Riello RL 28/1 User manual

Installation, use and maintenance instructions
Instrucciones de Instalación, Funcionamiento y Mantenimiento
Instruções de Instalação, Funcionamento e Manutenção
Bruciatori di gasolio
Quemadores de gasóleo
Queimadores a gasóleo
One stage operation
Funcionamiento a una llama
Funcionamento a uma chama
2916092 (0)
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3472080 RL 28/1 657 T80
3472081 RL 28/1 657 T80
GB
E
P

1
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 5
Choice of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan gate adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Burner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 13
Resetting the control box and using diagnostics. . . . . . . . . . . 13
Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 14
Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
N.B.
Figures mentioned in the text are identified as follows:
1)(A) = part 1 of figure A, same page as text;
1)(A)p.3 = part 1 of figure A, page number 3.
NOTE
In conformity with Efficiency Directive 92/42/EEC the application
of the burner on the boiler, adjustment and testing must be car-
ried 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.
GB

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.
VARIANTS
ACCESSORIES (optional):
•STATUS (see page 15): code 3010321
• DEGASSING UNIT
It may occur that a certain amount of air is contained in the light oil sucked up by the pump. This air may originate from the light oil itself as a
consequence of depressurization or air leaking past imperfect seals.
In double-pipe systems, the air returns to the tank from the return pipe; in single-pipe systems, the air remains in circulation causing pressure var-
iations in the pump and burner malfunctions.
For this reason, we advise installing a degassing unit near the burner in single-pipe installations.
Degassing units are provided in two versions:
CODE 3010054 without filter
CODE 3010055 with filter
Degassing unit characteristics
• Burner delivery : 80 kg/h max
• Light oil pressure : 0,7 bar max
• Ambient temperature : 40 °C max
• Light oil temperature : 40 °C max
• Attachment connectors : 1/4 inch
MODEL RL 28/1
TYPE 657 T80
OUTPUT (1)
DELIVERY (1)
kW 178 - 332
153 - 286
15 - 28
Mcal/h
kg/h
FUEL LIGHT OIL
- Net calorific value kWh/kg
Mcal/kg
11.8
10.2 (10200 kcal/kg)
- Density kg/dm30.82 - 0.85
- Viscosity at 20 °C mm2/s max 6 (1.5 °E - 6 cSt)
OPERATION • Intermittent (min. 1 stop in 24 hours).
• Single-stage (all - nothing).
NOZZLES numero 2
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATURE °C 0 - 40
COMBUSTION AIR TEMPERATURE °C max 60
ELECTRICAL SUPPLY V
Hz
220-230 ~ +/-10%
60 - single-phase
ELECTRIC MOTOR rpm
W
V
A
2800
300
220 - 240
2,4
MOTOR CAPACITOR µF/V 12.5/450
IGNITION TRASFORMER V1 - V2
I1 - I2
230 V - 2 x 5 kV
1.9 A - 30 mA
PUMP delivery (at 20 bar)
pressure range
fuel temperature
kg/h
bar
° C max
45
10 - 18
60
ELECTRICAL POWER CONSUMPTION W max 370
ELECTRICAL PROTECTION IP 44
IN CONFORMITY WITH EEC DIRECTIVES 89/336 - 73/23 - 92/42 - 89/392
NOISE LEVELS (2) dBA 70.0
Model Code Electrical
supply
Blast tube
lenght mm
RL 28/1 3472080
3472081
single-phase
single-phase
216
351

3
BURNER DESCRIPTION (A)
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Photocell for flame presence control
5 Screw for fixing fan to flange
6 Indexed selector.
Opens the fan gate to the value necessary at
the burner delivery
7 Slide bars for opening the burner and inspect-
ing the combustion head
8 Valve assembly
9 Pump
10 Plate prearranged to drill 4 holes for the pas-
sage of hoses and electrical cables.
11 Air inlet to fan
12 Fan pressure test point
13 Boiler mounting flange
14 Flame stability disk
15 Flame inspection window
16 Extensions for slide bars 7)
17 Motor capacitor
18 Control box with lock-out pilot light and lock-
out reset button
19 Plugs for electrical connections
20 Air gate valve
21 Pump pressure adjustment
N.B.
If the control box 18)(A) pushbutton (red led)
lights up, it indicates that the burner is in lock-
out.
To reset, hold the pushbutton down for between
1 and 3 seconds.
PACKAGING-WEIGHT (B)
Approximate measurements
• The burner is shipped in cardboard boxe with
the maximum dimensions shown in table (B).
• The weight of the burner complete with pack-
aging is indicated in table (B).
MAX. DIMENSIONS (C)
Approximate measurements.
The maximum dimensions of the burner are giv-
en in (C).
Bear in mind that inspection of the combustion
head requires the burner to be opened and the
rear part withdrawn on the slide bars.
The maximum dimension of the burner, without
casing, when open is give by measurement H.
STANDARD EQUIPMENT
2 - Flexible hoses
2 - Gaskets for flexible hoses
2 - Nipples for flexible hoses
1 - Thermal insulation screen
2 - Extensions 16)(A) for slide bars 7)(A)
(for model with 351 mm blast tube)
4 - Screws to secure the burner flange to the
boiler: M 8 x 25
2 - Fairleads for electrical connections
1 - Instruction booklet
1 - Spare parts lis
(A)
(B)
mm A B C kg
RL 28 /1 1010 620 495 35
(1) Blast tube: short-lang
mm A B C D (1) EFG H(1)
RL 28 /1 476 474 468 216 - 351 140 352 52 672 - 807
(C)
D452
D88
D3261
D3260
D583

4
FIRING RATES (A)
The burner delivery must be selected within area
of the adjacent diagram.
This area is called firing rate and provides the
delivery of the burner in relation to the pressure
in the combustion chamber.
The work point may be found by plotting a verti-
cal line from the desired delivery and a horizontal
line from the pressure in the combustion cham-
ber. The intersection of these two lines is the
work point which must lie within firing rate.
Important
The FIRING RATE area values have been ob-
tained considering a surrounding temperature of
20 °C, and an atmospheric pressure of 1000
mbar (approx. 100 m above sea level) and with
the combustion head adjusted as shown on page
6.
TEST BOILER (B)
The firing rate was set in relation to special test
boilers in accordance with the methods defined
in EN 267 standards.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example:
delivery 25 kg/hour:
diameter = 50 cm; length = 1,25 m.
Whenever the burner is operated in a much
smaller commercially-available combustion
chamber, a preliminary test should be per-
formed.
(A)
(B)
D585
D586
pressure mbar
Combustion chamber
Combustion chamber
length m

5
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A).
The position of the threaded holes can be
marked using the thermal screen supplied with
the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected ac-
cording to the indications provided by the manu-
facturer of the boiler, and in any case it must be
greater than the thickness of the boiler door com-
plete with its fettling. The range of lengths avail-
able, L, is as follows:
Blast tube 7): • short 216 mm
• long 351 mm
For boilers with front flue passes 10) or flame in-
version chambers, protective fettling in refractory
material 8) must be inserted between the boiler's
fettling 9) and the blast tube 7).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the refrac-
tory fettling 8)-9)(B) is not required unless it is ex-
pressly requested by the boiler manufacturer.
SECURING THE BURNER TO THE BOILER (B)
Disassemble the blast tube 7) from the burner 4)
by proceeding as follows:
- Remove the screws 2) from the two slide bars 3).
- Remove the screw 1) fixing the burner 4) to
the flange 5).
- Withdraw the blast tube 7) complete with
flange 5) and slide bars 3).
Secure flange 5)(B) to the boiler plate interpos-
ing the supplied gasket 6). Use the 4 supplied
screws provided after having protected the
thread with antiscruffing products (high-tempera-
ture grease, compounds, graphite). The burner-
boiler seal must be airtight.
CHOICE OF NOZZLES
Choose the couple of nozzles among those giv-
en in table (C).
Use nozzles with a 60° spray angle at the recom-
mended pressure of 12 bar.
When the burner fires only the first nozzle works.
Its delivery is higher than that of the second noz-
zle in order to assure a good flame stabilisation
to the stability disk, though the fan delivery has
been adjusted for both working nozzles.
Whenever ignition takes place with unusual
noise or pulsations, you should reduce the first
nozzle delivery making sure that the flame stabi-
lisation is still satisfactory.
Subsequently also the second nozzle starts
working.
The burner»s operating delivery consists of the
sum of the two nozzles deliveries.
Example
Boiler output = 230 kW
Efficiency 90 %
Output required by the burner =
230 : 0,9 = 255 kW
In table (C) the following nozzles are recom-
mended:
1° = 3,0 GPH + 2° = 2,0 GPH - 60° - 12 bar.
(A)
(B)
(C)
(1) We get the indicated delivery when both nozzles are working and light
oil has the following characteristics:
Density 0,84 kg/dm3- Viscosity 4,2 cSt/20 °C - Temperature 10 °C.
GPH kg/h (1) kW
12 bar
1° 2° 10 bar 12 bar 14 bar
2,25
2,50
2,75
3,00
3,00
3,50
3,50
4,00
4,00
+
+
+
+
+
+
+
+
+
1,50
1,75
1,75
2,00
2,25
2,25
2,50
2,75
3,00
14,4
16,3
17,3
19,2
20,2
22,1
23,0
25,9
26,9
15,9
18,0
19,1
21,2
22,3
24,4
25,4
28,6
29,7
17,3
19,6
20,7
23,0
24,2
26,5
27,7
31,1
32,3
189
213
226
251
264
289
301
339
352
D587
D588

6
NOZZLE ASSEMBLY
At this stage of installation the burner is still dis-
assembled from the blast tube; it is therefore
possible to fit two nozzles with the box spanner
1)(A) (16 mm), after having removed the plastic
plugs 2)(A), fitting the spanner through the cen-
tral hole in the flame stability disk. Do not use any
sealing products such as gaskets, sealing com-
pound, or tape. Be careful to avoid damaging the
nozzle sealing seat. The nozzles must be
screwed into place tightly but not to the maxi-
mum torque value provided by the wrench.
The firing nozzle is the one lying beneath the fir-
ing electrodes fig. (B).
Make sure that the electrodes are positioned as
shown in fig. (B).
Finally remount the burner 4)(C) to the slide bars
3) and slide it up to the flange 5), keeping it
slightly raised to prevent the flame stability disk
from pressing against the blast tube.
Tighten the screws 2) on the slide bars 3) and
screw 1) that attaches the burner to the flange.
If it proves necessary to change a nozzle with the
burner already fitted to the boiler, proceed as
outlined below:
- Retract the burner on its slide bars as shown
in fig. (B)p.5.
- Remove the nuts 1)(D) and the disk 2).
- Use spanner 3)(D) to change the nozzles.
COMBUSTION HEAD SETTING
The setting of the combustion head depends ex-
clusively on the delivery of the burner, in other
words, the combined delivery of the two nozzles
selected on page 5.
Turn screw 4)(E) until the notch shown in dia-
gram (F) is level with the front surface of flange
5)(E).
Example RL 28/1:
with nozzles:
1° = 2.75 GPH + 2° = 1.75 GPH and 14 bar pump
pressure.
Find the delivery of the two nozzles in Table
(C)p.5 , 20.7 kg/h.
Diagram (F) indicates that for a delivery of 20.7
kg/h the RL 28/1 Model requires the combustion
head to be set to approx. three notches, as
shown in fig. (E).
FAN GATE ADJUSTMENT
The fan gate is set using the indexed selector
1)(G), after having loosened the nut 2)(G).
The first time the burner is fired, this setting
should be left as originally set by the manufactur-
er: notch 2, see fig. (G).
2mm
÷4 mm3.5
(A)
(C)
COMBUSTION HEAD SETTING
(G)
(E)
Notches nr.
Light oil delivery kg/h
(D)
(F)
(B)
D460
D591
D462
D592
D593
D3263
D589

7
HYDRAULIC SYSTEM
FUEL SUPPLY
Double-pipe circuit (A)
The burner is equipped with a self-priming pump
which is capable of feeding itself within the limits
listed in the table at the side.
The tank higer than the burner A
The distance "P" must not exceed 10 meters in
order to avoid subjecting the pump's seal to ex-
cessive strain; the distance "V" must not exceed
4 meters in order to permit pump self-priming
even when the tank is almost completely empty.
The tank lower than the burner B
Pump depression values higher than 0.45 bar
(35 cm Hg) must not be exceeded because at
higher levels gas is released from the fuel, the
pump starts making noise and its working life-
span decreases.
It is good practice to ensure that the return and
suction lines enter the burner from the same
height; in this way it will be less probable that the
suction line fails to prime or stops priming.
The loop circuit
A loop circuit consists of a loop of piping departing
from and returning to the tank with an auxiliary
pump that circulates the fuel under 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/or height differ-
ence are higher than the values listed in the table.
Key (A)
H=
Pump/Foot valve height difference
L=Piping length
Æ=Inside pipe diameter
1=Burner
2=Pump
3=Filter
4=Manual on/off valve
5=Suction line
6=Foot valve
7 = Rapid closing manual valve remote con-
trolled (only Italy)
8 = On/off solenoid valve (only Italy)
9=
Return line
10 = Check valve (only Italy)
HYDRAULIC CONNECTIONS (B)
The pumps are equipped with a by-pass that
connects return line with suction line. The pumps
are installed on the burner with the by-pass
closed by screw 6)(B)p.11.
It is therefore necessary to connect both hoses
to the pump.
The pump will break down immediately if it is run
with the return line closed and the bj-pass screw
inserted.
Remove the plugs from the suction and return
connections of the pump.
Insert the hose connections with the supplied
seals into the connections and screw them
down.
Take care that the hoses are not stretched or
twisted during installation.
Route the hoses through the holes in the plate,
preferably using those on the rh side, fig. (B):
unscrew the screws 1), now divide the insert
piece into its two parts 2) and 3) and remove the
thin diaphragm blocking the two passages 4).
Install the hoses where they cannot be stepped
on or come into contact with hot surfaces of the
boiler.
Now connect the other end of the hoses to the
supplied nipples, using two wrenches, one to
hold the nipple steady while using the other one
to turn the rotary union on the hose.
(A)
(B)
9
10
7
5
8
4
7
9
53
2
1
6
6
10 cm
+ H V
P
- H
B
A
+ H
- H
(m)
L (m)
Æ (mm)
81012
+ 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
0 27 73 160
- 0,5 24 66 144
- 1,0 21 58 128
-2,0 194396
-3,0 152865
- 4,0 - 12 33
D3264
D3265

8
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM as set up by the manu-
facturer
LAYOUT (A)
Burner RL 28/1 (single-phase)
Key to layout (A)
C - Capacitor
RMO88.53A2 - Control box
F - Photocell
MV - Fan motor
TA - Ignition transformer
TB - Burner ground
VA - 1st nozzle solenoid valve
VF - 2nd nozzle solenoid valve
XP1 - Connector for STATUS
XP7 - 7 pole socket
NOTE
For remote-reset, connect a push-button switch
(NO) between terminal 3 and neutral of the con-
trol box (terminals 15, 16, 17 and 18).
ELECTRICAL CONNECTIONS (B)
set by installer
All the wires to connect to the burner plugs 3)(B)
must be routed through the fairleads, supplied by
the manufacturer for insertion into the holes in
the plate, preferably those on the left side, after
having removed the thin diaphragm effectively
closing the aperture, as already explained
above.
1 - Pg 11 Single-phase power supply
2 - Pg 9 Control deviceTL
LAYOUT (C)
RL 28/1 burner electrical connection
Cable section not indicated: 1,5 mm2
Key to layout (C)
h1 - Hourcounter
IN - Manual burner stop switch
S - Remote lock-out signal
TL - Limit control device system: this shuts
down the burner when the boiler tempera-
ture or pressure exceeds the setpoint
value.
TS - Safety control device system: this oper-
ates when TL is faulty.
X7 - 7 pole plug
NOTE
The RL 28/1 burner has been type-approved for
intermittent operation. This means it should
compulsorily be stopped at least once every 24
hours to enable the control box to check its own
efficiency at start-up. Burner halts are normally
provided for automatically by the boiler load
control system.
If this is not the case, a time switch should be fit-
ted in series to IN to provide for burner shut-
down at least once every 24 hours.
WARNING
Do not invert the neutral with the phase
wire in the electricity supply line.
ELECTRICAL EQUIPMENT FACTORY-SET
(A)
(B)
(C)
ELECTRICAL CONNECTION
ELECTRICAL CONNECTION
D3225
D3282
D3266
Black White Blue

9
PUMP (A)
1 - Suction G 1/4"
2 - Return G 1/4"
3 - Pressure gauge attachment G 1/8"
4 - Vacuum meter attachment G 1/8"
5 - Pressure adjustment screw
A - Min. delivery rate at 12 bar pressure
B - Delivery pressure range
C - Max. suction depression
D - Viscosity range
E - Light oil max. temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H - Filter mesh width
PUMP PRIMING
- Before starting the burner, make sure that
the tank return line is not clogged.
Obstructions in the line could cause the
sealing organ located on the pump shaft to
break. (The pump leaves the factory with the
by-pass closed).
- In order for self-priming to take place, one of
the screws 3)(A) of the pump must be loos-
ened in order to bleed off the air contained in
the suction line.
- Start the burner by closing the control devices
and the electrical network switch. The pump
must rotate in the direction of the arrow
marked on the cover.
- The pump can be considered to be primed
when the light oil starts coming out of the
screw 3). Stop immediately the burner and
tighten the screw 3).
The time required for this operation depends
upon the diameter and length of the suction tub-
ing. If the pump fails to prime at the first starting
of the burner and the burner locks out, wait ap-
prox. 15 seconds, reset the burner, and then re-
peat the starting operation as often as required.
After 5 or 6 starting operations allow 2 or 3 min-
utes for the transformer to cool.
Do not illuminate the photocell or the burner will
lock out; the burner should lock out anyway
about 10 seconds after it starts.
Important:
The a.m. operation is possible because the
pump is already full of fuel when it leaves the fac-
tory. If the pump has been drained, fill it with fuel
through the opening on the vacuum meter prior
to starting; otherwise, the pump will seize. When-
ever the length of the suction piping exceeds 20-
30 meters, the supply line must be filled using a
separate pump.
(A)
AN 57 C
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
45
10 - 18
0,45
2 - 75
60
2
12
0,150
PUMP SUNTEC AN 57 C
D602