Riello RL 25/1 BLU Quick start guide

Installation, use and maintenance instructions
Instrucciones de Instalación, Funcionamiento y Mantenimiento
20156111 (2) - 12/2021
Light oil burners
Quemadores de gasóleo
One stage operation
Funcionamiento a una llama
CODE - CÓDIGO MODEL - MODELO
20156024 RL 25/1 BLU
20157095 RL 25/1 BLU
GB
E

Translation of the original instructions
Traducción de las instrucciones originales

1 20156111
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Background ................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Technical data............................................................................................................................................................. 8
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Maximum dimensions.................................................................................................................................................. 9
4.6 Burner equipment........................................................................................................................................................ 9
4.7 Firing rate .................................................................................................................................................................. 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description ..................................................................................................................................................... 11
4.10 Control box RMO88................................................................................................................................................... 12
5 Installation ................................................................................................................................................................................ 13
5.1 Notes on safety for the installation ............................................................................................................................ 13
5.2 Handling .................................................................................................................................................................... 13
5.3 Preliminary checks .................................................................................................................................................... 13
5.4 Operating position ..................................................................................................................................................... 14
5.5 Preparing the boiler................................................................................................................................................... 14
5.5.1 Boring the boiler plate ............................................................................................................................................... 14
5.5.2 Securing the burner to the boiler............................................................................................................................... 14
5.6 Nozzle installation ..................................................................................................................................................... 15
5.6.1 Recommended nozzle............................................................................................................................................... 15
5.7 Combustion head adjustment.................................................................................................................................... 16
5.7.1 Adjustments prior to ignition ...................................................................................................................................... 16
5.7.2 Pump adjustment ...................................................................................................................................................... 16
5.7.3 Fan damper adjustment ............................................................................................................................................ 16
5.8 Light oil supply........................................................................................................................................................... 17
5.8.1 The loop circuit.......................................................................................................................................................... 17
5.8.2 Recommendations for both systems (A) and (B) ...................................................................................................... 18
5.8.3 One-pipe systems ..................................................................................................................................................... 18
5.8.4 Hydraulic connections ............................................................................................................................................... 19
5.9 Pump......................................................................................................................................................................... 20
5.9.1 Technical data........................................................................................................................................................... 20
5.9.2 Priming pump ............................................................................................................................................................ 20
5.10 Electrical connections................................................................................................................................................ 21
5.10.1 Supply cables and external connections passage .................................................................................................... 21
6 Start-up, calibration and operation of the burner ................................................................................................................. 22
6.1 Notes on safety for the first start-up .......................................................................................................................... 22
6.2 Adjustments prior to ignition...................................................................................................................................... 22
6.2.1 Nozzle ....................................................................................................................................................................... 22
6.2.2 Combustion head ...................................................................................................................................................... 22
6.2.3 Pump pressure.......................................................................................................................................................... 22
6.2.4 Fan damper............................................................................................................................................................... 22

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Contents
6.3 Burner ignition............................................................................................................................................................22
6.4 Operation sequence of the burner .............................................................................................................................23
6.4.1 Burner start-up ...........................................................................................................................................................23
6.4.2 Ignition failure.............................................................................................................................................................23
6.4.3 Burner flame goes out during operation.....................................................................................................................23
6.5 Burner start-up cycle diagnostics...............................................................................................................................24
6.5.1 Resetting of control box and diagnostics use ............................................................................................................24
6.5.2 Control box reset........................................................................................................................................................24
6.5.3 Visual diagnostics ......................................................................................................................................................24
6.5.4 Software diagnostics..................................................................................................................................................24
6.6 Final checks (with burner operating)..........................................................................................................................25
7 Maintenance ..............................................................................................................................................................................26
7.1 Notes on safety for the maintenance .........................................................................................................................26
7.2 Maintenance programme ...........................................................................................................................................26
7.2.1 Maintenance frequency..............................................................................................................................................26
7.2.2 Checking and cleaning...............................................................................................................................................26
7.2.3 Safety components ....................................................................................................................................................27
7.3 Electrical panel maintenance .....................................................................................................................................28
7.4 Opening the burner ....................................................................................................................................................28
7.5 Closing the burner......................................................................................................................................................28
8 Faults - Possible causes - Solutions.......................................................................................................................................29
A Appendix - Accessories ...........................................................................................................................................................31
B Appendix - Electrical panel layout...........................................................................................................................................33

3 20156111
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Declarations
Declaration of Conformity in accordance with ISO / IEC 17050-1
These products are in compliance with the following Technical Standards:
• EN 12100
•EN267
According to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
1 Declarations

20156111 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Cen-
tre of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20156111
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Information and general warnings
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The Manufacturer guarantees its new products from the date of
installation, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the appliance;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optionals;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20156111 6
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Safety and prevention
3.1 Background
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
Namely:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the ambient temperature must all be within the values in-
dicated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties;
Personnel must follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to inform their superiors of every
problem or dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
accepts no responsibility whatsoever for any which may
result from the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20156111
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4 Technical description of the burner
Designation Voltage Start-up Code
RL 25/1 BLU TC 1/230/50 Direct 20156024
RL 25/1 BLU TL 1/230/50 Direct 20157095
Class 2 EN267
Range: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R L 25 TC
Emission: ... Class 1 EN267
MZ Class 2 EN267
BLU Class 3 EN267
3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with variable speed (with Inverter)
/1 Ome-stage
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Extended head
MX
BLU
... Two-stage
/1 FS1

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Technical description of the burner
4.3 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1,013 mbar - Altitude 0 m a.s.l.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output. The sound power
is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3” measurement, as described in
EN ISO 3746.
4.4 Electrical data
Tab. B
Model RL 25/1 BLU
Power(1) min - max kW 115 - 260
Delivery (1)
Mcal/h 99 - 224.4
kg/h 10 - 22
Fuel Light oil
Max. viscosity at 20 °C: 6 mm2/s (1.5°E - 6 cSt)
Net Calorific Value kWh/kg 11,8
Mcal/kg 10.2 (10,200 kcal/kg)
Density kg/dm3 0.82 - 0.85
Intermittent – Intermittent (min. 1 stop in 24 hours)
– One-stage (all - nothing)
Pump Output at 12 bar
Pressure range
Fuel temperature
kg/h
bar
°c max
45
8 - 25
60
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Room temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB (A) 71 82
Weight (including packaging) kg 43
Model RL 25/1
Electrical power 1 Ph 1 N ~ 230 50 Hz
Motor rpm
V
W
A
2800
230
300
2.4
Fan motor capacitor µF 12.5/450
Ignition transformer V1 - V2
I1 - I2
220-240V - 2x12kV
0.2A - 30mA
Single-phase max. absorbed electric
power main electrical supply W max 550
Protection level IP 54

9 20156111
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Technical description of the burner
4.5 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Note that to inspect the combustion head the burner must be
moved backward and turned upward.
The maximum dimensions of the open burner, without cover, is
given by measurement U-U.
Tab. C
Tab. D
4.6 Burner equipment
Flexible hoses (L = 1530 mm) . . . . . . . . . . . . . . . . . . . .No. 2
Gaskets for flexible hoses . . . . . . . . . . . . . . . . . . . . . . .No. 2
Nipples for flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to fix the burner flange to the boiler: M 8 x 25 . . . . No. 4
7 pin plug for electrical wiring . . . . . . . . . . . . . . . . . . .No. 1
3 pin plug for electrical wiring . . . . . . . . . . . . . . . . . . .No. 1
Installer booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
T-T(1)
P
D
E
B
L
H
U-U(1)
Fig. 1
20152177
mm B D E L H P U T-T1 U (1)
RL 25/1 BLU 130 140 305 442 416 508 788 200-280 -
mm X Y Z
RL 25/1 BLU 995 466 490
Z
Y
X
Fig. 2
20158480

20156111 10
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Technical description of the burner
4.7 Firing rate
The burner output is chosen from within the diagram area
(Fig. 3). This area is known as the "firing rate" and provides the
burner output according to the pressure in the combustion cham-
ber.
The work point may be found by plotting a vertical line from the
desired delivery and a horizontal line from the pressure in the
combustion chamber The intersection of these two lines is the
work point which must lie within the firing rate.
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 4).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the manufac-
turer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 267 regulations.
In Fig. 4 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 35 kg/h - diameter 50 cm - length 1.5 m
WARNING
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1,013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 16.
Pressure in
Heat output Fig. 3
20158279
adjustment
Fig. 4
Combustion chamber
m
D454

11 20156111
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Technical description of the burner
4.9 Burner description
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Flame sensor for flame presence control
5 Screw for fixing fan to flange
6 Slide bars for opening the burner and inspecting the com-
bustion head
7 Valve group
8Pump
9 Plate prearranged to drill 4 holes for the passage of hoses
and electrical cables.
10 Fan air inlet
11 Fan pressure test point
12 Boiler fixing flange
13 Flame stability disc
14 Flame inspection window
15 Control box with lockout pilot light and lockout reset button
16 Socket for electrical connection
17 Air gate valve
18 Adjusting pump pressure
19 Plate prearranged to drill 2 holes for the passage of hoses.
Two types of burner failure may occur:
CONTROL BOX LOCKOUT: if the control box push-button (red
led) 17)(Fig. 5) lights up, it indicates that the burner is in lockout.
To reset, hold the button down for between 1 and 3 seconds.
1
2
3
64
8
10
11
12 13
7
5
9
14
15
16
17
18
19
Fig. 5
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Technical description of the burner
4.10 Control box RMO88...
Warning
 All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
 Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation). Check the system is not powered
and cannot be accidentally reconnected. Failure to do this
will lead to the risk of electrocution.
 Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
 Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
 Falls and collisions can negatively affect the safety func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
 Press the reset button of the burner lockout command or the
reset button (by applying a force of not more than 10 N),
without the aid of tools or sharp objects.
For the safety and reliability of the control box, comply with the
following instructions:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Technical data
Mechanical structure
The control box is made of plastic to resist knocks, heat and
flame propagation.
The control box contains the following components:
• a microprocessor that controls the program sequence, and a
relay for controlling the load
• an electronic flame signal amplifier
• a built-in reset button with 3 signalling colours (LED) for status
and error messages.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box RMO88... is a safety device!
Avoid opening or modifying it, or forcing its opera-
tion. Riello S.p.A. cannot assume any responsibil-
ity for damage resulting from unauthorised
interventions!
Mains voltage AC 220...240 V +10 % / -15 %
Mains frequency 50 / 60 Hz ±6%
Power absorption 20 VA
Protection level IP20
Safety class I
Weight approx. 260g
Cable length
Thermostat cable
Air pressure switch
Gas pressure switch
Remote reset
CPI
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95 % r.h.
Fig. 6
S8906

13 20156111
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model (A)(Fig. 7) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the data for electrical supply and the protection level (E);
the absorbed electrical power (F);
the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
the maximum viscosity of the light oil (L);
the category of the appliance/countries of destination (I).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected and
disposed of in the appropriate places.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
R.B.L.
A
CH
D
F
E
L
I
Fig. 7
20158029

20156111 14
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 9.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
Tab. E
5.5.2 Securing the burner to the boiler
Remove the blast tube unit 7) and the pipe coupling 5) from
the burner 4);
remove the screws 2) from the two slide bars 3).
remove the screw 1) and draw back the burner on the slide
bars 3).
Fix the unit 5) and 7)(Fig. 10) to the boiler plate, inserting the
insulating gasket 6)(Fig. 10) that was supplied.
Use the 4 screws, also supplied with the unit, after protecting
the thread with anti-locking products.
WARNING
The burner is designed to work only in posi-
tions 1, 2, 3 and 4 (Fig. 8).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 8
2 3 4 51
D3928
mm D1 SF E
RL 25/1 BLU 160 224 M 8
Ø
45
45
DF
D1
Fig. 9
20149117
Provide an adequate lifting system.
WARNING
The seal between burner and boiler must be
airtight.
123
456
7
8
9
10
10
Fig. 10
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15 20156111
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Installation
5.6 Nozzle installation
The burner complies with the emission requirements of the
EN 267 standard. In order to guarantee that emissions do not
vary, recommended and/or alternative nozzles specified by Riello
in the Instruction and warning booklet should be used.
Loosen the screws 2) and take out the flame stabiliser unit
1), remove the plastic plug 3) and fit the nozzle (Fig. 11).
Make sure that the electrodes are placed as in Fig. 12.
Then put the burner 4) back on the slide bars 3) and slide it
up to the flange 5), keeping it slightly raised to prevent the
flame stabiliser unit from pushing against the guide tabs 6) of
the blast tube (Fig. 13).
Tighten the screws 2) on the slide bars 3) and the screw 1)
that fixes the burner to the flange (Fig. 13).
Whenever the nozzle needs changing when the burner is
already applied to the boiler, open the burner on the slide
bars as in Fig. 10 on page 14 and proceed as described
above.
5.6.1 Recommended nozzle
The nozzle is selected from those indicated in the table (Tab. F).
Use nozzles with a hollow cone or semi hollow spray angle of 60°.
In the event of humidity caused by narrow combustion chambers
use nozzles with a full cone spray angle of 45°.
Tab. F
(1) Light oil: density 0.84 kg/dm3 - viscosity 4.2 cSt/20 °C - tem-
perature 10 °C
WARNING
It is advisable to replace the nozzle once a year
during periodical maintenance.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards
to people and objects.
The manufacturing company shall not be liable for
any such damage arising from non-observance of
the requirements contained in this manual.
WARNING
Do not use any sealing products such as gas-
kets, sealing compound, or tape.
Be careful to avoid damaging the nozzle seal-
ing seat.
The nozzle must be screwed into place tightly
but not to the maximum torque value pro-
vided by the wrench.
WARNING
The nozzle supplied can be used if adapted to the
required flow rate, otherwise it should be replaced
with a nozzle that has a flow rate that is suited to
the system.
GPH
Kg/h (1)
8 bar 11 bar 14 bar 17 bar 20 bar 22 bar
2.25
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.4
8.2
9.9
11.5
13.2
14.8
16.5
18.1
19.8
21.4
8.8
9.8
11.8
13.7
15.7
17.6
19.6
21.5
23.5
25.5
10.0
11.2
13.4
15.6
17.8
20.1
22.3
24.5
26.8
29.0
11.1
12.4
14.8
17.3
19.8
22.2
24.7
27.2
29.7
32.0
11.9
13.4
16.1
18.8
21.5
24.0
26.8
29.5
32,2
34.5
12.4
14.0
16.8
19.8
22.6
25.1
28.1
30.9
33,7
36.0
Fig. 11
D1752
Fig. 12
D1753
4
35
21
Fig. 13
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Installation
5.7 Combustion head adjustment
5.7.1 Adjustments prior to ignition
At this stage of the installation the blast tube and the pipe
coupling are secured to the boiler as shown in fig.10 on page
15. Therefore it is easy to adjust the combustion head that
depends only on the output of the burner, namely on the flow
rate of the nozzle selected in Tab. F on page 15.
Turn the screw 4)(Fig. 14) until the notch indicated by the
diagram (Fig. 15) lines up with the front part of the flange
5)(Fig. 14).
Example:
Burner RL 25/1 BLU with 3.5 GPH nozzle and pump pressure of
14 bar: from the table Tab. F you get an output of 15.6 kg/h.
The diagram (Fig. 15) indicates that for an output of 15.6 kg/h
the RL 25/1 BLU burner requires an adjustment of the com-
bustion head to about 3 notches, as shown in Fig. 15.
5.7.2 Pump adjustment
No adjustment to the pump is necessary, which has been set by
the manufacturer at:
– 22 bar: high pressure,
– 9 bar: low pressure,
This pressure should be checked and if necessary adjusted after
starting the burner.
5.7.3 Fan damper adjustment
The fan damper is adjusted by using the graduated sector
1)(Fig. 16), after loosening the nut 2)(Fig. 16). For the initial start-
ing, leave factory adjustment: notch 2, as in Fig. 16.
Fig. 14
0123
4
5
20157183
Fig. 15
No. notches
Burner output
20158280
Fig. 16
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17 20156111
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Installation
5.8 Light oil supply
The burner is equipped with a self-priming pump which is capable
of feeding itself within the limits indicated in Tab. G.
There are three types of fuel water circuits:
– Dual pipe circuits (most common)
– Single pipe circuits
– Loop circuits.
Depending on the configuration of the burner/tank, also two sup-
ply systems can be used:
– siphon type (the tank is higher than the burner);
– suction type (the tank is lower than the burner).
Siphon dual pipe systems (A) (Fig. 17)
P should not exceed 10 metres so as not to overly stress the
pump sealing organ; V should not exceed 4 metres in order to al-
low the pump to self-prime also when the tank is almost empty.
Suction dual pipe systems (B) (Fig. 17)
Pump depression values should never exceed 0.45 bar (35 cm
Hg) since the fuel releases gas at high levels, the pump becomes
noisy and its life shortens. It is good practice to ensure that the
return and suction lines enter the burner at the same height; in
this way it is more difficult that the suction line fails to prime or
else stops.
5.8.1 The loop circuit
A loop circuit consists of a closed pipe departing from and return-
ing to the tank with an auxiliary pump that circulates the fuel un-
der pressure.
A branch connection from the loop goes to feed the burner. This
circuit is extremely useful whenever the burner pump does not
succeed in self-priming because the tank distance and/the height
difference are higher than the values listed in Tab. G.
Tab. G
Key (Fig. 17)
H = Pump/Foot valve height difference
L = Line length Values calculated for light oil:
– Viscosity = 6 cSt / 20 °C
– Density = 0.84 kg/dm3
– Temperature = 0 °C
– Max. altitude = 200 m (a.s.l.)
Ø = Inside pipe diameter
1=Burner
2=Pump
3 = Filter
4 = Manual on/off valve
5 = Suction line
6 = Foot valve
7 = Return line
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure that the fuel interception tap is closed
before performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
+/- H
[m]
L [m]
Ø [mm]
810 12
+4,0 52 134 160
+3,0 46 119 160
+2,0 39 104 160
+1,0 33 89 160
+0.5 30 80 160
027 73 160
-4.0 24 66 144
-3.0 21 58 128
-2.0 15 43 96
-1.0 828 65
-0.5 -12 33
95
7
10
6
6
753
9
4
A
B
P
+H
8
10 cm
-H V
1
2
Fig. 17
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Installation
5.8.2 Recommendations for both systems (A) and
(B)
Use copper pipes where possible.
Make sure that the system curves have a wide radius.
Use bi-conic connectors at both ends of the pipe.
Whenever the burner is installed in areas with extremely
cold winter climates (temperatures lower than - 10°C), we
recommend insulating both the tank and the piping. Avoid
the smallest of the three pipe diameters provided in the
Table and lay the piping along the most protected route pos-
sible. The paraffin in the fuel begins to solidify below 0°C,
and the filters and nozzle begin to clog accordingly.
Put a filter on the suction piping, if possible with a clear
transparent tray that allows the regular flow of fuel and
check the condition of the filter.
The return pipeline does not require a shut-off valve, but if
you want to put it, choose one with lever control so that is
clear when the valve is open or closed (if the burner starts
with the return pipe closed, the sealing organ on the pump
shaft will be damaged).
The copper pipes should be fitted at a distance from the
burner that allows it to be drawn back on the slide guides
without straining or twisting the hoses.
When there are several burners in the same room, each
burner has to have its own suction pipe; they can share the
same return line pipe as long as the dimensions allow it.
The suction line must be completely airtight. To check the
seal, close the pump's return line. Fit a T coupling on the
attachment of the vacuometer. On one branch of the T cou-
pling install a pressure gauge and in the other inject air at a
pressure of 1 bar. After injecting the air the pressure gauge
should remain at a constant pressure.
5.8.3 One-pipe systems
There are two possible solutions:
Pump external by-pass (A) (recommended)
– connect the two flexible hoses to an automatic degassing
unit, (see paragraph Appendix - Accessories).
– in this case the screw 7) should not be removed (see the
diagram Fig. 19): pump internal by-pass closed.
Pump internal by-pass (B)
– Connect only the suction line flexible hose to the pump.
– Remove the screw 7), (Fig. 19), accessible from the return
fitting: pump internal by-pass open.
– Tap the fitting of the pump's return line.
– This solution is possible only with low pump depression
values (max. 0.2 bar) and fully airtight piping.
Fig. 18
D828
AB