Riello 468 M1 Quick start guide

Montage und Bedienungs Anleitung
Manuel d’entretien
Installation, use and maintenance instructions
Istruzioni per installazione, uso e manutenzione
2915837 (1)
Bruciatore di nafta
Heizölbrenner
Heavy oil burner
Brûleur à fioul lourd
CODICE
CODE
MODELLO - MODELL
MODELE - MODEL
TIPO - TYP
TYPE
3438958 PRESS 300 T/N 468 M1
3438959 PRESS 300 T/N 468 M1
3438960 PRESS 300 T/N 468 M1
3438961 PRESS 300 T/N 468 M1
3438962 PRESS 300 T/N 468 M1
3438963 PRESS 300 T/N 468 M1
I
D
GB
F

5837 1GB
INDEX
1. BURNER DESCRIPTION
One, two, third stage heavy oil burner.
1.1 BURNER EQUIPMENT
Flexible tubes . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Cable clamps . . . . . . . . . . . . . . . . . . . . . . No. 5 Screws . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Gasket for flange. . . . . . . . . . . . . . . . . . . . No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . No. 3
Extensions (only long head). . . . . . . . . . . . No. 2
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . 3
2.3 Working field . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 4
3.1 Heavy oil supply line . . . . . . . . . . . . . . . . . . 4
3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 5
3.3 Electrical connections . . . . . . . . . . . . . . . . 8
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . 10
4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . 10
4.3 Combustion head setting . . . . . . . . . . . . . . .11
4.4 Air shutters adjustments . . . . . . . . . . . . . . . .11
4.5 Spray temperature adjustment . . . . . . . . . . 12
4.6 Burner start-up cycle . . . . . . . . . . . . . . . . . 13
4.7 Three stage operation . . . . . . . . . . . . . . . . 13
4.8 Burner start-up cycle diagnostics . . . . . . . . 14
4.9 Operating fault diagnostics . . . . . . . . . . . . . 14
■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
and Machines 98/37/EEC.
1 - Suction line
2 - Return line
3 - Air shutter opening motor
4- Pump pressure adjustment screw
5 - Manometer plug (G1/4)
6 - Vacuometer plug (G1/4)
7 - Reset push-button of the motor overload relay
8- Electric board
9 - Cable clamps
10 - Control box reset push-button and lock-out lamp
11 - Adjustment thermostat
12 - Regulating bush for combustion head
13 - Wiring terminal board
14 - Ignition transformer
15 -Filter
16 - Valves group
17 - Manometer
18 -Lamp
19 - Commutator
20 - Low limit thermostat
21 - High limit thermostat
22 -Timer
Fig. 1

5837 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
OPERATION AND EFFICIENCY OF THE BURNER
TYPE 468 M1
Thermal power - Output 626 - 3420 kW – 55 - 300 kg/h (see tables below)
Fuel Oil with max. viscosity at 50° C 50 mm2/s (7° E)
for oil up to 500 mm2/s (65° E) with kit
Electrical supply Three-phase, 230V ±10% ~50Hz without neutral
400V ±10% ~50Hz with neutral
Motor (with starter ) 30 A / 230V – 17.5 A / 400V
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 19.6 kW
Absorbed electrical power 30 kW
Pump 470 kg/h at 25 bar
1st STAGE
Thermal power - Output
Minimum Maximum
kW kg/h kW kg/h
1st nozzle: ignition phase 570 50 1140 100
1st+2nd nozzle: intermediate phase 1140 100 2280 200
1st+2nd+3rd nozzle: operation phase 1710 150 3420 300
2nd STAGE
Thermal power - Output
Minimum Maximum
kW kg/h kW kg/h
1st nozzle: ignition phase 570 50 1140 100
1st+2nd nozzle: 1st stage of operation 1140 100 2280 200
1st+2nd+3rd nozzle: 2nd stage of operation 1710 150 3420 300
3rd STAGE
Thermal power - Output
Minimum Maximum
kW kg/h kW kg/h
1st nozzle: 1st stage of operation 570 50 1140 100
1st+2nd nozzle: 2nd stage of operation 1140 100 2280 200
1st+2nd+3rd nozzle: 3rd stage of operation 1710 150 3420 300

5837 3GB
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD (3 nozzles in operation)
Burner
COMBUSTION HEAD PROJECTION
For the combustion head projection carefully follow
the boiler manufacturer indications.
A proper protection with refractory material on the
combustion head projecting into the combustion
chamber shall be made, when boilers with frontal
smoke box are used.
Boiler front plate drilling
D2776
1000 246
376
506
858
447
496
ø 295
*
260
M18
260 300
D2777
It is possible with a spacer, upon request.
*
128
Thermal power
Pressure in combustion
chamber – mbar
When the burner operates with only one or two nozzles, the pressurization conditions are improved and no
problems arise.
limit
safety
Working field:
kg/h
kW
D2765

5837 4GB
3. INSTALLATION
3.1 HEAVY OIL SUPPLY LINE
RING SUPPLY LINE
For heavy oil with viscosity up to 50°E/50°C.
WARNING
- The oil could easily flow through the pipes if those are properly seized, protected and heated (by electricity,
steam or hot water).
- The forwarding pump capacity should be all the least double of that of the burner pump.
If several burners are supplied through the same ring supply line, the forwarding pump should have a capacity
of approx. 30% more than the sum of the single burners outputs.
- For starting-up: after excluding the burner by the shutter valves (5) let the oil flow into the supply ring up to
reach the required circulation; after than open the valves and supply normally the burner.
GRAVITY SUPPLY LINE
Only for oil with max. viscosity up to 7°E/50°C.
Attention:
before placing the burner in operation, ensure that the return line is open. Any obstruction may damage the pump
seal.
1- Tank (heated for heavy oil) 6- Burner (provided with kit for heavy oil code no. 3000721)
2- Filter (with resistance for oil > 7°E/50°C) 7- Pressure adjuster
3- Forwarding pump 8- Filter (with resistance for oil > 7°E/50°C)
4- Control manometer 9- Burner pump
5- Shutter valves (in couple)
excluding the burner
D2734
H
meters
L meters
ø 1” ø 1 1/4”
0210
0.5 3 11
1412
1.5 5 13
2614
Pump priming:
loose the tap of the vacuometer plug (6,
fig. 1) and wait for the oil flow.
H: Difference in the pipes height
L: Total length of the suction tube
D2735
H
max. 10m

5837 5GB
3.2 ELECTRICAL SYSTEM
CMV Fan motor contact maker
CR Resistor contact maker
CO Commutator
FR Photoresistence
L1 Lamps for 1st stage
L2 Lamps for 2nd stage
L3 Lamps for 3rd stage
MB Burner terminal strip
MV Fan motor
RMO Control box
RT Overload
SPre-heater tank
SM Air-damper actuator
SO Probe PT100
TA Ignition transformer
TB Burner earth
TE Electronic thermostat
Tm Minimal thermostat
TM Maximal thermostat
TP Timer
V1 Oil valves for 1st stage
V2 Oil valves for 2nd stage
V3 Oil valves for 3rd stage
VS Safety valve
D2737
D2738
PRE-HEATER CONNECTION
THERMOSTAT
COMMUTATOR
Brown Blue Black
PROBE TO ELECTRONIC
D2618
DIRECT START-UP
(carried out by the factory)

5837 6GB
CR Resistor contact maker
CO Commutator
FR Photoresistence
L1 Lamps for 1st stage
L2 Lamps for 2nd stage
L3 Lamps for 3rd stage
MB Burner terminal strip
MV Fan motor
RMO Control box
SPre-heater tank
SM Air-damper actuator
SO Probe PT100
TA Ignition transformer
TB Burner earth
TE Electronic thermostat
Tm Minimal thermostat
TM Maximal thermostat
TP Timer
V1 Oil valves for 1st stage
V2 Oil valves for 2nd stage
V3 Oil valves for 3rd stage
VS Safety valve
D2737
D2738
PRE-HEATER CONNECTION
THERMOSTAT
COMMUTATOR
Brown Blue Black
PROBE TO ELECTRONIC
STAR-TRIANGLE START-UP
(carried out by the factory)
D2624

5837 7GB
MA Starter terminal strip
SDisconnecting switch with interlock
FPower line fuses
F1 Control devices fuse
K1 Line contact maker
K2 Star contact maker
K3 Delta contact maker
K4 Timer relay for switching from star to delta
(factory calibration at 10s)
K2A Auxiliary contact block on k2
K3A Auxiliary contact block on k3
RT Thermal relay to be set at 9A for 400V
or at 18A for 230V
D2767
D2768
STAR-TRIANGLE STARTER

5837 8GB
3.3 ELECTRICAL CONNECTIONS TO THE BURNER TERMINAL STRIP
NOTE:
®Check the lock-out by darkening the photo-cell after removal of the cover.
ATTENTION HIGH VOLTAGE.
®In case of supply 230V without neutral, connect the motor and the pre-heater thank through delta (the “star”
connection is the original one, made for 400V).
DIRECT START-UP
(to be carried out by the installer)
D2619
HRemote lock-out signal
IN Optional switch on-off burner
MB Burner terminal strip
PS Reset push - button
SA High temperature oil alarm
TL Limit control device system
TS Safety control device system
T2 Load control system for 2nd stage
T3 Load control system for 3rd stage
230V 400V
A Ampere T63 T50
B Ampere T63 T50
C mm264
D mm210 6

5837 9GB
NOTE:
®Check the lock-out by darkening the photo-cell after removal of the cover.
ATTENTION HIGH VOLTAGE.
®In case of supply 230V without neutral, connect the pre-heater thank through delta (the “star” connection is
the original one, made for 400V).
STAR-TIRANGLE START-UP
(to be carried out by the installer)
D2625
230V 400V
A Ampere T63 T50
B mm210 6
C mm264
D mm242,5
HRemote lock-out signal
H1 Motor trip signal
IN Optional switch on-off burne
MA Start-up terminal strip
MB Burner terminal strip
PS Reset push - button
SA High temperature oil alarm
TL Limit control device system
TS Safety control device system
T2 Load control system for 2nd stage
T3 Load control system for 3rd stage

5837 10 GB
4. WORKING
4.1 CHOICE OF NOZZLES
First of all state the maximum output required with all three
nozzles in operation.
On the base of the maximum output choose, from table A,
three related nozzles.
Nozzles: 60° - Pump pressure: 25 bar.
The references of table B should be followed in case of
need of:
- modification of the pump pressure in order to vary the
output,
- diverse composition of the 3 nozzles group,
- knowledge of the output in 1st and 2nd stage.
4.2 PUMP PRESSURE
The pump pressure is referred to all three nozzles operating.
The pump pressure increases automatically when two noz-
zles are operating and becomes higher with only one nozzle.
Suggested pressure:
- Light oil: 25 bar
- Heavy oil: 28 bar (transformation kit)
Rated nozzles deliveries are listed on the table.
A tolerance of ±5% concerns the real delivery against the
rated one.
The pump leaves the factory set at 25 bar.
ANozzles
GPH 60°
Total output
kg/h 1st+2nd+3rd
1st 2nd 3rd 25 bar 28 bar
8.00 8.00 8.00 150 159
8.30 8.30 8.30 156 165
8.50 8.50 8.50 159 171
9.00 9.00 9.00 168 180
9.50 9.50 9.50 177 189
10.00 10.00 10.00 186 198
10.50 10.50 10.50 195 210
11.00 11.00 11.00 207 219
12.00 12.00 12.00 228 240
13.00 13.00 13.00 246 261
13.80 13.80 13.80 258 279
14.00 14.00 14.00 264 282
15.00 15.00 15.00 285 300
15.30 15.30 15.30 291 –
16.00 16.00 16.00 300
BGPH 25 bar
kg/h
28 bar
kg/h
8.00 50 53
8.30 52 55
8.50 53 57
9.00 56 60
9.50 59 63
10.00 62 66
10.50 65 70
11.00 69 73
12.00 76 80
13.00 82 87
13.80 86 93
14.00 88 94
15.00 95 100
15.30 97 102
16.00 100 107
D2741
1st
2nd 3rd

5837 11 GB
4.3 COMBUSTION HEAD ADJUSTMENT
On the base of the maximum delivery detect, from dia-
gramm C, the combustion head adjustment.
The adjustment should be made by turning the screw A
till the set-point (see diagram) is on the line with the
washer B.
4.4 AIR SHUTTERS ADJUSTMENTS
The adjustment of the air shutters shall be set each time,
with reference to the nozzles deliveries and the combustion
chamber pressurization.
Fig. 2 shows the positioning of the air shutters.
Fig. 3 shows the positioning of the cams of the motor.
1st STAGE adjustment:
manual regulation carried out by acting on the sector A,
fig. 2.
2nd - 3rd STAGE adjustment:
carried out by acting on the coloured levers of the motor
fig. 3:
Blue lever:
adjustment not necessary. Positioned by the factory on
the vertical of the motor axis. It maintains the shutters of
2nd and 3rd stage closed during the 1st stage operation
and in the stop periods. Do not turn clockwise (–) the le-
ver to avoid crawlings of the air shutters, turning the lever
anticlockwise (+) the motor will be in different position
during the passage from 2nd to 1st stage or during the
stop.
Orange lever:
for 2nd stage air shutters adjustment, it is adjustable both
in opening and in closing position.
Red lever:
for 3rd stage air shutters adjustment, it is adjustable both
in opening and in closing position.
Black lever:
it controls the opening of the 2nd stage oil valve. It has al-
ways to anticipate the orange lever.
The control of the 3rd stage valve is automatic through
one of the cam next to the red lever.
kg/h
Set-point
D2773
C
D2774
Fig. 2
Air shutter position 2nd and 3rd stage
2nd and 3rd stage air shutter motor
Sector A 1st stage air shutter
MV2 - Black lever
ST3 - Red lever
ST2 - Orange lever
0 - Blue lever
Opening +–Closing
Fig. 3 Black lever has to anticipate
the orange one
D2745
D2743
B
Set-point 6
A

5837 12 GB
4.5 SPRAY TEMPERATURE ADJUSTMENT
Thermostat for adjustment - maximum value - minimum value
Electronic adjustment thermostat by means of information relayed from a PT100 probe immersed in the
oil in the delivery manifold, the thermostat adjusts spray temperature. (The correct conditions for fuel spray
are shown in the temperature/viscosity graph below).
Example: fuel oil with 7 °E viscosity at 50 °C is pre-heated to approximately 110 °C.
Important: although the temperature set on the thermostat should correspond to the temperature of the fluid, it
is good practice to check that the thermometer shows the correct reading once the unit has been in operation for
a few minutes. The LED will illuminate to indicate that the heating resistances are working properly.
Minimum temperature thermostat, in addition to shutting down the burner if the fuel temperature should
fall below the critical value for correct combustion, this thermostat also provides a permissive signal at the
time of burner start-up. (Factory set at approximately 80°C, adjustable by removing the pre-heater cover and
relative plate).
Maximum temperature thermostat this switches off the resistance when, because of failure of the adjust-
ment thermostat, the temperature of the pre-heater increases to unacceptable levels; a “high temperature”
alarm output is provided on the burner terminal strip. (Factory setting is approximately 180°C).
Renewing the minimum and maximum temperature
thermostats.
Reposition the probes of the new thermostat, after hav-
ing first loosened the plate pack securing screws. Make
sure that the probe is touching the resistance and the
plate pack as shown in the adjacent figure. The same
precautions should be taken when renewing the resist-
ances in contact with the thermostat probes.
If the pre-heater should malfunction, use an ohmmeter
to check that the resistances located in contact with the
temperature probes are not burnt out (reading of ap-
proximately 35 Ohm).
Changing the PT100 probe in the oil delivery manifold.
Fit the supplied nut and biconical collar on the new
probe, insert a length of approximately 40mm in the man-
ifold, and secure firmly into place. At this point, the sec-
tion remaining outside the manifold can be bent as
required, with no risk of damaging the resistance.
°C
mm
2
/s °E
D2747
Thermometer
Adjustment thermostat probe
Pre-heater
Purge
Spray temperature
Viscosity at 50° C
D2746
Min. thermostat
Max. thermostat
Thermostat probe
Resistance
Tubes into aluminium plate
D2751
Aluminium
plate

5837 13 GB
4.6 BURNER START-UP CYCLE
(tx) Factory setting: 20 s.
This time determines the heavy oil tempera-
ture at ignition. It can be adjusted, accord-
ing to the fuel’s viscosity, by the timer 22)
(Fig. 1).
The adjacent diagram shows the suggest-
ed settings.
Motor lock-out
It is caused by the over load relay when overload
occurs or no current supply.
Re-set: push button 7) and 10) (fig. 1).
NB.: Periodically clean the filter of the pre-heater
tank.
4.7 THREE STAGE OPERATION
Lock-out because no ignitionNormal
Thermostat
Motor
Ignition transformer
1st flame valve
2nd flame valve
Lock-out lamp
D2848
Pre-purge
3rd flame valve
tx (s)
Viscosity at 50°C (°E)
D3211
t
x
max = 60 s
D2749
1st stage
2nd stage
3rd stage
0
max.

5837 14 GB
4.8 BURNERS START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the followin table:
4.9 OPERATING FAULT DIAGNOSTICS
The control box has a self-diagnostic system, which easily allows identifying the operating faults (RED LED signal).
ITo use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a minimum of 3 sec-
onds.
After releasing the button, the RED LED starts flashing as shown in the diagram below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will provide the information on the possible faults, according to the table below:
COLOUR CODE TABLE
Sequences Colour code
Pre-purging           
Ignition phase           
Operation, flame ok            
Operating with weak flame signal          
Electrical supply lower than ~170V           
Lock-out          
Extraneous light           
Key: HOff GYellow KGreen LRed
SIGNAL PROBABLE CAUSE
2 flashes The flame does not stabilise at the end of the safety time:
– faulty photocell;
– faulty or soiled oil valves;
– faulty ignition transformer
– poor burner regulation.
3 flashes – Not used.
4 flashes
– Light in the chamber before firing.
7 flashes Loss of flame during operations:
– poor burner regulation;
– faulty or soiled oil valves.
8 flashes – Faulty thermostat for oil permissive signal;
– Heating resistances blown.
10 flashes
– Wiring error or internal fault.
RED LED on
wait at least 10 s
Press button
for > 3 s Signal Signal
Interval
3 s