Riello 20045452 Quick start guide

20045701 (5) - 12/2012
Installation, use and maintenance instructions
Light oil burners
Single stage operation
CODE MODEL
20045452 RDB2.2R T1 BF FCX22
20045453 RDB2.2R T3 BF FCX30

1 20045701
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Danger: live components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Owner’s responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Packaging - weight - Approximate measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Burner dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Installation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Working position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.1 CF - Chimney Vent Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6.2 BF - Direct Vent Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 A typical layout for RDB burner intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8 Boiler fixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.9 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.9.1 General warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.9.2 Oil line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.9.3 Priming pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.10.1 Control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.11 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.1 Nozzles recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Pump pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Burner adjustment table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.6 Electrodes setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Fuel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 Burner start-up cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

20045701 2
Contents
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 Faults / Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.1 Exploded spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Information and general instructions
3 20045701
1.1 Information about the instruction manual
1.1.1 Introduction
The instruction manual supplied with the burner:
³is an integral and essential part of the product and must not be
separated from it; it must therefore be kept carefully for any
necessary consultation and must accompany the burner even
if it is transferred to another owner or user, or to another sys-
tem. If the manual is lost or damaged, another copy must be
requested from the Technical Assistance Service of the area;
³is designed for use by qualified personnel;
³offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation
of potential danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Safety precautions
Good safety practices must be used when working on burner
equipment. The potential energy in the electrical supply, fuel and
related equipment must be handled with extreme care to prevent
equipment failures, injuries and potential death.
1.1.4 Danger: live components
Other symbols
³This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
³The instruction manual is supplied to the user by the system
manufacturer, with the recommendation to keep it in the room
where the heat generator is to be installed.
³The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre;
³The system supplier carefully informs the user about:
– the use of the system,
– any further tests that may be necessary before the system is
started up,
– maintenance and the need to have the system checked at
least once a year by the manufacturer or another specialised
technician.
To ensure a periodic check, the manufacturer recommends
the drawing up of a Maintenance Contract.
1 Information and general instructions
WARNING
READ THESE INSTRUCTIONS AND SAVE FOR
REFERENCE
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
WARNING
If you smell gas, open window, extinguish any open
flames, stay away from electrical switches, evacu-
ate the building and immediately call the gas com-
pany.
If this equipment is not installed, operated, operated
and maintained in accordance with the manufactur-
ers intructions, this product could expose you to
substances in fuel or from fuel combustion which
can cause death or serious illness.
WARNING
Improper servicing of this equipment may create a
potential hazard to equipment and operators.
Servicing must be done by a fully trained and
qualified personnel.
DANGER
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with lethal
consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the ma-
chine with respect for the environment.
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20045701 4
Information and general instructions
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility
will no longer be valid, in the event of damage to things or injury
to people, if such damage/injury was due to any of the following
causes:
³incorrect installation, start-up, use and maintenance of the
burner;
³improper, incorrect or unreasonable use of the burner;
³intervention of unqualified personnel;
³carrying out of non authorised modifications on the equipment;
³use of the burner with safety devices that are faulty, incorrectly
applied and/or not working;
³installation of untested supplementary components on the
burner;
³powering of the burner with unsuitable fuels;
³faults in the fuel power supply system;
³use of the burner even following an error and/or an irregularity;
³repairs and/or overhauls incorrectly carried out;
³modification of the combustion chamber with inserts that pre-
vent the regular development of the flame, as structurally
established;
³insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
³use of non-original components, including spare parts, kits,
accessories and optionals;
³force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
1.2.1 Owner’s responsibility
Please pay attention to the Safety Warnings contained within
this instruction manual. Keep this manual for your records and
provide it to your quali fi ed service agency for use in profession-
ally setting up and maintaining your burner.
Your burner will provide years of ef fi cient operation if it is pro-
fessionally installed and maintained by a qualifi ed service tech-
nician. If at any time the burner does not appear to be operating
properly, immediately contact your qualifi ed service agency for
consultation.
We recommend annual inspection/service of your gas heating
system by a qualifi ed service agency.
Failure to follow these instructions, misuse, or incorrect adjust-
ment of the burner could lead to equipment malfunction and re-
sult in asphyxiation, explosion or fire.
WARNING
Failure to observe the information given in this man-
ual, operating negligence, incorrect installation and
the carrying out of non authorised modifications will
result in the annulment by the manufacturer of the
guarantee that it supplies with the burner.
WARNING
If you smell gas:
³Do not touch any electrical items.
³Open all windows.
³Close all gas supply valves.
³Contact your local gas authority immediately.
• Do not store flammable or hazardous materials
in the vicinity of fuel burning appliances.
• Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury or death.
• Refer to this manual for instructional or addition-
al information.
• Consult a certified installer, service representa-
tive or the gas supplier for further assistance.
• Burner shall be installed in accordance with
manufacturers requirements as outlined in this
manual, local codes and authorities having ju-
risdiction.

Safety and prevention
5 20045701
2.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burn-
er or other items. Inattention, thoughtlessness and excessive
confidence often cause accidents; the same applies to tiredness
and sleepiness.
It is a good idea to remember the following:
³The burner must only be used as expressly described.
Any other use should be considered improper and therefore
dangerous.
In particular:
it can be applied to boilers operating with water, steam,
diathermic oil, and to other users expressly named by the
manufacturer;
the type and pressure of the fuel, the voltage and frequency of
the electrical power supply, the minimum and maximum deliv-
eries for which the burner has been regulated, the pressurisa-
tion of the combustion chamber, the dimensions of the
combustion chamber and the room temperature must all be
within the values indicated in the instruction manual.
³Modification of the burner to alter its performance and destina-
tions is not allowed.
³The burner must be used in exemplary technical safety condi-
tions. Any disturbances that could compromise safety must be
quickly eliminated.
³Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
³Only those parts envisaged by the manufacturer can be
replaced.
2.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people
working around it.
The user:
³Undertakes to entrust the machine exclusively to suitably
trained and qualified personnel.
³Must take all the measures necessary to prevent unauthorised
people gaining access to the machine.
³Undertakes to inform his personnel in a suitable way about the
application and observance of the safety instructions. With
that aim, he undertakes to ensure that everyone knows the
use and safety instructions for his own duties.
³Must inform the manufacturer if faults or malfunctioning of the
accident prevention systems are noticed, along with any pre-
sumed danger situation.
³Personnel must always use the personal protective equipment
envisaged by legislation and follow the indications given in this
manual.
³Personnel must follow all the danger and caution indications
shown on the machine.
³Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
³Personnel are obliged to inform their superiors of every prob-
lem or dangerous situation that may arise.
³The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and all responsibility for any damage that may
be caused by the use of non-original parts.
2 Safety and prevention

20045701 6
Technical description of the burner
3.1 Technical data
Tab. A
(1) Reference conditions: ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
BF (Direct Vent Application) or CF (Chimney Vent Apllication)
*# 1 ASTM D 396 & # 2 Fuel Oil
3.2 Burner models designation
3.3 Accessories (optional)
• CF conventional flue conversion kit
• Light oil filter
NOTE
:
The installer is responsible for the supply and installation of
any required safety device(s) not indicated in this manual.
3 Technical description of the burner
Model RDB 2.2R T1 BF FCX22 RDB 2.2R T3 BF FCX30
Output (1)
Delivery (1)
Btu/hr(2)
GPH 70.000 - 98.000 0.50 - 0.70 81.200 - 154.000 0.58 - 1.10
Fuel # 1 and # 2 Fuel Oil
Operation Single stage
Nozzle number 1
Ambient temperature °F 32 - 104
Combustion air temperature °F max 140
Main power supply (+/- 10%) V/Ph/Hz Single phase, ~ 60Hz 120V ± 10%
Electric motors rpm 3450
Motor V
W - HP
A
µF
120
90 - 0.12
2.2
12.5
Ignition transformer Secondary 8 kV - 16 mA
Pump Delivery (at 174 PSI)
Pressure range GPH PSI 15 116 - 217
Electrical power consumption W max 150 - 0.2
Model Code Voltage Flame safeguard
RDB 2.2R T1 BF FCX22 20045452 120/1/60 Burner mounted
RDB 2.2R T3 BF FCX30 20045453 120/1/60 Burner mounted

Technical description of the burner
7 20045701
3.4 Burner description
1 Oil 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 Bleeder connection
8 Flame detector
9 Combustion head
10 Air intake (CF)
11 Motor
3.5 Packaging - weight - Approximate measurements
The burners are skid mounted. Outer dimensions of packaging are
indicated in Tab. B.
The weight of the burner complete with packaging is indicated in
Tab. B.
Tab. B
3.6 Standard equipment
1 - Burner head gasket
1 - Flange with insulating gasket
1 - Screw of by-pass pump
1 - Screw and nuts for flange
1 - 4 pin plug
1 - Hexagonal key
1 - Nipple 3/8 - 1/4
4 - Screws for flange to be fixed to boiler
1 - Nipple 3/8 - 3/8
2 - Pipe connectors
2 - Female adaptors 1/4 NPT
9
4
17
2
10
8
3
6
5
11
Fig. 1
D12187
inch A B C lbs
RDB 2.2R T1 BF FCX22 15 35/64“ 11 39/64“ 12 1/64“ 24.3
RDB 2.2R T3 BF FCX30 15 35/64“ 11 39/64“ 12 1/64“ 24.3 Fig. 2
D36

20045701 8
Technical description of the burner
3.7 Burner dimensions
The maximum dimensions of the burner is given in Fig. 3.
Fig. 3
Flange Burner CF version
3 25/64”8 9/64”
51/8”
51/64”
45°
ø31/2”
8 55/64”
7/16”
6 11/16”
D4592
253/64”
45°
9 11/64”
7 3/32”
5 23/64”5
29/32”
5 29/32”
D4087
253/64”
51/64”
8 9/64”
3 25/64”
611/16”
911/64”
855/64”
523/64”5
29/32”
ø31/2”
ø61/64”
Burner BF version

Technical description of the burner
9 20045701
3.8 Firing rate
WARNING
The firing rate area values (Fig. 4) have been obtained considering an ambient temperature of 68 °F, and an atmospheric
pressure of 30” Hg.
0. 8 0. 9 1. 0 1. 1 1. 2 1. 3
0. 0
0. 70. 60. 50. 4
0. 2
0. 4
0. 6
0. 8
1. 0
1. 2
1. 4
1. 6
1. 8
1. 4 1. 5
Fig. 4
D12188
Delivery - GPH
Combustion chamber pressure
“wc

20045701 10
Installation
4.1 Installation precautions
4Installation
WARNING
AIR FOR COMBUSTION
Do not install burner in room with insufficient air for combustion. Be sure there is an adequate air supply for combustion if
the boiler room is enclosed. It may be necessary to create a window to permit sufficient air to enter the boiler room.
The installer must follow local ordinances in this regard.
CANADA It is suggested that the installer follow CSA standard B139.
USA It is suggested that the installer follow NFPA manual #31.
CHIMNEY
Be sure chimney is sufficient to handle the exhaust gases. It is recommended that only the burner be connected to the
chimney. Be sure that it is clean and clear of obstructions.
OIL FILTER
An external oil filter is REQUIRED, even though there is an internal strainer in the pump.
The filter should be replaced at least once a year, and the filter container should be thoroughly cleaned prior to installing
a new filter cartridge.
DRAFT
Follow the instructions furnished with the heating appliance.
The pressure in the combustion area should be kept as close to zero as possible. The burner will operate with a slight draft
or pressure in the chamber.
ELECTRICAL CONNECTIONS
CANADA All electrical connections should be done in accordance with the C.E.C. Part 1, and all local codes.
The system should be grounded.
USA All electrical connections should be done in accordance with the National Electrical Code, and all local ordi-
nances. The system should be grounded.
CONTROL BURNER OPERATION
Check out the burner and explain its operation to the homeowner. Be sure to leave the Owner’s Instruction sheet with the
homeowner.
FIRE EXTINGUISHER
If required by local codes, install an approved fire extinguisher.
ELECTRICAL CONNECTIONS
In most localities, a number 14 wire should be used inside a metal conduit. The system should be grounded.
A service switch should be placed close to the burner on a fireproof wall in an easily accessible location.
WARNING
The burner settings used in this manual were obtained under laboratory conditions and may vary from those ob-
tained in the actual installation of the burner.
Combustion results must be verified using proper combustion test equipment.
Riello will not be responsible for the improper installation or set-up of the appliance.

Installation
11 20045701
4.2 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
4.3 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
With regard to the transport in the obligatory passages, refer to
the burner dimensions shown in Fig. 3, page 8.
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 quickly move if the burner should fall). During the handling,
keep the load at not more than 10” from the ground.
4.4 Preliminary checks
Checking the consignment
4.5 Working position
The burner is designed to work only in the positions 1, 2, 3 and 4
(Fig. 5).
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out by
qualified personnel, as indicated in this manual and
in accordance with the regulations of authorities
having jurisdiction.
Reference for the recommended installation prac-
tises shall be made to NFPA#31 for USA, CSA
Standard B139 (oil burner only) for Canada.
Oil-burning equipment shall be connected to flues
having sufficient draft at all times, to assure safe
and proper operation of the burner.
WARNING
The handling operations for the burner can be high-
ly dangerous if not carried out with the greatest at-
tention: keep any unauthorised people at a
distance; check the integrity and suitableness of the
available means of handling.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
CAUTION
After removing all the packaging, check the integrity
of the contents. In the event of doubt, do not use the
burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of dan-
ger and pollution; they should be collected and dis-
posed of in the appropriate places.
WARNING
The output of the burner must be within the boiler's
firing rate.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
WARNING
The burner must be installed in conformity with leg-
islation and local standards.
DANGER
Any other position could compromise the correct
working of the appliance.
Installation 4 is not recommended for safety rea-
sons.
Installation 5 is forbidden for safety reasons.
Fig. 5
S8218
1 2 3
4 5

20045701 12
Installation
4.6 Burner assembly
4.6.1 CF - Chimney Vent Application
In case of CF applications, the burner shall not operate without pro-
tection A)(Fig. 6) of the suction inlet.
4.6.2 BF - Direct Vent Application
In case of BF applications an optional snorkel and gasket are avail-
able replacing A) with B)(Fig. 6).
This item can be supplied separately.
The combustion air supply is through a flexible or rigid pipe con-
nected to the air intake.
Consequently, you must comply with the following requirements
and instructions:
The combustion air intake tube must be:
³fastened securely to the burner;
³made of a suitable material, with temperature characteristics
in the range - 22 °F to 176 °F;
³in compliance with all requirements of applicable regulations
in force in the country of destination.
³The intake-tube / burner system must not allow a loss of over
70.67 ft3/h at 0.2"wc: for instance, the above requirements will
be met if you use flues for pressure exhaust of flue gases (the
condensation kind).
³Make sure the air intake tube’s inlet is positioned so that it is
not likely to be obstructed by foreign matter and, where neces-
sary, use suitable screens.
³The temperature of the incoming air must not exceed 104 °F;
³The inside diameter of the intake tube must be at least 4 inch.
³The intake tube can be up to 100 ft in length.
³Under no circumstances should the air’s entry in the hose
intake area be obstructed.
³The hose must not be blocked in any way or feature a shutting
device (valves, membranes etc.).
³Coaxial tubes must not be installed for any reason.
WARNING
For correct bf application, the burner must be in-
stalled on an appropriate BF boiler.
WARNING
Length is reduced if there are bends in the intake
section.
For instance, using a tube with a smooth inside sur-
face, you must allow for the following losses:
– for each 45° bend, tube length is reduced by
5ft;
– for each 90° bend, tube length is reduced by
10 ft.
WARNING
Burner installation must comply with one of the in-
stallations illustrated in the Fig. 7.
D5884
D5883
Fig. 6
A
B

Installation
13 20045701
4.7 A typical layout for RDB burner intake air
A Use an approved air intake kit.
B Always keep intake air run to the minimum.
C Maximum intake air run of 4 (inch) diameter, flexible or rigid
type of venting = 100ft.
D Reduce intake air length by 10’ for every 90° elbow used. 5’
for every 45° elbow used.
E It is suggested that air intake venting be insulated with R7
(min.) foil lined insu lation a minimum of 10’ from air intake
source (prevent condensation or corrosion of intake air vent-
ing).
F Used approved type of intake air vacuum breaker and to be
installed in the same room and the burner, for the event of
intake air source being blocked, this device should be tested
to prove that in the event of intake air source is blocked that
the vacuum breaker balancer is set correctly and can provide
sufficient air for combustion for the burner.
If the room that the burner is installed into cannot provide
enough air or air quality is a concern, an additional air inlet
source will have to be providing to this room.
Fig. 7
S8212
RDB BF burner installation example
THIS INTAKE AIR LAYOUT FOR CHIMNEY APPLICATIONS ONLY
for retrofit applications
RDB 2.2R burner
Approved fresh air intake kit
Vacuum breaker or approved equivalent
Combustion air in
Flue gases out

20045701 14
Installation
4.8 Boiler fixing
³Put on the flange 1)(Fig. 8) the screw and two nuts.
³Fix the flange 1)(Fig. 9) to the boiler door 4) using screws 2).
³If necessary, the nuts 3)(Fig. 9) interposing the insulating gas-
ket 5).
Fig. 8
1
E9095
5
1
E9094
2
4
3
Fig. 9

Installation
15 20045701
4.9 Hydraulic systems
4.9.1 General warnings
On the market we can find many variants of liquid bio fuels and also
blends of mineral and bio-fuels of various origin, including low qual-
ity or not standardised products.
For this very important reason, damage to burner hydraulic compo-
nents can occur, when the fuel is changed.
4.9.2 Oil line connections
This burner is shipped with the oil pump set to operate on a single
line system.
To operate on a two-line system the by-pass plug 3)(Fig. 10) must
be installed.
Pump pressure must be set at time of burner start-up.
A pressure gauge is attached to the pressure port 4)(Fig. 10) for
pressure readings. Two pipe connectors 2) are supplied with the
burner for connection to either a single or twoline system.
Also supplied are two adaptors 1), two female 1/4” NPT, to adapt
oil lines to burner pipe connectors.
All pump port threads are British Parallel Thread design.
Direct connection of NPT threads to the pump will damage the
pump body.
Riello manometers and vacuum gauges do not require any adapt-
ers, and can be safely connected to the pump ports.
An NPT (metric) adapter must be used when connecting other
gauge models.
1 Adaptors
2 Pipe connectors
3 By-pass plug
4 Pressure port
5 Pressure adjuster
6 Suction gauge connection
7Valve
8 Auxiliary pressure test point
9 Pump cover
10 Supply port
11 Return port
WARNING
³Do not operate a single line system with the by-
pass plug installed.
³Operating a single line system with the by-pass
plug installed will result in damage to the pump
shaft seal.
WARNING
The pump requires periodic maintenance carried
out by a qualified and authorised technician in con-
formity with legislation and local standards.
Maintenance is essential for the reliability of the
pump, avoiding the excessive consumption of fuel
and consequent pollution.
WARNING
If the pump cover 9) is removed for any reason, be
sure the O-ring, is properly seated in the pump cov-
er before re-attaching the pump cover to the pump
housing.
WARNING
The suction plug 10)(Fig. 10) is made of plastic.
Once removed, it must not be used again.
In single-pipe installations, the plug in the return line
11)(Fig. 10) must be tottally in steel.
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 dam-
age of the pump seal.
WARNING
Fuel pipe supply system
³The fuel pipe supply system must be carried
out according to the indications supplied in the
instruction manual.
³It is advisable to use a pipe with internal diame-
ter of 3/8".
³Check periodically the pipes conditions.
³It is necessary to install a filter on the fuel sup-
ply line.
CAUTION
To install the by-pass plug
³Remove the return plug 11) and install the by-
pass plug 3) using the 2.5 mm hexagonal key.
Fig. 10
D10904
2
1
9
10
311
4
5
7
6
8

20045701 16
Installation
4.9.3 Priming pump
On the system in Fig. 11 it is sufficient to loosen the suction gauge
connection 6)(Fig. 10) and wait until oil flows out.
On the systems in Fig. 12 and Fig. 13 start the burner and wait for
the priming. Should lock-out occur prior to the arrival of the fuel,
await at least 20 seconds 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. 13) 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.
H= difference of level
L= Max. lenght of the suction line
P= Max. lenght
WARNING
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.
SINGLE LINE SYSTEM-PIPE LENGHTS
H
ft
L ft
3/8” 12/”
1.5
3.0
5.0
6.5
33
65
130
195
65
130
260
325
H
P
min. 0.33 ft
D5741
Fig. 11
Fig. 12
H
D1842
P
H
TWO LINE SYSTEM-PIPE LENGHTS
H
ft
L ft
3/8” 12/”
0
1.64
3.29
4.93
6.58
9.87
11.5
115
100
80
65
50
25
20
330
330
330
295
230
100
65
WARNING
³Pipe dope or Teflon tapes are NOT to be used
on any direct oil connection to the fuel pump.
³The height ‘P’ in pipe length charts should not
exceed 13 feet (4 m).
³The vacuum should not exceed 11.44 inches of
mercury.
WARNING
An external, appropriately listed and certified oil fil-
ter must be placed in the fuel line between the fuel
tank and the burner pump.
WARNING
ALWAYS KEEP THE VALVE FROM THE TANK
SHUT OFF IF THE BURNER IS SHUT DOWN FOR
AN EXTENDED PERIOD OF TIME.
WARNING
IT IS IMPORTANT THAT THE FUEL LINE BE
COMPLETELY SEALED AND FREE FROM AIR
LEAKS OR ANY INTERNAL BLOCKAGES.
WARNING
WHEN THE BYPASS PLUG IS INSTALLED, A
TWO-PIPE SYSTEM MUST BE USED OR FAIL-
URE OFTHE PUMP SHAFT WILL OCCUR.
D5740
Fig. 13
HP
H

Installation
17 20045701
4.10 Electrical wiring
Testing:
Check the shut-down of the burner by opening the thermostats and
the lock-out by darkening the photoresistance.
4.10.1 Control box
To remove the control box (Fig. 14) from the burner proceed as fol-
lows:
³loosen the screw 1), open the protection 2) and remove all
components;
³remove the coil 3) and loosen the two screws 4);
³move a little the control box and remove the high voltage
leads.
DANGER
³The electrical wiring must be carried out with the electrical supply disconnected.
³Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force in
the country of destination.
³The manufacturer declines all responsibility for modifications or connections different from those shown in the electri-
cal layouts.
³Do not invert the neutral with the phase in the electrical supply line.
Any inversion would cause a lockout due to firing failure.
³The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement.
In the event of doubt, have the electrical system checked by qualified personnel.
Do not use the gas tubes as an earthing system for electrical devices.
³The electrical system must be suitable for the maximum input power of the device,as indicated on the label and in the
manual, checking in particular that the section of the cables is suitable for the input power of the appliance.
³Do not touch the device with wet or damp body parts and/or in bare feet.
³Do not pull the electric cables.
³Wires of AWG 18 or 16 (0.82 or 1.31 mm2) section and standard rated 221° F. (Unless requested otherwise by local
standards and legislation).
WARNING
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
The installation of the control box must be carried
out by qualified personnel, as indicated in this man-
ual and in compliance with the standards and regu-
lations of the laws in force.
E9151 Fig. 14
12
3
4
4

20045701 18
Installation
4.11 Electrical wiring
PA
h
~ 60Hz - 120V
LNPE
Main switch
Fuse T6A
Safety
thermostat
Limit
thermostat
7 pin plug
7 pole socket
CONTROL BOX
535ARSE/LD
Ignition
electrodes
Burner-earth
Motor
Capacitor
Heater
Start
thermostat
Black
White
Black
White
Blue
Remote lock-out lamp
(120V - 0.5A max.)
Carried-out
in the factory
To be done by
the installer
Oil valve
Photoresistance
Air pressure
switch
20050153
White
Black Black
Green