Riello DB 6 LM C10 TC FS1 A0 T150 Quick start guide

Istruzioni per installazione, uso e manutenzione
Installation, use and maintenance instruction
Bruciatore industriali di olio
Oil industrial burner
Brûleur industriel à huile
20082652 (1) - 12/2013
CODICE - CODE MODELLO - MODELL TIPO - TYPE
20082532 DB 6 LM C10 TC FS1 A0 T150 82532X
I
GB
F

2
Index
CHAPTER 1 Introduction . . . . . . . . . . . . . . . . . . . . . page 3
Selection code description . . . . . . . . . . . . . . . . . . . . . . 3
Specification of the burner type and coding . . . . . . . . . . . . . 3
CHAPTER 2 Burner description. . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air side pressure drop . . . . . . . . . . . . . . . . . . . . . . . . 7
CHAPTER 3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal of the locking screws from the shutter . . . . . . . . . . . 8
Fixing to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 4 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . 9
General supply layout (oil and gas) . . . . . . . . . . . . . . . . . 9
Pressure regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHAPTER 5 Preparation for start up . . . . . . . . . . . . . . . . . .11
Combustion head adjustment . . . . . . . . . . . . . . . . . . . . 11
Ignition pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Servomotor adjustment . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure switches adjustment. . . . . . . . . . . . . . . . . . . . 12
Nozzles (mechanical atomisation) . . . . . . . . . . . . . . . . . 13
CHAPTER 6 Burner start up and adjustment . . . . . . . . . . . . . .14
Air/fuel adjustment
(oil version/mechanic atomisation). . . . . . . . . . . . . . . . . 14
Pressure switches setting . . . . . . . . . . . . . . . . . . . . . . 15
Final checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHAPTER 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . .16
Checking the flame detector . . . . . . . . . . . . . . . . . . . . 16
Periodic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Problems and remedies . . . . . . . . . . . . . . . . . . . . . . . 17

3
1Introduction
1.1 Selection code description 1.2 Specification of the burner type and
coding
DB 6 L TC A-0
supply
A-0 = from below
A-90 = from the right
Combustion head
TC = standard head
Fuel
S= natural gas
P= LPG
Adjustment
E= electronic cam
Dimension
Series
N= fuel oil
NS = fuel oil / natural gas
NP = fuel oil / LPG
NA = fuel oil assisted atomisation
L= light oil
TL = long head
Combustive air
NAP = fuel oil assisted atomisation / LPG
M= progressive (modulating, mechanical cam)
LS = light oil / natural gas
LP = light oil / LPG
NAS = fuel oil assisted atomisation / natural gas
TXL = special head
A-180 = from above
A-270 = from the left
9 - 12
MTYPE CODE
DB 6 LM TC A0 20082532

4
2Burner description
2.1 Technical data
2.2 Firing rate
Model DB 6
Capacity Min./Max. light oil [kW] 4200 ÷ 7800
Output adjustment Modulating
Modulation ratio against maxi-
mum rated output
Light oil 1 : 4
Fuel Light oil/Fuel oil viscosity 5°E at 50°C option L
Combustive air temperature Max. 150°C
Electrical supply 230 V +/-10% 50/60 Hz
110 V +/-10% 50/60 Hz (on request)
Ignition Electrogas type (pilot burner with natural gas or LPG)
Ignition transformer V1 - V2
l1 - l2
230 V - 2 x 5 kV
1.4 A - 20 mA
Flame control Standard (1 stop in 24 hours) FS1
Continuous self-check (on request) FS2
Fig. 1
D7889
GAS
0
50°C
150°C
800 1800
kW
Air temperature
DB6
7800
7000
Air temperature

5
CHAPTER 2Burner description
2.3 Burner components
Key
1Electrical control box base for electrical connections
2Air box
3Cover with handle
4Photocell QRA2
5Tie-rod for combustion head modulation
6Air delivery adjustment cam
7Servomotor
8Air pipe attachment flange
9Air pressure switch
10 Flame inspection window
11 Combustion head
12 Boiler attachment
13 Maximum oil pressure switch on return line
14 Eccentric
15 Safety valve in outlet VS
16 Safety valve in outlet VF
17 Safety valve on the return VR
18 Oil pressure gauge in outlet nozzle
19 Oil pressure gauge on the nozzle return
Fig. 2
20082848

6
CHAPTER 2Burner description
2.4 Overall dimensions
Air duct connection
Fig. 4 Fig. 5
FLANGE DIMENSIONS
Fixing to the boiler
D7549
45
45
453
M18
350
D7884
Fig. 3
20082849
380
495

7
CHAPTER 2Burner description
2.5 Air side pressure drop (taken upstream from the completely open air damper)
The pressure curves refer to the different adjustment conditions for the combustion head. Refer to Paragraph 5.1
InIn the case of air supply at a higher temperature than 20°C and/or an altitude higher than 100 m. a.s.l., the pressure drop in the
head that is shown in the graph must be multiplied by the Kccoefficient as indicated in the table below.
Example
Burnt output = 9800 kW - Altitude = 750 m. a.s.l. - Combustive air temperature = 120 °C
From the diagram (curve 3), with an output of 9800 kW, a total pressure drop (head + air damper) is shown of: 'p20 = 35 mbar
(combustive air at 20 °C and altitude 100 m. a.s.l.).
The table gives a multiplying coefficient, for combustive air at 120 °C and altitude 750 m. a.s.l., equal to Kc= 1.449.
The total pressure drop of the burner head is:
'p= 'p20 x Kc= 35 x 1.449 = 50.7 mbar.
Altitude Kc
Air temperature °C
m. a.s.l. 0 20 30 40 50 60 70 80 90 100 120 140 150
0 0..920 0.988 1.021 1.055 1.089 1.122 1.156 1.190 1.223 1.257 1.325 1.392 1.426
100 0.932 1.000 1.034 1.069 1.103 1.137 1.171 1.205 1.239 1.273 1.342 1.410 1.444
500 0.976 1.047 1.083 1.119 1.155 1.190 1.226 1.262 1.298 1.333 1.405 1.477 1.512
750 1.007 1.080 1.117 1.154 1.191 1.228 1.265 1.302 1.338 1.375 1.449 1.523 1.560
1000 1.038 1.114 1.152 1.190 1.228 1.266 1.304 1.342 1.380 1.418 1.494 1.570 1.608
1250 1.069 1.147 1.186 1.226 1.265 1.304 1.343 1.382 1.421 1.460 1.539 1.617 1.656
1500 1.102 1.182 1.223 1.263 1.304 1.344 1.384 1.425 1.465 1.505 1.586 1.667 1.707
1750 1.130 1.213 1.254 1.295 1.337 1.378 1.419 1.461 1.502 1.544 1.626 1.709 1.751
2000 1.174 1.260 1.303 1.346 1.389 1.432 1.475 1.518 1.561 1.604 1.690 1.776 1.819
2250 1.206 1.294 1.338 1.382 1.427 1.471 1.515 1.559 1.603 1.647 1.736 1.824 1.868
2500 1.251 1.343 1.389 1.434 1.480 1.526 1.572 1.618 1.664 1.709 1.801 1.893 1.939
2750 1.284 1.378 1.425 1.472 1.519 1.566 1.613 1.660 1.707 1.754 1.848 1.942 1.989
3000 1.320 1.417 1.465 1.514 1.562 1.610 1.659 1.707 1.755 1.804 1.901 1.997 2.046
60
50
40
30
20
10
mbar
KW
DB6
0 1000 2000 3000 4000 5000 6000 7000 8000
D7890
Fig. 6
'p
Burner output Pb [kW]

8
3Installation
3.1 Removal of the locking screws from the
the shutter
3.2 Fixing to the boiler
3.3 Lifting points
To move the burner, the attachment points indicated in Fig. 9 should be used.
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
The installation of the burner must be carried out by
qualified personnel, as indicated in this manual and in
compliance with the standards and regulations of the
laws in force.
Remove the screws and the nuts 1) and 2) (Fig. 7),
before installing the burner on the boiler. Replace them
with the screws 3) M12 X 16 supplied with the burner.
1
2
1
2
3
3
Fig. 7
D12015
DANGER
WARNING
WARNING
The figure alongside shows how to fix the burner to a boiler without a
cooled frontal. The head should not jut out more than 200 mm.
In any case, the fettled wall should not extend beyond the end of the
burner combustion head.
REFRATTARI O
500MAX
363 / 312
380 / 350
D8401
Fig. 8
Refractory
Fig. 9
20082850

9
4Fuel supply
4.1 General supply layout (oil and gas)
Key AD Air dumper CAnti-vibration joint Cm Regulating cam GF Gas filter HPG High gas pressure regulator LPG Low gas pressure regulator MM Pressure gauge MN Oil delivery pressure gauge MR Oil return pressure gauge NNozzle
NL Oil lance PA Minimum air pressure switch PCV Gas pressure regulator PGM Maximum gas pressure switch PGm Minimum gas pressure switch PO Maximum oil pressure switch RG Gas butterfly valve RP Oil return pressure regulator SM Servomotor SRV Pressure limiting valve with outlet into the
environment
VE Fan VF Oil safety solenoid valve
VPS Leak detection control device VR Gas pressure regulator solenoid valve VR Safety solenoid valve on the nozzle return VRS Safety solenoid valve on the nozzle return VSG Gas safety solenoid valve VSN Heavy oil safety solenoid valve VS Oil valve (safety)
M
Fig. 10
D10017
max. 500 mbar 0,5 - 4 mbar
Heavy oil pre-heater

10
CHAPTER 4Burner description
4.2 Pressure regulator
To calibrate cam (1): remove the gear-case, loosen screws (2), act on screw (3) until required eccentricity is obtained.
Turning the screw (3) to the left (+sign) eccentricity is increased, thus increasing the difference between nozzle maximum and min-
imum delivery.
Turning screw (3) to the right (- sign) eccentricity is reduced; thereby reducing the difference between nozzle maximum and min-
imum delivery.
Every variation of the eccentricity may require a travel offset using nut and locknut (4).
NB.
- To obtain a correct calibration, cam (1) must operate over the travel range of the servo-motor as wider as possible; every vari-
ation of the servo-motor must be matched by a variation in pressure.
- Never give the variator piston a snug fit: stop ring determines the maximum travel.
- When the adjustment has been made, manually check that there is knocking between maximum and minimum and that max.
and min. pressures match pre-selected values as indicated on the delivery nozzle diagram.
If, at maximum nozzle delivery (maximum return pressure), pressure oscillations are detected on pressure gauge (6), slightly
reduce pressure until the oscillations are eliminated.
4.3 Wiring diagrams
D8416
6
5
4
1
2
3
Fig. 11
MB Burner terminal strip
PA Air pressure switch
PO Maximum oil pressure switch
SM Servomotor
TA Ignition transformer
TB Burner earth
UV UV cell
VF Operation valve
VR Oil return valve
VS Oil safety valve
D8403
Fig. 12

11
5Preparation for start up
5.1 Combustion head adjustment
In addition to varying air flow depending on the output requested, the air gate valve servomotor 7)(Fig. 2) by means of a lifting
assembly, varies the setting of the combustion head. This system allows an optimal setting even at a minimum firing rate. For the
same servomotor rotation, combustion head opening can be varied by moving the tie rod onto holes 1-2-3 (Fig. 13).
The choice of the hole (1-2-3) to be used is decided on the basis of diagram in Fig. 14 against the required maximum output.
Setting is pre-arranged in the plant for the maximum run (hole 3).
When dealing with boilers featuring a strong back pressure, if air delivery is insufficient even with the damper fully open, you can
use a different setting to that illustrated in diagram in Fig. 14, do this by moving the tie rod onto the next highest hole numerically
speaking, thus increasing the combustion head’s opening and hence air delivery)
5.2 Ignition pilot
Make sure that the electrodes are positioned as shown in Fig. 15.
Fig. 14
D8417
Maximum burner output
N° Hole
kW7800 8200740070006600620058005400500044004000
0
1
2
3
kW
Fig. 13
20082173
8÷ 10mm
4÷ 4,5mm
47
D8321 Fig. 15

12
CHAPTER 5Preparation for start up
5.3 Servomotor adjustment
1 - 4 :Limit switch cam (max. air damper opening)
2:Limit switch cam (air damper closed)
3 - 5 :Minimum delivery (and ignition) position cam
6:Positioning reading indicator
7:Servomotor release
The servomotor contemporarily regulates, by transmission, air delivery
and pressure and delivery of the fuel being used.
It is fitted with a number of adjustable cams that action the same
number of selector switches.
Cam pos.1: limits maximum opening of the servomotor.
Cam pos.2: limits servomotor limit switch in the 0° position.
When the burner is off, the air damper is completely
closed.
Cam pos.3: fixes the minimum modulation position.
It is set in the factory at approx. 20° (just one type of
fuel).
Cam pos.4: limits maximum opening of the servomotor (for mixed burners working with gas).
Cam pos.5: limits minimum delivery. It is set in the factory at approx. 20° (for mixed burners working with gas).
Cam rest: available.
Important: the position of 130° must not be exceeded for limit switches (cam 1 - 4).
5.4 Pressure switches adjustment
As the reference pressure levels cannot yet be established, before beginning setting operations, adjust the air pressure switch
(Fig. 17) on the burner air box, at the start of the scale (with the burner turned off).
Fig. 16
D1500
D2215
Air pressure switch
Fig. 17

13
CHAPTER 5Preparation for start up
5.5 Nozzles (mechanical atomisation)
Fig. 19
Delivery (%)
Return pressure (bar)
D8033
• BERGONZO, type B5
Complete range of nozzles:
Bergonzo B5 45° - 450 - 500 - 550 - 600 - 650 - 700 - 750 - 800
850 - 900 - 950 - 1000 - 1050.
For intermediate delivery levels, choose the nozzle with delivery slightly
higher than that effectively required.
Normally atomisation angles are recommended of 45÷60°; for narrow
combustion chambers use nozzles with 30÷35° angles .
Fig. 18
RECOMMENDED NOZZLES
Delivery pressure: 25 bar
Oil viscosity: 2 °E
Example
Nominal nozzle delivery: 800 kg/h
Maximum required delivery: 760 kg/h (95%)
Maximum return pressure: 20 bar
Required modulation ratio: 1 : 3.8
Minimum delivery: 200 kg/h (25%)
Maximum return pressure: 7 bar

14
6Burner start up and adjustment
6.1 Air/fuel adjustment (oil version/mechanic atomisation)
When setting the air/fuel ratio for oil burners, the following adjustments must be made:
a) delivery pressure of the oil pump: turn the screw (1) on the pump (to adjust the pressure refer to the diagram on page 13).
b) air cam: turn the threaded regulators (2) after loosening the screws (3).
c) oil cam: change eccentricity by turning the screw (4) after loosening the screws (7). By tightening the screws (4) eccentricity
increases, in this way the difference increases between maximum and minimum return pressure to the nozzle.
Procedures for setting the burner
1Fit the suitable nozzle to obtain the maximum required delivery. Refer to Paragraph 5.5.
2Check that the eccentricity of the oil cam is sufficient for a run of approx. 8 mm for the oil modulator shaft. Normally, with an 8
mm run for the shaft, the pressure variation required for modulating the output from minimum to maximum is obtained. To carry
out this control, manually turn the cam after releasing the servomotor using the lever (7)(Fig.16), so that the shaft run is not
excessive or insufficient. When the control is terminated, remember to block the servomotor.
3Ignite the burner with the selector switch on the control panel in the manual position. At this point, after the pre-ventilation
phase, the servomotor will stop at approx. 20°.
4Adjust the pump delivery pressure as given in point a), to obtain a delivery pressure of 25 bar.
5Adjust the return pressure to a minimum of approx. 4 bar.
To do this, the length of the shaft (5) Fig. 22 must be adjusted, by turning the nut.
6Proceed with setting the air delivery by adjusting the variable profile cam, by turning the screws (2) Fig. 20.
7After this first adjustment, increase supply output using the automatic return selection switch on the control panel. Stop when
the servomotor has turned by 15° and then effect a new adjustment using the variable profile air cam.
We recommend sufficient setting so as not to create a smoky flame and to reach maximum output as soon as possible (max-
imum run for the servomotor 130°): set the return pressure on the eccentric (screw 4, Fig. 22) to obtain the output required by
the nozzle and then continue with setting the intermediate levels.
8Check the levels of the combustion parameters at the various modulation outputs and adjust if necessary.
9When perfect adjustment has been reached, remember to block the adjustment screws of the cam profiles by tightening the
screws (3).
N.B. When setting the cams, do not exceed the servomotor run limits 0° ÷ 130°, to avoid crawling.
Check, by effecting a manual movement of the cam of 0-130°, that there are no mechanical blocks before the micro-switches 1-2
on the servomotor trigger.
1Cam
2Adjustment screws
3Fixing screws
4Variable profile
3
2
4
1
Fig. 20
D1499
D1498
Fig. 21
Pressure guage
adjustment 1
D8416
5
4
7
Fig. 22

15
CHAPTER 6Burner start up and adjustment
6.2 Pressure switches setting
Air pressure switch
Adjust the air pressure switch after having performed all other burner adjustments with
the air pressure switch set to the start of the scale (Fig. 23). With the burner operating
at max. output, increase adjustment pressure by slowly turning the relative knob clock-
wise until the burner locks out. Then turn the knob anti-clockwise by about 20% of the
set point and repeat burner starting to ensure it is correct.
If the burner locks out again, turn the knob anticlockvise a little bit more.
Attention: as a rule, the air pressure switch must limit the CO in the fumes to less than
1% (10,000 ppm). To check this, insert a combustion analyser into the chimney, slowly
close the fan suction inlet (for example with cardboard) and check that the burner locks
out, before the CO in the fumes exceeds 1%.
Maximum oil pressure switch (mechanic atomisation)
Setting is not normally required on site. It is set in the factory at 8 bar. If necessary, adjust pressure on the basis of the exhaust
pressure from the supply ring.
Minimum oil pressure switch (assisted atomisation)
Setting is not normally required on site. It is set in the factor at 12 bar.
6.3 Final checks
Before leaving the plant:
• ensure the adjustment and safety devices work correctly;
• check all the mechanical blocking systems on the adjustment devices are tightly closed.
D2215
Fig. 23

16
7Maintenance
7.1 Checking the flame detector
UV cell
Minimum current for correct working is 70 μA.
If the value is lower, it could be due to:
• exhausted photocell;
• low current (lower than 187 V);
• bad regulation of the burner.
In order to measure the current, use a microamme-
ter of 100 PA c.c., connected in series to the photocell, as in the scheme, with a capacitor of 100 PF - 1V c.c. at the same level of
the instrument.
7.2 Periodic checks
We recommend carrying out the following checks:
³LIST OF MONTHLY CHECKS
1 Inspect the flame detection device and check it is undamaged and clean.
2 Check the ignition device and clean if necessary.
3 Check the right pressure levels for fuel and air.
4 Check the correct movement and setting of the air damper and relative lifting assemblies.
5 Check the start up sequence and the safety interlocks, by simulating the relative anomaly situation.
³ LIST OF YEARLY CHECKS
1 Check the fuel blocking valves are still well sealed.
2 Check the settings on the pressure switches.
3 Visual check of the wires and connectors.
4 Check and clean the pressure test points.
5 Check the installation pipes for leaks.
6 Visual check of any damage and/or deformation of the following components:
- cylinder/distributor unit;
- flame disc;
- ignition unit;
- flame pipes.
D1143
Fig. 24

17
CHAPTER 7Maintenance
7.3 Problems and remedies
If the burner does not work properly, first you must:
1check that the electric connections have been correctly performed;
2make sure that the fuel is flowing;
3check that all the adjustment parameters (e.g. boiler water temperature or boiler steam pressure) are correctly set.
Fault Possible cause Recommended remedy
The burner does not start • No electrical power supply . . . . . . . . . . . . . . . . . . . .Close all switches - Check connec-
tions
• A limiter or safety control device is open. . . . . . . . . .Adjust or replace
• Control box lock-out . . . . . . . . . . . . . . . . . . . . . . . . .Reset control box
• Control box fuses blown . . . . . . . . . . . . . . . . . . . . . .Replace
• Erroneous electrical connections . . . . . . . . . . . . . . .Check connections
• Defective control box . . . . . . . . . . . . . . . . . . . . . . . .Replace
• Air pressure switch in operating position . . . . . . . . .Adjust or replace
• Contact 1 of the servomotor, terminals 11-8 . . . . . . .Adjust cam 1 or replace the
of the control box do not operate . . . . . . . . . . . . . . .servomotor
The burner does not start and a
function lock out occurs
• Flame simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace control box
The burner starts but stops at
maximum air damper setting
• Contact 1 of the servomotor, or terminals 9-8. . . . . .Adjust cam 1 or replace the
of the control box do not operate . . . . . . . . . . . . . . .servomotor
The burner ignites but then
blocks
Air pressure switch inoperative due to insufficient air pressure:
• Air pressure switch adjusted badly . . . . . . . . . . . . . .Adjust or replace
• Pressure switch pressure point pipe blocked . . . . . .Clean
is blocked
• Head wrong adjusted . . . . . . . . . . . . . . . . . . . . . . . .Adjust
The burner starts and then locks
out
• Fault in flame detection circuit . . . . . . . . . . . . . . . . .Replace control box
The burner stays in the pre-
purge stage
• Contacts 3 or 5 of the servomotor, or terminals . . . .Adjust cams 3 or 5 or replace
10-8, of the control box do not operate . . . . . . . . . . .the servomotor
After pre-purge and safety time,
the burner goes to lock-out and
the flame does not appear
• Defective ignition transformer . . . . . . . . . . . . . . . . .Replace
• Erroneous valve or transformer electrical . . . . . . . .Repeat connections
connections
• Defective control box . . . . . . . . . . . . . . . . . . . . . . . .Replace
The burner goes to lock-out right
after flame appearance
• Defective control box . . . . . . . . . . . . . . . . . . . . . . . .Replace
Lock out without symbol indica-
tion
• Flame simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace control box
During operation, the burner
stops in lock out
• Fault on air pressure switch . . . . . . . . . . . . . . . . . . .Replace
Lock out when burner stops • Flame remains in combustion head or flame . . . . . .Eliminate persistence of flame
simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or replace control box
Ignition with pulsation • Poorly adjusted head . . . . . . . . . . . . . . . . . . . . . . . .Adjust
• Poorly adjusted air damper, too much air . . . . . . . . .Adjust
• Output during ignition phase is too high . . . . . . . . . .Reduce

Con riserva di modifiche - Subject to modifications - Sous réserve de modifications
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.riello.it
http:// www.rielloburners.com