Riello RDB3 CF 489T50 Quick start guide

2902587 (2)
Installation, use and maintenance instructions
Kerosene and gas oil burners
One stage operation
CODE MODEL TYPE
3748950 RDB3 CF 489T50
3748850 RDB4 CF 488T50

2587
1
INDEX
1. BURNER DESCRIPTION
1.1 BURNER EQUIPMENT
Flange and gasket . . . . . . . . . . . . No. 1 Screw of by-pass pump . . . . . . . . . . . . . . . . . . . . No. 1
Screw and nuts for flange . . . . . . No. 1 Bolts for flange to be fixed to boiler . . . . . . . . . . . No. 4
Hexagonal key. . . . . . . . . . . . . . . No. 1 Screws and terminal screw for feeding cable . . . . No. 3
Flexible oil pipe with nipple . . . . . No.1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions. . . . . . . . . . . . . . . . . 2
2.3 Working field . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Mounting the burner. . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Nozzles recommended . . . . . . . . . . . . . . . . 6
4.3 Electrodes setting . . . . . . . . . . . . . . . . . 7
4.4 Combustion head setting . . . . . . . . . . . . . 8
4.5 Air damper adjustment . . . . . . . . . . . . . . 8
4.6 Pump pressure . . . . . . . . . . . . . . . . . . . . 8
4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9
■One stage kerosene and gas oil burner.
■In case of BF applications the intake air temperature must not be over 70°C.
■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,
Machines 98/37/EEC and Efficiency 92/42/EEC.
■CE Reg. N: 0036 0275/99 (489 T50) - 0036 0274/99 (488 T50), as 92/42/EEC.
1– Pump
2– Control-box
3– Reset button with lock-out lamp
4– Flange with insulating gasket
5– Air damper adjustment screw
6– Photoresistance
7– Pump pressure adjustment screw
8– Pressure gauge port
1
D4069
Fig. 1
4
5
2
3
7
8
6

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2
2. TECHNICAL DATA
2.1 TECHNICAL DATA
◆
Gas oil is not permitted on low level discharge of flue gas products.
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD
(as EN 267)
TYPE 489T50 488T50
Output – Thermal power
(with air at 20°C)
3.0 – 5.8 kg/h 4.7 – 9.5 kg/h
35.6 – 68.7 kW 55.7 – 113 kW
(Hi= 11.97 kWh/kg)
Fuel Kerosene, viscosity 1.6 – 6 mm
2
/s at 20 °C
Gas oil, viscosity 4 – 6 mm
2
/s at 20 °C
◆
Electrical supply Single phase, ~ 50Hz 230V ± 10%
Motor Run current 1.3A – 2750 rpm – 288 rad/s
Capacitor 5
µ F
Ignition transformer Secondary 8 kV – 16 mA
Pump Kerosene, maximum pressure 10 bar (145 psi)
Gas oil, maximum pressure 15 bar (218 psi)
Absorbed electrical power 0.16 kW
BurnerFlange 167 A 253
30
11
204
D1844
83 83
268
163
45°
45°
189
168
140
106
øB
A78 111
ø B88 105
489T50
488T50
0.4
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
D1845
0.2
0.6
0.8
1.0
1.2
3456789
30 40 50 60 70 80 90 100 110
0
1.4
10
488T50489T50

2587
3
3. INSTALLATION
3.1 BOILER FIXING
➤ Put on the flange (1) the screw and two nuts, (see fig. 2).
➤ Widen, if necessary, the insulating gasket holes (5), (see fig. 3).
➤ Fix the flange (1) to the boiler door (4) using screws (2) and ( if necessary ) the nuts (3) interposing the
insulating gasket (5)
, (see fig. 4).
3.2 MOUNTINGTHE BURNER
5
1
2
4
3
E1661
Fig. 2
D5012
Fig. 3
E1660
Fig. 4
1
2
B
E1556
1) In case of CF applications, the burner shall not
operate without protection of the suction inlet. 2) In case of BF applications an optional snorkel and gasket are available replacing (B) with (C).
This item can be supplied separetely.
The combustion air supply is through a flexible
tube connected at the socket.
E1557
C

2587
4
3.3 HYDRAULIC SYSTEMS
■Check periodically the flexible pipes conditions.
Using kerosene, they have to be replaced at least every 2 years.
■A metal bowl filter with replaceable micronic filter must be fitted in the oil supply pipe.
H= difference of level L= Max. lenght of the suction line I.D. = Interminal diameter of the oil pipes
Fig.5
D5912 2
3
4
7
6
5
18
■The pump is designed to allow working with one pipe.
In order to obtain two pipes working it is necessary to
unscrew the return plug (2), screw the by-pass screw (3)
and then screw again the plug (2). (See fig. 5).
■In the two pipes systems, before starting the burner make
sure that the return pipe-line is not clogged. An excessive
back pressure would cause the damage of the pump seal.
WARNING:
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve
8- Auxiliary pressure test point
PRIMING PUMP:
On the system in fig. 6 it is sufficient to loosen the suction gauge
connection (6, fig. 5) and wait until oil flows out.
On the systems in fig. 7 and 8 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 sec-
onds before repeating the operation.
The pump suction should not exceed a maximum of 0,4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely
tight.
In the vacuum systems (fig. 8) the return line should terminate within the
oil tank at the same level as the suction line. In this case a non-return
valve is not required. Should however the return line arrive over the
fuel level, a non-return valve is required. This solution however is less
safe than previous one, due to the possibility of leakage of the valve.
H
meters
L meters
I. D.
8 mm I. D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
max. 4 m
H
H
D1560
Fig. 7
D1558
max. 4 m
H
H
Fig.8
H
max. 4 m
min. 0.1 m
D1559
Fig.6

2587 5
3.4 ELECTRICAL WIRING
CONTROL BOX (see fig. 9)
To remove the control box from the burner follow of the istruction:
➤Loosen the screw (1), open the protection (2) and remove all
components.
➤Remove the coil (3).
➤Loosen the two screws (4).
➤Move a little the control box and remove the high voltage leads.
E9154
4
4
3
12
Fig. 9
Capacitor
LN
~50Hz - 230V
Regulating
Oil valve
D4240
CONTROL BOX
Photoresistance
535SE/LD
thermostat
Limit thermostat
with manual
resetting
Motor
Remote lock-out lamp
(230V - 0.5A max.)
Main switch
T6A
Blue
White
Black
PE
Ignition
electrodes
TESTING:
Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
Burner-earth
NOTES:
– Wires of min. 1 mm2section.
(Unless requested otherwise by local stand-
ards and legislation).
– The electrical wiring carried out by the install-
er must be in compliance with the rules in
force in the Country.
DO NOT EXCHANGE NEUTRAL WITH PHASE
WARNING

2587 6
4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and
testing must be carried out observing the instruction manual of the boiler, including verification of the CO and
CO2concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of the
combustion head, and the air damper opening in accordance with the following schedule.
The values shown in the table are measured on a CEN boiler (as per EN 267). They refer to 12.5% CO2at sea
level and with fuel and room temperature of 20°C.
4.2 NOZZLES RECOMMENDED: Hago type ES - B ; Delavan type W - B;
Steinen type S ; Danfoss type S.
Nozzle Pump
pressure Burner output Combustion head adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
489T50
GAS OIL
0.75 60° 12 3.0 0.5 1.0
0.85 60° 12 3.4 0.5 1.4
1.00 60° 12 4.0 1.5 2.0
1.10 60° 12 4.4 3.0 2.6
1.25 60° 12 5.0 4.5 3.0
1.35 60° 13 5.6 6.0 4.0
KEROSENE
1.10 60° 7 3.08 0.0 1.1
1.25 60° 8 3.74 0.0 1.4
1.35 60° 8 4.04 0.5 1.9
1.50 60° 8 4.49 1.5 2.2
1.65 60° 8 4.93 3.0 2.5
1.75 60° 8 5.23 4.5 3.1
1.75 60° 10 5.85 6.0 4.0
488T50
GAS OIL
1.10 60° 12 4.4 2.0 2.8
1.25 60° 12 5.0 2.5 3.4
1.35 60° 12 5.4 2.5 3.7
1.50 60° 12 6.0 3.0 4.3
1.65 60° 12 6.6 3.0 5.0
1.75 60° 12 7.0 3.5 5.5
2.00 60° 12 8.0 4.0 7.5
2.25 60° 12 9.0 5.0 8.3
KEROSENE
1.65 60° 7 4.65 2.0 2.8
1.75 60° 8 5.23 2.5 3.1
2.00 60° 8 5.98 2.5 3.9
2.25 60° 8 6.73 3.0 5.1
2.50 60° 8 7.48 3.5 5.9
2.75 60° 8 8.22 4.0 7.4
3.00 60° 9 9.51 5.0 8.5

2587 7
MAINTENANCE POSITION
ACCESS TO THE COMBUSTION HEAD, ELECTRODES AND NOZZLE (see fig. 10).
➤Remove the burner out of the boiler, after loosing the fixing nut to the flange.
➤Hook the burner to the flange (1), by removing the blast tube (2) after loosing the fixing screws (3).
➤Remove the electrodes assembly (5) from the nozzle holder (4) after loosing its fixing screw (A, fig. 11).
➤Screw the nozzle (6).
4.3 ELECTRODES SETTING
E1662 E1663
1
2
3
5
6
4
Fig. 10
Before removing or assembling the
nozzle, loosen the screw (A, fig. 11)
and move the electrodes ahead.
TYPE
489T50 2 – 2.5 mm
488T50 4 ±0.5 mm
ATTENTION
D
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230 AD
Fig. 11

2587 8
4.4 COMBUSTION HEAD SETTING
This is done when fitting the nozzle, with the blast tube removed.It depends on the output of the burner and
is carried out by rotating the regulating rod, till the terminal plane of the blast tube is level with the set-point,
as indicated in the schedule.
4.5 AIR DAMPER ADJUSTMENT
The settings indicated in the schedule refer to the combustion-chamber with “zero” depression.
These regulations are purely indicative. Each installation however, has its own unpredictable working con-
ditions: actual nozzle output; positive or negative pressure in the combustion-chamber, the need of excess
air, etc.
All these conditions may require a different air-damper setting.
4.6 PUMP PRESSURE:
The pump leaves the factory set for kerosene working.
10 bar: maximum pressure for kerosene.
FOR GAS OIL INCREASE PRESSURE
12 bar: pressure suitable for gas oil in most cases.
14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.
4.7 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
Combustion head settings indicated in the
schedule are valid for most cases.
The setting of the fan output according to the
installation should normally be done only
through the air damper.
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5398
2
135
In the sketch on the
left, the combustion
head is set for an
output of 1.10 GPH
at 12 bar (
for gas oil )
or 1.65 GPH at 8 bar
(
for kerosene ).
489T50
The shutter is level with set-point 3, as required
by the schedule at page 6.
In the sketch on the
left, the combustion
head is set for an
output of 1.50 GPH
at 12 bar (
for gas oil )
or 2.25 GPH at 8 bar
(
for kerosene ).
488T50
Normal
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s
Lock-out due to failure to light
E
E

2587 9
5. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for some problems that could cause a
failure to start or a bad working of the burner.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box
(3, fig. 1, page 1).
When lock out lamp lights the burner will attempt to light only after pushing the reset button.
After this if the burner functions correctly, the lock-out can be attributed to a temporary fault.
If however the lock out continues the cause must be determined and the solution found.
WARNING
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error
in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the
technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
The burner will not
start when the ad-
justment thermostat
closes.
Lack of electrical supply.
Check presence of voltage in the
L - N clamps of the control box.
Check the conditions of the fuses.
Check that thermostat limit is not
lock out.
The photoresistance sees false light. Eliminate the light.
The connections in the control box
are wrongly inserted. Check and connect completely all the plugs.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective. Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned. Adjust them according to the instructions of this manual.
Air output is too high. Set the air output.
Nozzle dirty or worn. Replace it.