Riello P 200 T/G Quick start guide

Installation, use and maintenance instructions
2915906 (3) - 11/2012
Light oil burners
CODE MODEL TYPE
3477785 P200 T/G 477 T80
3477786 P200 T/G 477 T80

5906 1
TECHNICAL DATA
ELECTRICAL DATA
Motor IE1
Motor IE2
1- Suction line
2- Return line
3- Pump pressure adjustment screws
4- Manometer plug (G 1/8)
5- Vacuometer plug (G 1/2)
6- Reset push-button of the motor overload relay
7- Wiring terminal board
8- Control box reset push-button and lock-out lamp
9-
Cable clamps
10 - Ignition transformer
11 - Regulating bush for combustion head
12 - Valves group with hydraulic jacks
13 - Electric board
Thermal power - Output 530 / 2370 kW - 45 / 200 kg/h (see page 2)
Operation 1st stage - 2nd stage - 3rd stage
Fuel Light oil, max. viscosity at 20° C: 6 mm2/s (1.5° E)
Electrical supply Three-phase 220V +10% -10% ~ 60Hz without neutral
380V +10% -10% ~ 60Hz with neutral
Motor 15.9 A / 220V - 9.2A / 380V
Ignition transformer Primary: 2 A - Secondary: 2x 6.5 kV - 35 mA
Absorbed electrical power 5.5 kW
Electrical supply Three-phase 220V +10% -10% ~ 60Hz without neutral
380V +10% -10% ~ 60Hz with neutral
Motor 14.6 A / 220V - 8.5A / 380V
Ignition transformer Primary: 2 A - Secondary: 2x 6.5 kV - 35 mA
Absorbed electrical power 5.5 kW
Fig. 1
Quantity Accessories
2 Flexibles tubes
2 Nipples
4Screws
1 Gasket for flange
4 Cable clamps

5906 2
DIMENSIONS (mm)
* It is possible with a spacer upon request.
OPERATION AND EFFICIENCY OF THE BURNER
ACCESSOIRES
RADIO DISTURBANCE PROTECTION KIT: Code 3010386
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m) owing
tothepresenceofanINVERTER,orinapplications where the length of the thermostat connections exceeds 20 metres,
a protection kit is available as an interface between the control box and the burner.
1st STAGE
POWER AND OUTPUT
MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle: ignition phase 391 33 782 66
1st + 2nd nozzle: intermediate phase 794 67 1576 133
1st + 2nd + 3rd nozzle: operation phase 1186 100 2372 200
2nd STAGE
POWER AND OUTPUT
MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle: ignition phase 391 33 782 66
1st + 2nd nozzle: 1st stage of operation 794 67 1576 33
1st + 2nd + 3rd nozzle: 2nd stage of operation 1186 100 2372 200
3rd STAGE
POWER AND OUTPUT
MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle: 1st stage of operation 557 47 794 67
1st + 2nd nozzle: 2nd stage of operation 1067 90 1576 133
1st + 2nd + 3rd nozzle: 3rd stage of operation 1186 100 2372 200
Boiler front plate
drilling Burner

5906 3
COMBUSTION CHAMBER PRESSURE - MAXIMUM OUTPUT
(three nozzles in operation)
Operation field in accordance with DIN 4787
When the burner operates with only one, or two nozzles, the pressurization conditions are improved and no prob-
lems arise.
DIMENSIONS OF THE TESTING COMBUSTION CHAMBER
(in compliance with ISO 5063 - 1978)
For the combustion head projection carefully
follow the boiler manufacturer indications.
A proper protection with refractory material on
the combustion chamber shall be made, when
the boilers with frontal smoke box are used.
Testing thermal load
D = Boiler diameter in mm
P = Position of the mobile
movable wall (mm)

5906 4
SUPPLY LINE
NOTICE
Before placing the burner in operation, ensure that the return line is open.
Any obstruction may damage the pump seal.
Pump priming: Fill the pump with the light oil from the vacuometer plug (5) (fig. 1), put the burner in operation, purge
the air from the manometer plug (4) (fig. 1) and wait for the pump priming. If lock-out occurs repeat the procedure.
H= Difference in the pipes height L= Total length of the suction tube
øi = Internal diameter of the tube. Copper tubes ø 14 and 16 mm could be replaced by steel tubes G 1/2” and G 3/4”.
Pump priming: Loose the tap from the vacuometer
plug 5 (fig. 1) and wait for the flow of the fuel.
Pay attention to do not overcome the max. depression of 0.45 bar (35 cm Hg), over this
value the fuel may turn into gas.
Check the pipes are perfectly sealed.
When the fuel tank is under the burner level we suggest to let the return line arrive where
the suction line starts.
In this case the foot valve is not necessary.
Should the return line arrive over the fuel level, the foot valve is indispensable. Notice that
this solution is less safe than the previous one, because it is possible the valve has not a
good sealing.
H
meters L meters
I.D. 14 mm I.D. 16 mm
005
0,5 5 10
11020
1,5 20 40
23050
H
meters L meters
I.D. 14 mm I.D. 16 mm
0 50 100
0.5 40 80
13060
1.5 20 40
21020
3510

5906 5
INTERNAL WIRING DIAGRAM
(carried out by the factory)
KEY TO LAYOUT
CMV Fan motor contactor MB Wiring terminal board
CO Commutator MV Fan motor
FR Photocell RT Thermal relay
h 1 1 st stage hourcounter TA Ignition transformer
h 2 2 nd stage hourcounter TB Burner ground (earth) connection
h 3 3 rd stage hourcounter VS Safety solenoid valve
L1 1 st stage lamp V1 1 st stage solenoid valve
L2 2 nd stage lamp V2 2 nd stage solenoid valve
L3 3 rd stage lamp V3 3 rd stage solenoid valve
L4 Lock - out motor lamp
2567

5906 6
ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK
(to be carried out by the installer)
D2648
KEY TO LAYOUT
HRemote lock - out signal TL Load limit remote control system
I1 Burner manual stop switch TS Safety load control system
MB Wiring terminal board T2 2 nd stage load control system
PS Reset push - button T3 3 rd stage load control system
TB Burner ground (earth) connection
220V 380V
F Ampere T35 T25
S mm24,0 2,5
Check the lock-out by darkening the photo-cell after removal of the cover.
ATTENTION: HIGH VOLTAGE
Important:
In systems where the run of wiring connecting the thermostat exceeds 20 metres in length, or in places
where the burner is subject to particularly disturbing electromagnetic interference (over 10 v/m), you must
insert the relay-inter face kit item number 3010386.
Note:

5906 7
CHOICE OF: NOZZLES - PUMP PRESSURE -
COMBUSTION HEAD ADJUSTMENT
•State, first of all, the maximum output required with all three nozzles in operation.
•On the base of the maximum required output, choose-from table A or B - three related nozzles.
Nozzles: 60° - Pump pressure: 12 bar
For three-stage operation (up to 170 kg/h) 1st and 2nd nozzle are not equal to the 3rd one. Follow this procedure
in order to obtain higher values of CO2(during 1st and 2nd stage of operation), complying with German Standard
DIN.
•The references on the table C have to 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.
SUGGESTED NOZZLES
(1) The pump pressure is referred to all three nozzles operating, the pressure increases automatically with two noz-
zles in operation and more with only one.
1st Stage / 2nd Stage
ANozzles 60°
Pump 12 bar (1)
Total delivery
kg/h
GPH
1st 2nd 3rd 1st + 2nd + 3rd
8.00 8.00 8.00 102.90
8.30 8.30 8.30 106.80
8.50 8.50 8.50 109.50
9.00 9.00 9.00 115.80
9.50 9.50 9.50 122.40
10.00 10.00 10.00 128.70
10.50 10.50 10.50 135.30
11.00 11.00 11.00 141.60
12.00 12.00 12.00 154.50
13.00 13.00 13.00 167.40
13.80 13.80 13.80 177.60
14.00 14.00 14.00 180.30
15.00 15.00 15.00 193.20
15.30 15.30 15.30 197.10
3rd Stage
BNozzles 60°
Pump 12 bar (1)
Total delivery
kg/h
GPH
1st 2nd 3rd 1st + 2nd + 3rd
10.00 10.00 5.00 107.30
10.50 10.50 5.00 111.70
10.50 10.50 6.00 115.90
11.00 11.00 6.50 122.30
12.00 12.00 6.50 130.90
12.00 12.00 7.50 135.20
13.00 13.00 7.50 143.80
13.80 13.80 7.50 150.70
13.80 13.80 10.00 161.30
13.80 13.80 12.00 169.90
13.80 13.80 13.80 177.60
14.00 14.00 14.00 180.30
15.00 15.00 15.00 193.20
15.30 15.30 15.30 197.10

5906 8
Rated nozzles delivery are shown in the table.
The real nozzle delivery may vary from the rated one up to ± 5%, its detection is made by weighing the oil sprayed
out from the nozzle inserted in a tube.
The pump leaves the factory rated at 12 bar.
Pay attention to not overcome the pump pressure values of 10 and 14 bar.
• At the end, on the base of the maximum output, you obtain the combustion head adjustment from the diagram D.
The adjustment should be made by turning the screws A till the
set-point (see diagram) is on the line with the washer B.
Nozzles delivery
Pump pressure
Combustion head adjustment
Maximum output
Combustion head adjustment
(set-point)
Set-point 6
B
A

5906 9
AIR DAMPER ADJUSTMENT
The air dampers adjustment shall be set each time in relation with the nozzles delivery and the combustion chamber
pressurization.
Fig. 2 shows the placement of the air dampers as fig. 3 their correspondent hydraulic jacks.
To open or close the air dampers proceed as follows:
Loose the ring nut (1), turn clockwise the hexagonal body (2)
in order to decrease the air flow, and counterclocwise to in-
crease it.
The right adjustment of the air dampers may be detect by checking the combustion results in the three stages of
burner operation.
To check the combustion during the different stages, the commutator (see page 10) should be set to the position
corresponding to the burner stage to be controlled.
Fig. 2 Fig. 3
3 rd stage hyd. jack
2 nd stage hyd. jack
1 st stage hyd. jack
1 st stage air damper
2 nd stage air damper
3 rd stage air damper

5906 10
ELECTRIC PANEL
Hourcounter
Deducting the number of hours of 2nd nozzle hourcounter from those indicated in the 1st nozzle hourcounter you
could know how many hours the burner has been performing only at 1st stage; the same procedure to detect the
performance hours of the 2nd stage alone - deduct from the 2nd stage hourcounter the hours indicated in the 3rd
nozzle hourcounter -. The hours of 3rd stage operation are shown rightly on the 3rd nozzle hourcounter.
Commutator
Pos. 0: Burner stop
Pos. 1: Burner operation only at 1st stage
Pos. 2: Burner operation at 1st and 2nd stage
Pos. 3: Burner operation at 1st, 2nd and 3rd stage
MOTOR LOCK-OUT
It is caused by the overload relay in case of overload or no electric supply.
Push the proper reset button (after removal of the protective cover).
1 st nozzle hourcounter with
operation signal
2 nd nozzle hourcounter with
operation signal
3 rd nozzle hourcounter with
operation signal
Motor lock-out signal
4 position commutator
Control box lock-out signal
with re-set push-button

5906 11
BBURNER START-UP CYCLE
ALTERNATIVE START-UP CYCLES
1) If you desire the pre-ignition being present during the complete pre-purge phase (29,5 s) remove the bridge from
the terminals 11 - 3 and put it on the terminals 11 - 7 of the control box.
2) If you desire to reduce the pre-purge period from 29,5 s to 16 s with contemporaneous presence of the pre-ignition
remove the wire from the terminal no. 7 tothe no. 3 ofthe control box, maintaining thebridge tothe terminals 11 - 3.
THREE STAGE OPERATION
Lock-out because no ignitionNormal
Thermostat
Motor
Ignition transformer
1 st flame valve
2 nd flame valve
Lock-out lamp
Safety valve
3 rd flame valve
2896
1 st stage
2 nd stage
3 rd stage
max.
0

5906 12
BURNER START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the followin table:
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: Off Yellow Green Red
RED LED on
wait at least 10 s
Press button
for > 3 s Signal Signal
Interval
3 s
In the event of a burner lockout, more than two conse-
cutive burner reset operations could cause damage to
the installation. On the third lockout, contact the After-
sales Service.
WARNING
If further lockouts or burner faults occur, interventions
must only be made by qualified, authorised personnel
(as indicated in this manual, and in compliance with
the laws and regulations currently in force).
DANGER
SIGNAL PROBABLE CAUSE
2 flashes The flame does not stabilise at the end of the safety time:
– faulty photocell;
– faulty or soiled oil valves;
– neutral/phase exchange;
– faulty ignition transformer
– poor burner regulation (insufficient gas oil).
3 flashes Min. air pressure switch (if installed) does not close:
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– max. air pressure switch triggered (if installed).
4 flashes Min. air pressure switch (if installed) does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
7 flashes Loss of flame during operations:
– poor burner regulation (insufficient gas oil);
– faulty or soiled oil valves;
– short circuit between photocell and earth.
8 flashes – Oil enabling thermostat fault;
– Break in heating elements.
10 flashes – Wiring error or internal fault;
– Presence of electromagnetic disturbance: use the radio disturbance protection kit

Subject to modifications
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.riello.it
http:// www.rielloburners.com