Riello RG2 Quick start guide

2902613 (4) - 05/2010
Installation, use and maintenance instructions
Montage- og driftsinstruktion
Instruktioner för installation, användning och underhåll
Anvisninger for installasjon, bruk og vedlikehold
Light oil burner
Oliebrænder
Oljebrännare
Oljebrenner
One stage operation
Et-trins funktion
Enstegsfunktion
Ett-trinns brenner
CODE - KODE
KOD MODELL - MODEL TYPE - TYP
3737720 RG2 377T1
GB
DK
S
N

2613 GB
4
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burner
Model: RG2
These products are in compliance with the following Technical Standards:
EN 267
EN 292
and according to the European Directives:
BED 92/42/EEC Efficiency Directive
MD 2006/42/EC Machine Directive
LVD 73/23/EEC - 2006/95/EC Low Voltage Directive
EMC 89/336/EEC - 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO
9001.
Legnago, 31.03.2010 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.

2613 1GB
INDEX
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . . . . . No. 1 Screw and nuts for flange to be fixed to boiler . . . . . .No. 4
Screw and nuts for flange . . . . . . . . . No. 1 Flexible oil pipes with nipples . . . . . . . . . . . . . . . . . . .No. 2
7 pin plug . . . . . . . . . . . . . . . . . . . . . . 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 Firing rate . . . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Recommended nozzles. . . . . . . . . . . . . . 6
4.3 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7
4.5 Combustion head setting. . . . . . . . . . . . . 8
4.6 Air damper adjustment . . . . . . . . . . . . . . 8
4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
1– Oil pump
2– Control-box
3– Reset button with lock-out
lamp
4– Flange with insulating
gasket
5– Air damper adjustment assembly
6– Nozzle holder assembly
7– Photoresistance
CE Certification No.: 0036 0344/03 as 92/42/EEC.
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.
The burner meets protection level of IP X0D (IP 40), EN 60529.
Fig. 1
S7208

2613 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 FIRING RATE, (as EN 267)
TYPE 377T1
Output - Thermal power 4 –10 kg/h - 47 –119 kW
Fuel Light oil, viscosity 4 –6 mm2/s at 20 °C
Electrical supply Single phase, ~50Hz 230V ±10%
Motor Run current 0.9A – 2720 rpm – 285 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 –15 bar
Absorbed electrical power 0.18 kW
202 115 189
140
168
10
28
230
280
11
8383
106
45°
45°
D5707
255
ø95
03 4 5 Light oil output – kg/h
35 45 55 Thermal power – kW
1.0
0.8
0.6
0.4
0.2
Pressure in combustion
chamber – mbar
D5416
67
65 75
891011
85
1.2
95 105 115 125

2613 3GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
Put on the flange (1) the screw and two nuts, (see fig. 3).
Widen, if necessary, the insulating gasket holes (5).
Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3) interposing the insu-
lating gasket (5), (see fig. 2).
3.2 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate (1)
and closing plate (2) should be reversed, (see fig. 4).
Fig. 2
Fig. 3 S7209
D5709
1
Fig. 4
2 21

2613 4GB
3.3 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.
PRIMING PUMP:
On the system in fig. 6 it is sufficient to loosen the suction gauge
connection (5, 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 seconds
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 re-
quired. 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
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
Fig. 6
H
max. 4 m
D5713
H
max. 4 m
max. 4 m
H
H
H
D5714
Fig. 7 Fig. 8
SYSTEM NOT PERMITTED
IN GERMANY
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
OThe pump is designed to allow working with two
pipes. In order to obtain one pipe working it is
necessary to unscrew the return plug (2), remove the
by-pass screw (3) and then screw again the plug (2).
(See fig. 5).
OBefore 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:
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 gauge
Fig. 5
1
234567
8
D5026

2613 5GB
3.4 ELECTRICAL WIRING
D4034
ESEGUITO IN FABBRICA
WARNING
CONTROL BOX
To remove the control-box from the burner, loosen screw (A, fig. 9)
and pull to the arrow direction, after removing all components, the
7 pin plug and earth wire.
In case of disassembly of the control box, retighten the screw
(A) with a torque wrench setting of 1 – 1.2 Nm.
DO NOT EXCHANGE NEUTRAL WITH PHASE
7 pin plug
7 pole socket
Black
White
Capacitor
Main switch
T6A
Motor
Safety
thermostat
Blue
Oil valve
Hour counter
(230V - 0.
1A max.)
Limit
thermostat Remote lock-out signal
(230V - 0.5A max.)
Ignition
electrodes
Brown
Burner-earth
CARRIED-OUT IN THE FACTORY
553SE/H
CONTROL BOX
Photoresistance
PE L N
~ 50Hz 230V
Blue
Brown Blue
TESTING
Check the shut-down of the
burner by opening the thermo-
stats and the lock-out by dark-
ening the photoresistance.
NOTES:
– Wires of min. 1 mm2section. (Unless requested
otherwise by local standards and legislation).
– The electrical wiring carried out by the installer
must be in compliance with the rules in force in
the Country.
S7217
Fig. 9
A

2613 6GB
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 CO2
concentration 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 light oil and room temperature of 20 °C
4.2 RECOMMENDED NOZZLES: Delavan type W - B ; Danfoss type S - B
Monarch type R ; Steinen type S - Q.
For 1.75 - 2.00 - 2.25 GPH nozzles it is advisable to use
full cones.
MAINTENANCE POSITION
THE ACCESSIBILITY TO THE NOZZLE, THE
DIFFUSER DISC AND THE ELECTRODES IS
MADE EASY IN 2 WAYS:
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 small cables (4) from the electrodes
and the diffuser disc-holder assembly (5) from
the nozzle-holder assembly after loosing its fix-
ing screw (3, fig. 12, page 7).
Screw the nozzle (6) correctly and tighten it as
shown in the figure.
Nozzle Pump
pressure Burner output Combustion head adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
1.00 60° 12 4.0 0 0.9
1.10 60° 12 4.4 1 3.1
1.25 60° 12 5.0 2 3.4
1.50 60° 12 6.0 3 3.8
1.75 60° 12 7.0 4 4.5
2.00 60° 12 8.0 5 4.9
2.25 60° 14 9.8 6 6.0
AFig. 10
2
5
4
3
6
1
S7480
A

2613 7GB
Fig. 11
Remove nozzle-holder assembly (1) after loos-
ing screws (2) and nut (3), remove the small ca-
bles (4) from the control box and the
photoresistance (6).
Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc-holder assem-
bly (10) from the nozzle-holder assembly (1)
after loosing screw (3, fig. 12).
Screw the nozzle (11) correctly and tighten it
as shown in figure.
ATTENTION
During the reassembly of the nozzle-holder as-
sembly screw the nut (3) as shown in the figure
below.
4.3 ELECTRODES ADJUSTMENTS (see fig. 12)
4.4 PUMP PRESSURE
The pump leaves the factory set at 12 bar.
To change it act on pump pressure adjust screw (4, fig. 5, page 4).
S7210
BFig. 11
B
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684
WARNING
Lean the diffuser disc-holder
assembly (1) on the nozzle-holder
(2) and lock it by screw (3). For
prospective adjustments loosen
screw (4) and move the elec-
trodes assembly (5).
ATTENTION
To have access to the electrodes carry
out operation as described in
chapter
4.2
RECOMMENDED NOZZLES”
(page 6) .
Fig. 12
4 – 5 mm
4.5 – 0.5 mm
0
1
MEASURES MUST BE
23
5
4
D5537
RESPECTED

2613 8GB
4.5 COMBUSTION HEAD SETTING (see fig. 11, page 7)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting
screw (5) until the set-point marked on the regulating rod (9) is level with the outside plane of the nozzle-holder
assembly (1).
In the sketch the combustion head is set for an output of 1.50 GPH at 12 bar.
The set-point 3of the regulating rod (9) is at the same level with the outside plane of the nozzle-holder as-
sembly (1) as shown in the schedule.
4.6AIR DAMPER ADJUSTMENT (see fig. 11, page 7)
To vary the setting adjust the screw (7) after loosing the nut (8).
When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.
4.7 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and conse-
quent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the burner
acting on the main switch of the system.
THE BASIC CHECKS ARE:
Check that there are not obstructions or dents in the supply or return oil pipes.
Clean the filter in the oil suction line and in the pump.
Clean the photoresistance, (7, fig. 1, page 1).
Check for correct fuel consumption.
Replace the nozzle (see fig. 10, page 6) and check the correct position of electrodes (fig. 12, page 7).
Clean the combustion head in the fuel exit area, on the diffuser disc.
Leave the burner working without interruptions for 10 min. and set rightly all the components stated in this
manual. Then carry out a combustion check verifying:
Smoke temperature at the chimney; Contentof CO2(%); ContentofCO(ppm);
Smoke value according to opacity smokes index according to Bacharach scale.
Lock-out due to failure to light
C
Normal
D5029
~12s
Thermostat
Motor
Ignition transformer
Oil valve
Flame
Lock-out lamp ~12s 5s
C