gasket
5– Air damper adjustment screw
6– Pump pressure adjustment screw
7– Pressure gauge port
8– Photoresistance
1
D6115
Fig. 1
4
5
2
3
6
7
8

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2
2. TECHNICAL DATA
2.1 TECHNICAL DATA
◆
Light oil is not permitted on low level discharge of flue gas products.
2.2 OVERALL DIMENSIONS
2.3 FIRING RATES,
(as EN 267)
TYPE 483T50 485T50 501T2K 487T50
Output – Thermal power
(with air at 20°C)
kg/h 1.8 – 3.4 1.5 – 2.5 1.8 – 2.8 2.3 – 3.9
kW 21.6 – 40.6 18 – 29.9 21.6 – 33.5 27.6 – 46.6
Fuel Kerosene, viscosity 1.6 – 6 mm
2
/s at 20 °C (Hi= 11.97 kWh/kg)
Light oil, viscosity 4 – 6 mm
2
/s at 20 °C
◆
(Hi= 11.86 kWh/kg)
Electrical supply Single phase,
~
50Hz 230V
±
10%
Motor Run current 0.7A – 2700 rpm – 283 rad/s
Capacitor 4.5
µ F
Ignition transformer Secondary 8 kV – 16 mA
Pump Kerosene, maximum pressure 10 bar (145 psi)
Light oil, maximum pressure 15 bar (218 psi)
Absorbed electrical power kW 0.115 0.125
Flange Burner
140 A 202
130
20
45°
øB
223.5
11
168
D6114
180
72 72
150
45°
136
TYPE A Ø B
483T50 96 90
485T50 90 84
501T2K 50 85
487T50 96 90
1.4
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
0.8
1.0
1.2
0.4
0.2
0.6
D4503
0
15 20 4025 30 35 45
22.5 33.5
1.5 4
487T50483T50501T2K485T50

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3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
➤
Put on the flange (1) the screw and two nuts, (see fig. 2).
➤
Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3) interposing the
insulating gasket (5)
, (see fig. 3).
3.2 BURNER ASSEMBLY
In case of
CF applications, the burner shall not operate without pro-
tection
(A) of the suction inlet.
FOR CORRECT BF APPLICATION, THE BURNER MUST BE
INSTALLED ON AN APPROPRIATE BF BOILER.
In case of BF applications an optional snorkel and gasket are availa-
ble replacing
(A) with (B) . This item can be supplied separately.
The combustion air supply is through a flexible or rigid pipe connect-
ed to the air intake.
Consequently, you must comply with the following requirements and
instructions:
➤
The combustion air intake tube must be:
- fastened securely to the burner;
- made of a suitable material, with temperature characteristics in
the range - 30 °C to 80 °C;
- in compliance with all requirements of applicable regulations in
force in the country of destination.
RESET
TWICE
ONLY
5
1
2
4
3
E9149
Fig. 2
Fig. 3
1
E9148
D5884
A
B
D5883
CF APPLICATION
BF APPLICATION

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➤
The intake-tube / burner system must not allow a loss of over 2 m
3
/h at 0.5 mbar:
for instance, the above requirements will be met if you use flues for pressure exhaust of flue gases (the
condensation kind).
➤
Make sure the air intake tube’s inlet is positioned so that it is not likely to be obstructed by foreign matter
and, where necessary, use suitable screens.
➤ The temperature of the incoming air must not exceed 40 °C;
➤
The inside diameter of the hose must be at least 80 mm.
➤
The intake tube can be up to 6 metres in length.
Warning : length is reduced if there are bends in the intake section.
For instance, using a tube with a smooth inside surface, you must allow for the following losses:
- for each 45° bend, tube length is reduced by 0.5 m;
- for each 90° bend, tube length is reduced by 0.8 m.
BURNER INSTALLATION MUST COMPLY WITH ONE OF THE INSTALLATIONS ILLUSTRATED IN THE
FIGURES BELOW.
➤
Under no circumstances should the air’s entry in the hose intake area be obstructed.
➤
The hose must not be blocked in any way or feature a shutting device (valves, membranes etc.).
➤
Coaxial tubes must not be installed for any reason.
ATTENTION
S7851
S7853
S7876

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3.3 HYDRAULIC SYSTEMS
H= difference of level L= Max. lenght of the suction line I.D. = Interminal diameter of the oil pipes.
Fig.4
D5912 2
3
4
7
6
5
18
➤Check periodically the flexible pipes conditions.
Using kerosene, they have to be replaced at least every 2 years.
➤A metal bowl filter with replaceable micronic filter must be fitted in the
oil supply pipe.
➤The pump is designed to allow working with one pipe.
In order to obtain two pipes working it is necessary to unscrew the
return plug (2), screw the by-pass screw (3) and then screw the
return flexible oil pipe. (See fig. 4).
➤In the two pipes systems, before 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.
WARNING:
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve
8- Auxiliary pressure test point
PRIMING PUMP
On the system in fig. 5 it is sufficient to loosen the suction gauge
connection (6, 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 lock-out occur prior to the arrival of the fuel, await at least 20 sec-
onds before 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 previ-
ous one, due to the possibility of leakage of the valve.
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
H
max. 4 m
min. 0.1 m
Fig.5
D5741
Fig.6 Fig.7
D5740
max. 4 m
H
H
max. 4 m
H
H
D1842

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3.4 ELECTRICAL WIRING
E9153
4
4
3
12
CONTROL BOX (see fig. 8)
To remove the control box from the burner follow of the istruction:
➤Loosen the screw (1), open the protection (2) and remove all
components.
➤Remove the coil (3).
➤Loosen the two screws (4).
➤Move a little the control box and remove the high voltage leads.
Fig. 8
Capacitor
LN
~50Hz - 230V
Limit
Oil valve
D4240
CONTROL BOX
Photoresistance
535SE/LD
thermostat
Safety
thermostat
Motor
Remote lock-out signal
(230V - 0.5A max.)
Main switch
T6A
Blue
White
Black
PE
Ignition
electrodes
TESTING:
Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
Burner-earth
NOTES:
– Wires of min. 1 mm2section.
(Unless requested otherwise by local stand-
ards and legislation).
– The electrical wiring carried out by the install-
er must be in compliance with the rules in
force in the Country.
DO NOT EXCHANGE NEUTRAL WITH PHASE
WARNING

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4. WORKING
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 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.
4.2 NOZZLES RECOMMENDED : Delavan type W; Steinen type Q - S; Danfoss type H - S.
Angle : 60° - In most cases.
80° - In case of flame detachment, during ignitions at low
temperatures.
4.3 ELECTRODES SETTING
4.4 PUMP PRESSURE
The pump leaves the factory set for kerosene working.
10 bar: maximum pressure for kerosene.
FOR LIGHT OIL INCREASE PRESSURE
12 bar: pressure suitable for light oil in most cases.
14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.
4.5 AIR DAMPER ADJUSTMENT
The air damper is set in factory. This regulation is purely indicative. Each installation however, has its
own unpredictable working conditions: actual nozzle output; positive or negative pressure in the combus-
tion-chamber, the need of excess air, etc. All these conditions may require a different air damper setting.
Before removing or assembling the
nozzle, loosen the screw (A, fig. 9)
and move the electrodes ahead.
TYPE
483T50 3 – 3.5 mm
485T50 2 – 2.5 mm
501 T2K 2 – 2.5 mm
487T50 3 – 3.5 mm
ATTENTION
B
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230 AB
Fig. 9

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4.6 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the
burner acting on the main switch of the system.
THE BASIC CHECK ARE:
➤Check that there are not obstructions or dents in the supply or return oil pipes.
➤Clean the filter in the oil suction line and in the pump.
➤Clean the photoresistance,(8, fig. 1, page 1).
➤Check for correct fuel consumption.
➤Replace the nozzle and check the correct position of electrodes (fig. 9, page 7).
➤Clean the combustion head in the fuel exit area, on the diffuser disc.
➤Leave the burner working without interruptions for 10 min. and set rightly all the components stated in
this manual. Then carry out a combustion check verifying:
●Smoke temperature at the chimney; ●Contentof CO2(%); ●ContentofCO(ppm);
●Smoke value according to opacity smokes index according to Bacharach scale.
Normal
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s
Lock-out due to failure to light
C
C

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6. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for some problems that could cause a
failure to start or a bad working of the burner. A fault usually makes the lock-out lamp light which is
situated inside the reset button of the control box (3, fig. 1, page 1). When lock out lamp lights the burner
will attempt to light only after pushing the reset button.
After this if the burner functions correctly, the lock-out can be attributed to a temporary fault. If however the
lock out continues the cause must be determined and the solution found.
WARNING
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error in
installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the tech-
nical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
The burner will not
start when the limit
thermostat closes.
Lack of electrical supply.
Check presence of voltage in the
L - N clamps of the control box.
Check the conditions of the fuses.
Check that safety thermostat is not
lock out.
Resistance or start thermostats are
faulty. Replace them.
The connections in the control box
are wrongly inserted. Check and connect completely all the plugs.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective. Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned. Adjust them according to the instructions of this manual.
Air output is too high. Set the air output.
Nozzle dirty or worn. Replace it.