Riello RL 800/M FS2 Quick start guide

20034064 (1) - 02/2011
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Light oil burner
Quemadore de gasóleo
Modulating operation
Funcionamiento modulante
CODE MODEL TYPE
20033673 RL 800/M TC FS2 33673 X
GB
E

1 20010305
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general instructions....................................................................................................................................... 4
2.1 Information about the instruction manual.................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Danger: live components............................................................................................................................................. 4
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 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 Burner weight.............................................................................................................................................................. 8
4.5 Overall dimensions...................................................................................................................................................... 9
4.6 Firing rate.................................................................................................................................................................. 10
4.7 Test boiler.................................................................................................................................................................. 10
4.8 Burner description..................................................................................................................................................... 11
4.9 Description of panel board ........................................................................................................................................ 12
4.10 Burner equipment...................................................................................................................................................... 12
5 Installation ................................................................................................................................................................................ 13
5.1 Notes on safety for the installation............................................................................................................................ 13
5.2 Handling.................................................................................................................................................................... 13
5.3 Preliminary checks.................................................................................................................................................... 13
5.4 Operation position..................................................................................................................................................... 14
5.5 Preparing the boiler................................................................................................................................................... 14
5.5.1 Boring the boiler plate ............................................................................................................................................... 14
5.5.2 Blast tube length........................................................................................................................................................ 14
5.6 Securing the burner to the boiler............................................................................................................................... 14
5.7 Accessibility to the interior of the combustion head .................................................................................................. 15
5.8 Position of electrodes................................................................................................................................................ 15
5.9 Nozzle installation ..................................................................................................................................................... 16
5.9.1 Recommended nozzle............................................................................................................................................... 16
5.10 Combustion head setting........................................................................................................................................... 17
5.11 Light oil supply........................................................................................................................................................... 18
5.11.1 Double-pipe circuit..................................................................................................................................................... 18
5.11.2 The loop circuit.......................................................................................................................................................... 18
5.11.3 Hydraulic connections............................................................................................................................................... 18
5.11.4 Pressure regulator..................................................................................................................................................... 19
5.11.5 Hydraulic system layout ............................................................................................................................................ 20
5.11.6 Pump priming............................................................................................................................................................ 20
5.12 Electrical wiring ........................................................................................................................................................ 22
5.12.1 Entry for power cables and external leads................................................................................................................ 22
5.13 Calibration of the thermal relay ................................................................................................................................. 22
6 Start-up, calibration and operation of the burner ................................................................................................................. 23
6.1 Notes on safety for the first start-up.......................................................................................................................... 23
6.2 Adjustments before first firing.................................................................................................................................... 23
6.3 Burner starting........................................................................................................................................................... 23
6.4 Combustion air adjustment........................................................................................................................................ 24
6.4.1 Maximum output........................................................................................................................................................ 24
6.4.2 Minimum output......................................................................................................................................................... 24

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Contents
6.4.3 Intermediate outputs..................................................................................................................................................24
6.5 Air/fuel adjustment .....................................................................................................................................................25
6.6 Servomotor ................................................................................................................................................................26
6.7 Adjustment pressure switches ...................................................................................................................................26
6.7.1 Air pressure switch - CO check..................................................................................................................................26
6.8 Operation sequence of the burner .............................................................................................................................27
6.8.1 Steady state operation...............................................................................................................................................27
6.8.2 Undesired shutdown during operation .......................................................................................................................27
6.8.3 Firing failure...............................................................................................................................................................27
7 Maintenance ..............................................................................................................................................................................28
7.1 Notes on safety for the maintenance.........................................................................................................................28
7.2 Maintenance programme...........................................................................................................................................28
7.2.1 Checking and cleaning...............................................................................................................................................28
7.3 Opening the burner....................................................................................................................................................29
7.4 Closing the burner......................................................................................................................................................29
8 Faults - Possible causes - Solutions.......................................................................................................................................30
A Appendix - Accessories ...........................................................................................................................................................33
B Appendix - Electrical panel layout...........................................................................................................................................35

3 20034064
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Declarations
1 Declarations
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: RL 800/M TC FS2
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 292
and according to the European Directives:
GAD 2009/142/EC Gas Devices 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
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx limits specified by German standard “1. BImSchV 2009”.
Product Type Model
Light oil burner 33673X RL 800/M TC FS2
Legnago, 30.03.2010 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.
CE- Clase 1 (EN 267)

20034064 4
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Information and general instructions
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
Service 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 Danger: live components
Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
The instruction manual is supplied 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 Assist-
ance Centre.
The system supplier carefully informs the user about:
– the use of the system,
– any further tests that may be necessary before the system
is started up,
– maintenance and the need to have the system checked at
least once a year by the manufacturer or another special-
ised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2 Information and general instructions
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
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
This symbol indicates a list.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................

5 20034064
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Information and general instructions
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, 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 non authorised modifications on the equip-
ment;
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 power 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 flame, as structurally
established;
insufficient and inappropriate surveillance and care of those
burner components most 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 the carrying out of non authorised modifi-
cations will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20034064 6
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Safety and prevention
3.1 Introduction
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.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other users 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 room temperature must all be within the values indi-
cated 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;
must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
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
declines any and all responsibility for any damage that may
be caused by the use of non-original parts.
3 Safety and prevention

7 20034064
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4 Technical description of the burner
Designation Electrical supply Starting Code
RL 800/M FS2 TC 3/400/50 Star/Delta 20033673
Series : R
Size
Fuel : Natural gas
Light oil
Light oil / Methane
Setting :
Flame control system :
FS1
FS2 Standard (1 stop every 24 h) Continuos working (1 stop every 72 h)
Electrical supply to the system :
3/400/50
3/230/50
Auxiliary voltage :
230/50/60
110/50/60
R L 800 MTC FS2 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 Variable speed (with Inverter)
P Air/gas proportioning valve
BP Two-stage (light oil) / Proportioning valve (gas)
M Mechanical cam
S
L
LS
N
Head : TC Standard head
TL Extended head

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Technical description of the burner
4.3 Technical data
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 5) (Fig. 5) with zero pressure in the combustion chamber and maximum burner output.
(3) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ= ± 1.5 dB, in the manufacturer’s com-
bustion chamber with burner operating on test boiler at maximum output.
4.4 Burner weight
The weight of the burner complete with its packaging is shown in
table.
Model RL 800/M FS2
Type 33673 X
Output (1)
Delivery (1) MIN - MAX kW kg/h 1750/3500 ÷ 8000 147/295 ÷ 674
Fuel LIGHT OIL, viscosity at 20 °C: 6 mm2/s (1.5 °E - 6 cSt)
Operation Continuos
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Room temperature °C 0 - 50
Combustion air temperature °C max 60
Electrical supply 3N ~ 400 / 230V +/-10% 50 Hz
Electric motors rpm 2900
Fan motor V
kW
A
380 - 415 660 - 718
21
40 - 23
Pump motor V kW
A
230/400
1.5
6.4/3.7
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 5 kV 1 A - 20 A
Pump delivery (at 16,5 bar)
pressure range
fuel temperature
kg/h
bar
°C max
560
6 - 30
140
Electrical power consumption (Light oil) kW max 26
Protection level IP 54
Noise level (3) Sound pressure
Sound power dB (A) 89,6
Model kg
RL 800/M 300
Fig. 1
D11082

9 20034064
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Technical description of the burner
4.5 Overall dimensions
The maximum dimensions of the burner are given in (Fig. 2).
Bear in mind that inspection of the combustion head requires the burner to be opened by rotating the rear part on the hinge.
The overall dimensions of the burner when open are indicated by L and R.
Position I is a reference for the thickness of the boiler door refractory fettling.
mm A B C D E G H I L R
RL 800/M 1333 505 550 363 582 940 866 460 1190 1055
I
BA
D
E
H
G
R
L C
Fig. 2
D11083

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Technical description of the burner
4.6 Firing rate
MAXIMUM OUTPUT must be selected in the hatched area of the
diagram. (Fig. 3)
MINIMUM OUTPUT must not be lower than the minimum limit
shown in the diagram:
RL 800/M = 1750 kW
4.7 Test boiler
The burner/boiler matching does not pose any problems if the
boiler is CE type-approved and its combustion chamber dimen-
sions are similar to those indicated in diagram (Fig. 4).
If the burner must be combined with a boiler that has not been CE
type-approved and/or its combustion chamber dimensions are
clearly smaller than those indicated in diagram (Fig. 4), consult
the manufacturer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 7000 kW:
diameter 120 cm,
length 6m.
MODULATION RATIO
The modulation ratio, determined using test boilers according to
standard (EN 676 for gas, EN 267 for light oil), is 2.4 : 1.
WARNING
The FIRING RATE area values (Fig. 3) have been
obtained considering a surrounding temperature
of 20 °C, and an atmospheric pressure of 1013
mbar (approx. 0 m above sea level) and with the
combustion head adjusted as shown on page 17.
Fig. 3
Pressure in combustion
chamber - mbar
Thermal output - kW
D10725
400 1200 2000 2800 3600 4400
0
2
4
6
8
10
12
14
16
18
20
5200 6000 6800 7600 8400
22
Class 1 EN267
Fig. 4
Combustion chamber
m
D2448

11 20034064
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Technical description of the burner
4.8 Burner description
1 Lifting eyebolts
2Fan
3Fanmotor
4 Servomotor
5 Pressure gauge attachment of pump
6 Combustion head
7 Ignition electrodes
8 Flame stability disk
9 Electric panel board - cover
10 Hinge for opening burner
11 Air inlet to fan
12 Manifold
13 Thermal insulation screen for securing burner to boiler
14 Oil modulator
15 Shutter
16 Lever for movement of combustion head
17 Gears for movement of air damper
18 Air pressure switch
(differential operating type)
19 Air pressure test point
20 Nozzle delivery pressure gauge
21 Photocell RAR9
22 Air pressure test point pressure test point “+”
23 Pump
24 Pump motor
25 Minimum oil pressure switch
26 Maximum oil pressure switch
27 Pressure gauge for pressure on nozzle return
11
6
7
8
910
11
12 13
15
16
17 19
5
14
20
23
25
27
26
3
2
4
18
21 22
24
Fig. 5
D11084

20034064 12
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Technical description of the burner
4.9 Description of panel board
1 Terminal strip for kits
2 Relay outlet - clean contacts
3 Ignition transformer
4 Bracket for mounting the power regulator RWF40
5 Stop push-button
6 Dial for off - automatic - manual
7 Power dial for increase - decrease of power
8 Start enabled light
9 Motor thermal cutout tripped warning light
10 Signal light for burner failure and lock-out reset button
11 Control box
12 Star-powered/delta-powered starter
13 Timer
14 Air pressure switch
15 Main supply terminal strip
16 Entry for power cables and external leads
17 Plug-socket maximum gas pressure switch
18 Auxiliary circuits fuse
19 Servomotor plug/socket
20 Plug-socket valve /Pump motor
21 Fan motor thermal cut-out
22 Pump motor contactor and thermal cut-out
23 Plug-socket flame sensor
NOTE
Two types of burner failure may occur:
Control box lock-out: if the control box 11) (Fig. 6) push-
button (red led) and the reset button 10) (Fig. 6) light up, it
indicates that the burner is in lock-out.
To reset, press the pushbutton 10) (Fig. 6).
Motors trip: release by pressing the push button on ther-
mal.
4.10 Burner equipment
Thermal screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N. 1
Screws to secure the burner flange to the boiler:
M 18 x 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N. 4
Spacers (see Fig. 15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N. 2
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N. 1
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N. 1
D11085
1
12
13
14
15 16
17
18
19
20
21
22
23
2
3
4
5678910 11
Fig. 6

13 20034064
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, 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 (see A in 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 electrical input power (F);
the types of gas used and the relative supply pressures (G);
the data of the burner’s minimum and maximum output pos-
sibilities (H) (see Firing rate)
Warning. The output of the burner must be within the
boiler’s firing rate;
the category of the device/countries of destination (I).
light oil (L) max. viscosity.
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.
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).
During the handling, keep the load at not more
than 20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
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.
GAS-KAASU
GAZ-AEPIO
0085
RIELLO S.p.A.
I-37045 Legnago (VR)
CE
HEIZÖL FUEL
Fig. 7
D9243
ABC
EDF
HG
GH
I
L

20034064 14
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Installation
5.4 Operation position
The burner is designed to operate only in the positions 1, 2, 3 and
4.
Installation 1is preferable, as it is the only one that allows the
maintenance operations as described in this manual.
Installations 2, 3 and 4 permit operation but make maintenance
and inspection of the combustion head more difficult.
Any other position could compromise the correct operation of the
appliance.
Installation 5is prohibited for safety reasons.
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in (Fig. 9).
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
5.5.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling.
For boilers with front flue passes 1) (Fig. 10) or flame inversion
chambers, protective fettling in refractory material 5) must be in-
serted between the boiler fettling 2) and the blast tube 4).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers having a water-cooled front the refractory fettling 2)-
5)(Fig. 10) is not required unless it is expressly requested by the
boiler manufacturer.
5.6 Securing the burner to the boiler
Prepare an adequate system of hoisting by hooking onto the
rings 3) (Fig. 10).
Slip the thermal protection (standard equipment) onto the
blast tube 4) (Fig. 10).
Place entire burner on the boiler hole arranged previously,
see (Fig. 9), and fasten with the screws given as standard
equipment.
Fig. 8
2 3 4 51
D7739
mm A B C
RL 800/M 400 495 M 18
Fig. 9
D455
WARNING
The burner-boiler seal must be airtight.
1
2
5
4
1
7
833
Fig. 10
D11086

15 20034064
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Installation
5.7 Accessibility to the interior of the combustion head
In order to reach inside the combustion head (Fig. 11) proceed as
follows:
disconnect the electrical wiring related to oil pump/servomo-
tor and servomotor 1 - 2;
disconnect the leverages related to air damper 3) and head
movement 4);
unscrew the 4 x fixing screws 5);
Release the cable of the electrodes 6 from the burner head);
Disconnect the oil pipes by unscrewing the two connec-
tors 7).
Remove the screw 8) of the combustion head;
Extract the internal part 9) of the combustion head.
5.8 Position of electrodes
WARNING
While unscrewing, some fuel may leak out of
the swivel fittings.
1
2
3
4
5
5
6
7
89
Fig. 11
D11087
4-5mm
26
Fig. 12
D11104

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Installation
5.9 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.
Fit the nozzle with the box spanner, fitting the spanner through
the central hole in the flame stability disk (Fig. 13).
Nozzles with no fuel shutoff needle must be fitted on the nozzle
holder.
To set the delivery range within which the nozzle must work, noz-
zle return line fuel pressure must be adjusted according to
Tab. A and Tab. B.
5.9.1 Recommended nozzle
• Bergonzo type B5 45°
• Fluidics type N4 45°
Intermediate flow rates may be obtained by choosing the nozzle
with a nominal flow rate slightly higher than that actually required.
Complete range of nozzles:
Bergonzo type B5 45°:
350 - 375 - 400 - 425 - 450 - 475 - 500 - 525 - 550 - 575 -
600 - 650 - 700 - 750. We normally recommend 45° angles
of pulverisation.
Tab. A
Fluidics type N4 45°:
375 - 400 - 450 - 500 - 550 - 600 - 650 - 700 - 750. We nor-
mally recommend 45° angles of pulverisation.
Tab. B
WARNING
It is advisable to replace nozzles every year
during regular maintenance operations.
CAUTION
The use of nozzles other than those specified
by Riello S.p.A. and inadequate regular main-
tenance may result into emission limits non-
conforming to the values set forth by the reg-
ulations in force, and in extremely serious cas-
es, into potential hazards to people and
objects.
The manufacturing company shall not be lia-
ble for any such damage arising from nonob-
servance 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 nozzles must be screwed into place
tightly but not to the maximum torque value
provided by the wrench.
Fig. 13
D11105
kg/h Delivery pressure
bar
Return
pressure
bar kg/h kW
375 20 11.5 147 1750
20 17 295 3500
550 20 10 170 2000
20 17 421 5000
650 20 8 180 2150
20 16.5 565 6650
750 25 11.5 227 2700
25 20.5 675 8000
kg/h Delivery pressure
bar
Return
pressure
bar kg/h kW
375 20 12 147 1750
20 18.5 295 3500
550 20 7 170 2000
20 16 421 5000
650 20 6 180 2150
20 17 565 6650
750 25 17 227 2700
25 22 675 8000

17 20034064
GB
Installation
5.10 Combustion head setting
In addition to varying air flow depending on the output requested,
the air gate valve servomotor 4) (Fig. 5) by means of a lifting as-
sembly - varies the setting of the combustion head.
This system allows an optimal setting even at a minimum firing
rate.
For the same servomotor rotation, combustion head opening
can be varied by moving the tie rod onto holes 1-2-3) (Fig. 14).
The choice of the hole (1-2-3) to be used is decided on the basis
of diagram (Fig. 16) against the required maximum output.
Setting is pre-arranged in the plant for the maximum run (hole 3,
Fig. 14).
If combustion requirements require you to move spacer 1)
(Fig. 15) onto the 1st or 2nd hole of the gear and, at the same
time, the hinge is on the right, you need to fit the spacers 4)
(Fig. 15) supplied with the burner.
Proceed as follows (Fig. 15):
unscrew nuts 2), remove tie rod 3);
unscrew spacer 1) and position it on the hole you want;
screw the spacers (4) onto spacer (1) and screw (5) respec-
tively;
Refit the tie rod and nuts.
Fig. 14
0
1
2
3
4
6
3
2
1
4
D3093
D3409
Fig. 15
3
2
1
0
2400 2800 3200 3600 4400 4800 52001200 1600 2000
800 5600 6000 6400 6800 7200 7600 80004000
Fig. 16
D9244
N° holes
Max burner output - kW

20034064 18
GB
Installation
5.11 Light oil supply
5.11.1 Double-pipe circuit
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 higher than the burner A (Fig. 17)
The distance "P" must not exceed 10 meters in order to avoid
subjecting the pump’s seal to excessive 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 (Fig. 17)
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 proba-
ble that the suction line fails to prime or stops priming.
Key to layout (Fig. 17)
H = Pump/foot valve height difference
L = Piping length
Ø = 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 controlled (only Italy)
8 = On/off solenoid valve (only Italy). See layout of electric
panel board. Electrical connections set by installer (SV)
9 = Return line
10 = Check valve (only Italy)
5.11.2 The loop circuit
A loop circuit consists of a loop of piping departing from and re-
turning 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 difference are higher than the values listed in the Table.
5.11.3 Hydraulic connections
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) ( Fig. 20).
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 by-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 con-
nections and screw them down.
Take care that the hoses are not stretched or twisted during in-
stallation.
Install the hoses where they cannot be stepped on or come into
contact with hot surfaces of the boiler and where they do not
hamper the opening of the burner.
Now connect the other end of the hoses to the suction and return
lines by using the supplied nipples.
V
10 cm
1
4
8
5
9
10
7
6
6
7
A
B
3
5
9
2
P
H- H+
Fig. 17
D11088
H (m) L (m) Ø (mm)
10 12 14 16
414305595
3,5 13 28 52 89
312264882
2.5 11 24 44 76
210224170
1.5 9 20 37 63
1 8 18 33 57
0,5 7 16 29 51
0 6 14 26 44
-0,5 5 12 22 38
-1 4 10 18 32
-1,5 3 8 15 25
-2 6 11 19
-2,5 4 7 13
-3 4 7