Riello 629 T80 Parts list manual

2916203 (2) - 06/2012
Instrucciones de instalación, uso y mantenimiento
Instruções para instalação, uso e manutenção
Instruction for installation, use and maintenance
Fuel-oil-fired burner
Quemador de aceite pesado
Queimador de nafta
CODE
CÓDIGO MODEL MODELO TYPE
TIPO
3436081 PRESS 100 N/ECO 629 T80
3436082 PRESS 100 N/ECO 629 T80
GB
E
P
Two-stage operation
Funcionamiento biestadio
Funcionamento bifásico

6203
1GB
INDEX
1. BURNER DESCRIPTION
Two stage heavy oil burner.
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 operation with emulsified
fuel oil (see page 10) . . . . . . . . . . . . . . . . . . . . . . . No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Field of operation . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 4
3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 4
3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 5
3.3 Electrical connections . . . . . . . . . . . . . . . . 6
4. OPERATION. . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 7
4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 7
4.3 Combustion head setting . . . . . . . . . . . . . . . 7
4.4 Adjustment of the air damper motor . . . . . . . 7
4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . 8
4.6 Atomisation temperature adjustment . . . . . . . 8
4.7 Start-up programme . . . . . . . . . . . . . . . . . . . 9
4.8 Ecological oil burners . . . . . . . . . . . . . . . . . 10
4.9 Emulsified fuel oil functioning . . . . . . . . . . . 10
4.10 Start-up programme diagnostics . . . . . . . . . 10
4.11 Operating fault diagnostics . . . . . . . . . . . . . 11
2895
OThe burner meets protection level IP 40, EN 60529.
OBurner with CE marking in conformity with EEC directives: EMC 2004/108/EC, Low Voltage
2006/95/EC and Machines 2006/42/EEC.
1 - Suction line
2 - Return fitting
3 - Pump pressure adjustment
4 - Manometer fitting (G1/8)
5 - Vacuometer fitting (G1/2)
6 - Air damper opening motor
7 - Control box reset push-button and
lock-out indicator
8 - Fan overload cutout reset
9 - Regulating screw for combustion head
10 - Double filter
11 - Valve assembly
12 - Manometer with protection valve
13 - Adjustment thermostat
14 - Preheater contact maker
15 - Transformer
16 - Terminal strip
17 - Cable glams
18 - Antigas valve
19 - Thermometer
20 - Pump motor starter with reset
21 - Air pressure switch
Fig. 1

6203 2GB
2. TECHNICAL DATA
2.1 ELECTRICAL DATA
Motor IE1
Motor IE2
Type 629 T80
Thermal power - Capacity 285/490 ÷ 1140 kW – 25/43 ÷ 100 kg/h
Fuel Oil with max. viscosity at 50° C 115 sq.mm/s (15° E)
Pump 150 kg/h at 20 bar
Electrical supply Three-phase, 230V ±10% ~60Hz without neutral
400V ±10% ~60Hz with neutral
Fan motor rpm
kW
V
A
2850
1.5
220 - 380
5.5 - 3.2
Pump motor kW
V
A
220 - 380
0.37
2.1 - 1.2
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 7 kW
Electrical intake power kW max 9.4
Electrical supply Three-phase, 230V ±10% ~60Hz without neutral
400V ±10% ~60Hz with neutral
Fan motor rpm
kW
V
A
2930
1.5
220 - 380
6.2 - 3.6
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 7 kW
Electrical intake power kW max 9.4

6203 3GB
2.2 DIMENSIONS
2.3 FIELD OF OPERATION (2 nozzles in operation)
D2715
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 long - head version.
Use the pin extensions supplied to move the burner back.
*
876 250
410 625 290
*
47
Diam.195
370
D2710
Thermal power
Pressure in combustion
chamber – mbar
When the burner operates with only one nozzle, the pressurization conditions are improved and no prob-
lems arise. Minimal fuel capacity with one only nozzle: 25 kg/h - 285 kW.
kg/h
kW
D2709

6203 4GB
3. INSTALLATION
3.1 FUEL OIL SUPPLY SYSTEMS
GRAVITY SYSTEM
SUCTION SYSTEM
LOOP SYSTEM (max loop system 3 bar)
Pump priming:
loosen the cap of the vacuometer fitting
(5, fig. 1) and wait for the fuel flow.
H: Difference in height
L: Length of the suction tube
For fuel oil with viscosity max. 7°E at 50°C.
D2727
max. 30m
H
H
metres
L metres
diam.
1” gas diam. 1 1/4” gas
035
0.5 6 10
1915
1.5 12 20
21525
Not advised, to be used only when
there is a previously existing system.
Never exceed the max. vacuum 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 fuel oil with viscosity max. 7°E at 50°C.
D2728
H
metres
L metres
diam. 1
1/4” gas diam. 1
1/2”
01226
0.5 10 22
1918
1.5 7 15
2512
2.5 4 9
3–6
HH
max. 30m
1- Tank (properly heated for heavy oil) 5- Transfer pump
2- Filter (with resistor for oil > 7°E / 50°C) 6- Manometer
3- Burner 7- Burner pump
4- Air damper for eliminating burner (coupled) 8- Pressure adjuster
For heavy oil with viscosity up to 50°E/50°C.
Important note: to let the fuel flow properly all the pipes have to be properly sized, insulated and heated
(elec. resistor or steam or hot water).
Warning: before starting up the burner verify that there is no obstruction in the pipes.
any obstruction may damage the sealing of the pump.
D2729

6203 5GB
3.2 ELECTRICAL SYSTEMBURNER (carried out in the factory)
531
624
A1
A2
CR
S
789123456
TM
TB
M
R3
R2
R1
A1
13
14
3M
531
A2
96
95
642
MV
RT
TE
V2
7
8
6
11
2
5
3
4
1
+
-
MV2HS1ST0
ST1
ST2R1
R2
M
SM
FR
V1
411 85918 13 17 10
TB
1612 15
TA
Tm
1
RT1
TB
A1
13
14
3M
531
A2
95
96
642
MP
P
PA
TAV
TB
RMO88.53A2
MB
A
12
P
F
L1R L2R L3R
N L1L2L3 LNS3 T130 T2T6T8
V21 V22
L1P L2P L3P
CMP
CMV
CMP Pump motor contact maker
CR Preheater contact maker
FSuppressor
FR Photocell
MB Burner terminal strip
MP Pump motor
MV Fan motor
PA Air pressure switch
R1 Atomiser 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 Oil valve for 1st stage
V2 Oil valve for 2nd stage
2615

6203 6GB
3.3 ELECTRICAL CONNECTIONS TOTHETERMINAL STRIP(to be carried out by the installer)
FASTENING OF THE ELECTRICAL WIRES
All the wires, which have to be connected to the burner terminal strip (16, fig. 1) shall pass through the cable
glams (17, fig. 1), see the figure below.
Any other signals or controls can be connected to the burner terminal strip by removing the presheared disc pre-
sheared hole and inserting a common cable glam for the passage and the clamping of the leads. To ensure the
IP 40 degree of protection in compliance with EN 60529 close the passage holes of the cables and 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.
CONNECTIONS
PRE-HEATER
230V 400V
A Ampere 16 10
B Ampere 6 4
C Ampere 25 16
D sq.mm 1.5 1.5
E sq.mm 2.5 1.5
F sq.mm 6 4
RESISTORS
NOTE
Wire section: min. 1 sq.mm.
(Unless required otherwise by local standards and legis-
lation).
For 230V supply make the triangle connection on the
pre-heater and on the motor (the original connection is
“star-type” for 400V).
TWO STAGE OPERATION
It is achieved by the remote control device connected to ter-
minals 5-6 (removing the jumper), that controls the 2nd valve.
D2711
IN Manual switch
MB Burner terminal strip
HLock-out signal
TL Limit remote control
TR Regulation remote control
TS Safety control device system
D3742
D2635
1-Single phase pre-heated resistor
power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21
2 - Motor three phase 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
5-2nd stage thermostat:. . . . . . . . . . . . . . . . .cable entry Pg 13.5

6203 7GB
4. OPERATION
4.1 CHOICE OF NOZZLES
Recommended nozzle:
- Monarch F 80 H0.
4.2 PUMP PRESSURE
Recommended pressure:
- Fluid oil: 20 bar
- Heavy oil: 25 bar
The flow rated of the nozzles indicated on the tables are
nominal, and are obtained for a light fuel oil having viscosity
from 3 to 5°E at 50° C pre-heated at 100°C. The actual flow
rate may vary by ± 5% of the nominal flow rate.
if flow rate values between those indicated in the table are
required, it is possible to vary the pump pressure or arrange
the nozzles differently.
The pump leaves the factory set at 20 bar.
4.3 COMBUSTION HEAD ADJUSTMENT
Turn the screw A, fig. 2 till the set-point, shown in the diagram,
is in line with the sleeve B, fig. 2.
4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR
PARKING - Blue lever
This lever leaves the factory vertically positioned and corre-
sponds to the complete closure of the air damper.
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 is off.
Do not exceed the position of the orange 1st stage lever.
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 for closing and opening.
The black lever controls the opening of the second oil valve
and it must always be slightly earlier than the red lever, but
never the orange one.
D2638
Black lever
Red lever
Orange lever
Blue lever
Opening +–Closure
Nozzle
GPH (45° - 60°) 20 bar kg/h 25 bar kg/h
3.50 + 3.50 42.00 47.40
4.00 + 4.00 48.00 54,20
4.50 + 4.50 54.00 61.00
5.00 + 5.00 60.00 67,80
5.50 + 5.50 66.10 74.50
6.00 + 6.00 72.10 81.40
6.50 + 6.50 78.10 88.10
7.00 + 7.00 84.10 95.00
7.50 + 7.50 90.10 101.60
8.00 + 8.00 96.10 –
8.50 + 8.50 100.00 –
kg/h
Set-points
D2712
D2637
B
Set-point 4
A
Fig. 2

6203 8GB
4.5 AIR PRESSURE SWITCH
4.6 ATOMISATION TEMPERATURE ADJUSTMENT
Thermostat for adjustment - maximum value - minimum value
Adjustment thermostat prevents the burner start up if the fuel temperature has not reached the required value
for good 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 must be carried
out.
Minimum value contact thermostat cuts in and stops the burner if the fuel temperature falls below the val-
ue necessary for a good combustion.
The maximum value contact thermostat switches off the resistors when, if the adjustment thermostat fails,
the temperature increases inside the pre-heater. In case of abnormal temperature, make sure of the regular
functioning of the control thermostat and of the resistor in contact with the thermostat probe. The thermostat
is calibrated by the factory at 180 °C.
D521
Carry out the regulation of the air pressure switch after
carrying out all the other regulations of the burner with
the air pressure switch adjusted 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 turning on of the burner. If the burner locks
out again turn the knob a bit further in a counterclock-
wise direction.
D2719
Thermostat
adjustment knob
Pre-heater
Purge
Atomisation temperature
Viscosity at 50° C
sq.mm °E D2694

6203 9GB
IMPORTANT NOTES
Pre-heater thermostats substitution.
Replace the probe of the new thermostat, after loosen-
ing the fixing screws of the plate pack, making sure
there is a good contact between the probe and the
pipes and the resistor, see the drawing opposite. The
same precautions should be taken when renewing the
resistors in contact with the thermostat probes.
Should exceptional changes or excessive tempera-
tures be detected during operation, verify the continuity
of the resistor in contact with the temperature probe us-
ing an ohmmeter (approximately 35 Ohm).
Only use filters with a groove on the tightening hex
head.
NOTE
The pre-heater might be fitted with a second maximum value thermostat with a manual reset.
This thermostat can be used to act as a switch on an external contact maker to cut off the current to the pre-
heater if the temperature is too high (kit code no. 3000800).
Before the burner start-up, verify that the pump is filled with fuel in order to prevent it functioning while empty
for too long.
Filter cleaning:
periodically clean the filters so the burner always works properly.
Supply line filter:
positioned on the suction line, it causes the increase of the vacuum in the pump making it noisier. Do not ex-
ceed the vacuum of 45 cm Hg (6 m W.c.) (5, fig. 1).
Pre-heater filter (10, fig. 1):
positioned in the delivery line, it causes a decrease in the atomisationing pressure which is monitored
with a manometer (12, fig. 1).
MANOMETER PROTECTION VALVE
After the atomisation pressure check, turn off the manometer (12, fig. 1) to avoid pressure shocks that it might
be subject to each time the burner is started up.
For this reason close the protection valve when the burner is not working and the manometer indicates 0 bar.
4.7 BURNER START-UP PROGRAMME
Motor lock-out
It is caused by the thermal motor overload relay if an overload occurs or there is no phase.
Thermostat probe
Resistor
Pipes into aluminium plate
Plate
D2751
Lock-out because of no ignitionNormal
Thermostat
Motors
Ignition transformer
1st flame valve
2nd flame valve
Lock-out indicator
2894