Riello 3433823 Quick start guide

2916192 (0)
Montage und Bedienungs Anleitung
Manuel d’entretien
Installation, use and maintenance instructions
Istruzioni per installazione, uso e manutenzione
Bruciatore di nafta
Heizölbrenner
Heavy oil burner
Brûleur à fioul lourd
CODICE
CODE
MODELLO - MODELL
MODELE - MODEL TIPO - TYP
TYPE
3433823 PRESS 30 N/ECO 626 T
3433824 PRESS 30 N/ECO 626 T
I
D
GB
F
Funzionamento bistadio
Zweistufiger Betrieb
Two-stage operation
Fonctionnement à deux allures

6192 1 GB
INDEX
1. BURNER DESCRIPTION
Two-stage operation fuel-oil burner.
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Field of operation . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3
3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 3
3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 4
3.3 Electrical connections . . . . . . . . . . . . . . . . 5
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 6
4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6
4.3 Combustion head adjustment . . . . . . . . . . . . 6
4.4 Air damper motor adjustment . . . . . . . . . . . . 6
4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . . .7
4.6 Atomisation temperature adjustment . . . . . . . 7
4.7 Start-up programme. . . . . . . . . . . . . . . . . . . . 9
4.8 Ecological oil burners . . . . . . . . . . . . . . . . . . 9
4.9 Emulsified fuel oil operation . . . . . . . . . . . . . 9
4.10 Start-up programme diagnostic . . . . . . . . . . 10
4.11 Operating fault diagnostic . . . . . . . . . . . . . . 10
2893
OThe burner corresponds with IP 40 grade of protection in accordance with EN 60529.
OBurner with CE marking in conformity with EEC directives: CEM 89/336/EEC, Low Voltage 73/23
/
CEE, Machines 98/37/EEC and Yield 92/42/EEC.
OIn conformity with the Yield Directive 92/42/EEC, the application of the burner to the boiler, adjustmen
t
and testing must be carried out in compliance with the said boiler's instruction manual, including the
checking of the CO and CO2concentration in the fumes, their temperature and the average temperature
of the boiler water.
1 - Suction fitting
2 - Return fitting
3 - Pump pressure adjustment screw
4 - Manometer fitting (G1/8)
5 - Vacuometer fitting (G1/2)
6 - Air damper opening motor
7 - Control box reset button and lock-out indicator
8 - Fan overload cutout reset
9 - Regulating screw for combustion head
10 - Double filter
11 - Valve group
12 - Manometer with protection valve
13 - Adjustment thermostat
14 - Pre-heater contact maker
15 - Transformer
16 - Terminal board
17 - Cable glands
18 - Antigas valve
19 - Thermometer
20 - Pump motor starter with reset
21 - Air pressure switch
Fig. 1
1.1 EQUIPMENT
Flexible tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples . . . . . . . . . . . . . . . . . . . . . . . No. 2
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Screws. . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Guide extensions (for the lengthened
head version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fitting for emulsified fuel oil
emulsified (see page 9) . . . . . . . . . . . . . . . . . . . . . No. 1

6192 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 DIMENSIONS
2.3 FIELD OF OPERATION (2 functioning nozzles)
TYPE 626 T
Thermal power - Capacity 85/171 - 342 kW – 7.5/15 - 30 kg/h
Fuel Oil with max. viscosity at 50° C 115 sq.mm (15° E)
Power supply Three-phase, 230 V ±10% ~50Hz without neutral
400V ±10% ~50Hz with neutral
Motor 230V - 400V Fan: 2.4A - 1.4A
Pump: 2.1A - 1.2A
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 2.8 kW
Intake electrical power 4.1 kW
Pump 60 kg/h at 20 bar
D2715
D2628
BurnerBoiler plate
NOTE
The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised
to hold the burner while it is being extracted so as not damage the flame disc and the said guides.
For elongated - head version.
Use the pin extensions provided as accessories when pulling the burner back.
*
783 185
320
625
290
*
94
Diam. 161
305
Thermal power
Pressure in combustion
chamber – mbar
D2627
When the burner operates with only one nozzle, the pressurisation conditions are better and no problems
arise. Minimal flow rate with one only nozzle: 7.5 kg/h - 85 kW.
kg/h
kW

6192 3 GB
3. INSTALLATION
3.1 FUEL OIL SUPPLY SYSTEMS
GRAVITY SYSTEM
SUCTION SYSTEM
LOOP SYSTEM (max loop system pressure 3 bar)
H
metres
L metres
Diam.
3/4”
Diam.
1” gas
0510
0.5 8 15
11120
1.5 14 25
21730
Pump priming:
loosen the tap from the vacuometer fitting
(5, fig. 1) and wait for the fuel to flow out.
H: Difference in height
L: Length of the suction tube
For light oil with max. viscosity 7°E at 50°C.
D2720
max. 30m
H
H
metres
L metres
diam.
1” gas
diam. 1
1/4”
02445
0.5 21 40
11835
1.5 15 30
21225
2.5 9 20
3615
Not advised. To be used only in case of
previously existing system.
Never exceed the max. vaccum of 0.5 bar
(38 cm Hg) measured at the vacuometer
fitting (5, fig. 1).
The pipes should be perfectly airtight.
When the tank is placed below of the burn-
er level, the return pipe should arrive at the
same level as the suction pipe.
In this case the foot valve is not required.
For light oil with max viscosity 7°E at 50°C.
D2721
max. 30m
HH
1- Tank (heated for heavy oil) 5- Transfer pump
2- Filter (with resistor for oil > 7°E / 50°C) 6- Control manometer
3- Burner 7- Burner pump
4- Burner cut-out gate valves (coupled) 8- Pressure adjuster
For heavy oil with viscosity up to 20°E / 50°C.
Important note: to allow the fuel to flow properly, all the pipes have to be properly sized, insulated and heat-
ed (electrically or by means of steam or hot water).
Warning: before using the burner, make sure that there is no obstruction in the return pipe,
any obstruction may damage the sealing of the pump.
D2631

6192 4GB
3.2 BURNER ELECTRICAL SYSTEM (made in the factory)
RMO88.53A2
PA
PMP
246 96
95
A2
135
M
3
14
13 A1
TB
RT1
1
Tm
TA
1512 16
TB
10
171318 9 5 8114
V1
TB
FR
SM
M
R2
R1
ST2
ST1
ST0
HS1
MV2
-+
1
4
3
5
2
11
6
8
7
V2
TE
R2 R3
RT
TM
MV
246 95
96
A2
135
M
3
14
13 A1
531
624
A1
A2
CR
S
MB
F
R1
TB
A
P
12
L1R
NL1 L2 L3 LN S3 T1 30T2T6T8
V21 V22
L1P L2P L3P
CMP
CMV
CMP Pump motor contact maker
CMV Fan motor contact maker
CR Pre-heater contact maker
FSuppressor
FR photocell
MB Burner terminal strip
MP Pump motor
MV Fan motor
PA Air pressure switch
R1 Spray holder resistor
R2 Pump resistor
R3 Valve assembly resistor
RMO Electrical control box
RT Fan motor thermal relay
RT1 Pump motor thermal relay
SPre-heater tank
SM Servomotor
TA Ignition transformer
TB Burner earth
TE Regulation thermostat and start-up enabling
signal
Tm Minimum contact thermostat
Tm Maximum contact thermostat
V1 First stage valve
V2 Second stage valve
2598

6192 5 GB
3.3 ELECTRICAL CONNECTIONS TO THE TERMINAL STRIP (to be made by the installer)
FASTENING OF THE ELECTRICAL WIRES
All the wires to be connected to the terminal strip (16, fig. 1) shall pass through the appropriate cable entries
(17, fig. 1), see the figure below.
Any other signals or controls can be connected to the burner terminal strip by pushing out the metal disc in the
pre-sheared holes and inserting a common cable entry for the passage and the clamping of the leads. To ensure
the IP 40 degree of protection in compliance with EN 60529 close any unused cable entries with appropriate
discs.
NOTES
- Make a safe earth connection.
- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.
IN Manual switch
MB Burner terminal strip
HLock-out signal
TL Limit remote control
TR Adjustment remote control
TS Safety remote control
NOTE
Wire cross-section: min. 1 sq. mm.
(Unless otherwise required by local standards
and legislation).
TWO STAGE OPERATION
It is achieved by means of the remote control
device connected to terminals 5-6 (removing
the jumper), that controls the second valve. RESISTOR CONNECTIONS
D2634
PRE-HEATER
2610
230V 400V
A Ampere 10 6
B Ampere 6 4
C sq.mm 1.5 1.5
D sq. mm 2.5 1.5
D2635
1- Single phase pre-heated resistor
power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21
2 - Three-phase power supply: . . . . . . . . . . . .cable entry Pg 16
3 - Single phase power supply and
safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
4- Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
5-2
nd stage thermostat:. . . . . . . . . . . . . . . . .cable entry Pg 13.5

6192 6GB
4. OPERATION
4.1 CHOICE OF NOZZLES
Recommended nozzles:
- Monarch F 80 H0.
4.2 PUMP PRESSURE
Recommended pressure:
- Fluid oil: 20 bar
- Heavy oil: 25 bar
Rated deliveries of the nozzles are indicated on the above
list and refer to a light oil (viscosity from 3 to 5°E at 50° C pre-
heated at 100°C). The actual flow rate may vary by ± 5%
compared with the rated flow rate.
In values in between those indicated in the tables are
required, the pump pressure could be changed or the
composition of the nozzles varied.
The pump leaves the factory set at 20 bar.
4.3 COMBUSTION HEAD ADJUSTMENT
Turn the screw A, fig. 2 till the set-point, detected from the dia-
gram, is in the line with the washer B, fig. 2.
4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR
STOP - Blue lever
This lever leaves the factory vertically positioned and corre-
sponds to the air damper fully closed.
A partial opening of the air damper might be obtained by
moving this lever leftwards (+on the plate).
The new position of the air damper is detectable when the
burner stops.
Do not exceed the position of the orange lever for the
1st stage.
1st STAGE - Orange lever
The orange lever controls the air damper position for the first
flame, it is adjustable both for opening and closing.
2nd STAGE - Red and black levers
The red lever controls the air damper position for the second
flame, it is adjustable both on closing and opening.
The black lever controls the opening of the second oil valve
and it must always be slightly before the red lever, but never
the first stage orange one.
Nozzle
GPH (45° - 60°)
20 bar
kg/h
25 bar
kg/h
1.25 + 1.25 15.00 17.00
1.50 + 1.50 18.00 20.30
1.75 + 1.75 21.00 23.80
2.00 + 2.00 24.00 27.10
2.25 + 2.25 27.00 30.50
2.50 + 2.50 30.00 –
D2638
Black lever
Red lever
Orange lever
Blue lever
Opening +–Closing
kg/h
Set-points
D2636
D2637
B
Set-point 4
A
Fig. 2

6192 7 GB
4.5 AIR PRESSURE SWITCH
4.6 ATOMISATION TEMPERATURE ADJUSTMENT
Control thermostat - minimum value - maximum value
Adjustment thermostat prevents the burner start up if the fuel temperature has not reached the value required
for a better atomisation as indicated in the diagram below.
Example
Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.
The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob
to get approximately 100°C at the nozzles).
The value has to be read after some minutes of operation and later the necessary adjustments carried out.
Minimum value contact thermostat intervenes by stopping the burner if the fuel temperature falls below
the value necessary for better combustion.
Maximum value contact thermostat switches off the resistors when in case of failure of the adjustment
thermostat, the temperature increases inside the pre-heater. In case of abnormal cut ins ,check the control
thermostat the resistor in contact with the said thermostat probe are operation properly.
D2640
D2719
Thermostat adjustment
knob
Pre-heater
Purge
Atomisation temperature
Viscosity at 50° C
sq. mm/sec °E
°C
Carry out the regulation of the air pressure switch after
carrying out all the other regulations of the burner with
the air pressure switch regulated at the beginning of
the scale.
With the burner operating at the MIN power increase
the pressure of the adjustment by slowly turning the
appropriate knob clockwise until the burner locks out.
Then turn the knob counterclockwise to a value equal
to about 20% of the regulated value and then check
the correct start up of the burner. If the burner locks out
again turn the knob a bit further in a counterclockwise
direction.
D68
D 521

6192 8GB
IMPORTANT NOTES
If the pre-heater thermostat or the resistor in contact with
the probe is to be replaced, the probe has to be positioned
in contact with the resistor and with the pipes of the last
aluminium plate, after loosening of the fixing screws of the
aluminium plate pack. See drawing opposite.
If, during the operation exceptional differences or temper-
atures that peak too high should be detected, verify the
continuity of the resistor, using an ohmmeter, contacting
the temperature probe (value approximately 35 Ohm).
Only use filters marked with a recognizable printing on the screwing hexagon.
NOTES
yThe pre-heater might be fitted with a second thermostat of maximum value.
This thermostat can be used as a switch on an external contact maker to cut off current to the pre-heater in
case of excess temperature (Kit code no. 3000800).
yResistor Ron the nozzle-holder is wired to the supply line of the pre-heater (see pag. 4).
When the burner is off, the pre-heater supply line shall remain fed.
Should the pre-heater line be turned off, the fuel must be pre-heated for approximately 30 minutes before the
burner start-up. On the contrary, the nozzle-holder resistor must be supplied with an independent single-
phase line, protected by a 1A fuse.
This line shall never be switched off, when the burner is off.
yBefore the burner start-up, verify that the pump is filled of fuel in order to avoid it running empty for too long.
yFilter cleaning:
periodically clean the filters in order to avoid malfunctioning in burner operation.
ySupply line filter:
positioned on the suction line, it causes the increase of the vacuum in the pump with the consequent flow of
gas and noise. Do not exceed the vacuum of 38 cm Hg (5 m W.c.) at the vaccumeter attachment (5, fig. 1).
yPre-heater filter (10, fig. 1):
positioned in the delivery line, it causes a decrease of the atomising pressure which can be checked on
the manometer (12, fig. 1).
MANOMETER PROTECTION VALVE
After atomising pressure check, it is recommended to cut off the manometer (12, fig. 1) to avoid pressure shocks
that it might be subjected to at every burner starting.
Close protection valve when the burner is not operation and the manometer indicates 0 bar.
Thermostat probe
Resistor
Plate tubes
Plate
D2751

6192 9 GB
4.7 BURNER START-UP PROGRAMME
Motor lock-out
It is caused by the thermal motor overload relay if there is an overload or no phase.
4.8 ECOLOGICAL OIL BURNERS
WARNING
The transition from normal fuel oil to ecological fuel oil requires:
yThe tank to be emptied of normal fuel oil.
yCleaning of the tank and the pipes that carry the fuel oil to the burner.
yApplication of a filter if there is not one already on the burner fuel line with a filtering grade of 0.3 mm maxi-
mum.
If this is not done, Riello S.p.A. declines all liability if the burner fails to work properly or wears out prematurely.
NOTES
These burners are the result of careful study that allows them to be used with ecological fuels as well; oils, that
in certain temperature and speed conditions, are particularly aggressive for the vital parts of the burner.
The objective has been achieved with the reduction of the transiting speed in some of the parts and an appropri-
ate choice of materials (in particular surface treatments) as well as a redefinition of the backlashes and coupling
tolerances.
The burners for ecological oils are very different from normal fuel oil burners because they have a separate
pump (worked by its own motor at 1400 rpm) and the fact there is double filtration between pump and nozzle.
4.9 EMULSIFIED FUEL OIL OPERATION
Lock-out because of no ignitionNormal
Thermostat
Motors
Ignition transformer
1st flame valve
2nd flame valve
Lock-out indicator
2894
D3435
WARNING
In emulsified fuel oil it is necessary
to change the fitting on the burner
(*) with the one supplied with it.

6192 10 GB
4.10 START-UP PROGRAMME DIAGNOSTIC
During the start-up programme, the indications are shown in the following table:
4.11 OPERATING FAULT DIAGNOSTIC
The control box has a self-diagnostic system by which it it is possible to simply identify the possible causes
of malfunctioning (signal RED LED).
To use this function, wait at least ten seconds from the moment the control box is placed in safety mode,
and then press the reset button for a minimum of 3 seconds.
After releasing the button, the RED LED starts flashing as shown in the diagram below.
The pulses of the LED constitute a signalwith intervals of approximately three seconds.
The number of pulses will provide the information on the possible faults, as per the table below:
COLOUR CODE TABLE
Sequences Colour code
Preventilation
Ignition phase
Operation with flame ok
Operation with weak flame
Electrical supply lower than ~170V
Lock-out
Extraneous light
Key: Off Yellow Green Red
SIGNAL PROBABLE CAUSE
2 blinks No stable flame is detected in the safety time:
– photocell fault;
– oil valve fault;
– neutral/phase reversal;
– faulty ignition transformer
– poor burner regulation (insufficient fuel oil).
3 blinks Min. air pressure switch (if installed) does not close:
– air pressure switch faulty;
– air pressure switch not regulated;
– max. air pressure switch triggered (if installed).
4 blinks Min. air pressure switch (if installed) does not open or light in the chamber before
ignition:
– air pressure switch faulty;
– air pressure switch not regulated.
7 blinks Loss of flame during operation:
– burner not regulated (insufficient fuel oil);
– oil valve fault;
– short circuit between photocell and earth.
8 blinks – Not used.
10 blinks – Wiring error or internal fault.
RED LED on
wait at least 10 s
press the button
for > 3 secs. signal signal
Interval
3 secs

RIELLO S.p.A.
I - 37048 San Pietro di Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com
Con riserva di modifiche - Änderungen vorbehalten! - Subject modifications - Sous réserve de modifications