Riello DB 16 LSE FGR Quick start guide

Installation, use and maintenance instructions
20163598 (1) - 04/2019
Dual fuel light oil/gas burner
Two stage progressive or modulating operation
CODICE - CODE MODELLO - MODEL
20163106 DB 16 LSE FGR
GB

Original instructions

1 20163598
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Contents
1 Information and general warnings............................................................................................................................................ 3
1.1 Information about the instruction manual .................................................................................................................... 3
1.1.1 Introduction.................................................................................................................................................................. 3
1.1.2 General dangers.......................................................................................................................................................... 3
1.1.3 Other symbols ............................................................................................................................................................. 3
1.1.4 Delivery of the system and the instruction manual...................................................................................................... 4
1.2 Guarantee and responsibility....................................................................................................................................... 4
2 Safety and prevention................................................................................................................................................................ 5
2.1 Introduction.................................................................................................................................................................. 5
2.2 Personnel training ....................................................................................................................................................... 5
3 Technical description of the burner ......................................................................................................................................... 6
3.1 Burner designation ...................................................................................................................................................... 6
3.2 Models available.......................................................................................................................................................... 7
3.3 Burner categories - Countries of destination ............................................................................................................... 7
3.4 Technical data ............................................................................................................................................................. 7
3.5 Electrical data.............................................................................................................................................................. 7
3.6 Maximum dimensions.................................................................................................................................................. 8
3.7 Flange dimensions ...................................................................................................................................................... 8
3.8 Firing rate .................................................................................................................................................................... 9
3.9 Test boiler.................................................................................................................................................................... 9
3.10 Air side pressure drop (detected upline of the damper with complete opening) ....................................................... 10
3.11 Gas side pressure drops ........................................................................................................................................... 11
3.12 Description of burner components ............................................................................................................................ 12
3.13 Burner equipment...................................................................................................................................................... 12
3.14 Servomotor (SQM48.4....) ......................................................................................................................................... 13
3.15 AZL Display... ............................................................................................................................................................ 14
3.16 Control box for the air/fuel ratio (LMV51...) ............................................................................................................... 15
4 Installation ................................................................................................................................................................................ 17
4.1 Notes on safety for the installation ............................................................................................................................ 17
4.2 Handling .................................................................................................................................................................... 17
4.3 Preliminary checks .................................................................................................................................................... 17
4.4 Operating position ..................................................................................................................................................... 18
4.5 Removing the shutter lockout pins ............................................................................................................................ 18
4.6 Preparing the boiler ................................................................................................................................................... 18
4.6.1 Boring the boiler plate ............................................................................................................................................... 18
4.6.2 Blast tube length........................................................................................................................................................ 18
4.7 Lifting points .............................................................................................................................................................. 19
4.8 Boiler fixing................................................................................................................................................................ 19
4.9 Access to head internal part...................................................................................................................................... 20
4.10 Nozzles...................................................................................................................................................................... 21
4.10.1 Recommended nozzles............................................................................................................................................. 21
4.11 Mechanical atomization lance ................................................................................................................................... 21
4.12 Ignition pilot ............................................................................................................................................................... 21
4.13 Light oil supply........................................................................................................................................................... 22
4.13.1 General supply layout (example)............................................................................................................................... 22
4.13.2 Adjustment and calibration of the oil circuit and of the air output .............................................................................. 23
4.13.3 Priming pump (example) ........................................................................................................................................... 24
4.14 Gas feeding............................................................................................................................................................... 25
4.14.1 Gas feed connection to the burner ............................................................................................................................ 25
4.14.2 General gas feeding layout (example) ...................................................................................................................... 25
4.14.3 Gas train.................................................................................................................................................................... 26
4.14.4 Gas train installation.................................................................................................................................................. 26
4.14.5 Pilot - gas train connection ........................................................................................................................................ 26

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Contents
4.15 FGR duct system .......................................................................................................................................................27
4.16 Electrical wiring ..........................................................................................................................................................28
4.16.1 Supply cables and external connections passage .....................................................................................................28
5 Start-up, calibration and operation of the burner ..................................................................................................................29
5.1 Notes on safety for the first start-up...........................................................................................................................29
5.2 Combustion head adjustment ....................................................................................................................................29
5.3 Adjustments prior to ignition (light oil) ........................................................................................................................29
5.3.1 Nozzle ........................................................................................................................................................................29
5.4 Burner ignition (light oil) .............................................................................................................................................29
5.5 Adjustments prior to ignition (gas) .............................................................................................................................30
5.6 Burner start-up (gas)..................................................................................................................................................30
5.7 Ignition pilot burner ....................................................................................................................................................30
5.8 Burner ignition............................................................................................................................................................31
5.9 Combustion air adjustment ........................................................................................................................................31
5.9.1 Air / gas adjustment and output modulation...............................................................................................................31
5.9.2 Pressure switch adjustment .......................................................................................................................................31
5.10 Pressure switch adjustment .......................................................................................................................................32
5.10.1 Air pressure switch.....................................................................................................................................................32
5.10.2 Maximum gas pressure switch...................................................................................................................................32
5.10.3 Minimum gas pressure switch....................................................................................................................................32
5.10.4 Oil pressure switch.....................................................................................................................................................32
5.11 Final checks (with burner operating)..........................................................................................................................33
6 Maintenance ..............................................................................................................................................................................34
6.1 Notes on safety for the maintenance .........................................................................................................................34
6.2 Maintenance programme ...........................................................................................................................................34
6.2.1 Maintenance frequency..............................................................................................................................................34
6.2.2 Safety test - with gas ball valve closed ......................................................................................................................34
6.2.3 Checking and cleaning...............................................................................................................................................34
6.2.4 Flame sensor disassembling .....................................................................................................................................35
6.2.5 Safety components ....................................................................................................................................................36
6.2.6 Shutter replacement...................................................................................................................................................37
6.3 Opening the burner ....................................................................................................................................................38
6.4 Closing the burner......................................................................................................................................................38
7 Faults - Possible causes - Solutions.......................................................................................................................................39
7.1 Oil operation...............................................................................................................................................................39
7.2 Gas operation ............................................................................................................................................................40
A Appendix - Electrical panel layout...........................................................................................................................................41

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Information and general warnings
1.1 Information about the instruction manual
1.1.1 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 Ser-
vice 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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 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.

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Information and general warnings
1.1.4 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.
1.2 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 equipment;
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;
continuation of use of the burner when a fault has occurred;
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 optional;
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.

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Safety and prevention
2.1 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 uses expressly foreseen by the manufactur-
er;
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.
2.2 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 manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from the use of non-original parts.
In addition:
2 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.

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Technical description of the burner
3.1 Burner designation
3 Technical description of the burner
Range: DB
Size: 4 - 6 - 9 - 12 - 16 - 20
Fuel: Gas oil
Light oil / Natural gas
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation (1 stop every 72 h)
Combustion air supply:
A - 0 :
A - 90 :
DB 16 LS EFGR
Emission:
C011 Class 1 EN276 - Class 3 EN676
FS1 A - 0
BASIC DESIGNATION
EXTENDED DESIGNATION
TC
from the bottom
from the right
Heavy oil
E Electronic cam
SV Electronic cam with variable speed (with Inverter)
M Mechanical cam
L
LS
N
Head: TC Standard head
TL Long head
Assisted atomisation heavy oilNA
LPGP
Natural GasS
Light oil/ LPGLP
Heavy oil / LPG
NP
Heavy Oil / Natural GasNS
Heavy Oil / LPG
NP
Assisted atomisation heavy oil / LPG
NAP
Assisted atomisation heavy oil / LPGNAS
TXL Special head
A - 180 : from the top
A - 270 : from the left
FR
Maximum combustion air temperature:
T150 = 150°C
T250 = 250°C
Fuel supply:
FR = from the right
FL = from the left
Voltage of auxiliaries:
230/50/60
110/50/60
230V / 50-60Hz
110V / 50-60Hz
T150 230V / 50-60 Hz
FB = from the bottom
C013 Class 1 EN276 - Class 3 EN676
FGR Flue gas recirculation

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Technical description of the burner
3.2 Models available
Tab. A
3.3 Burner categories - Countries of destination
Tab. B
3.4 Technical data
Tab. C
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point (Fig. 8 on page 12) with zero pressure in the combustion chamber and at the maximum output of the burner.
3.5 Electrical data
Tab. D
Designation Voltage Code
DB 16 LSE FGR FS1 A0 T150 TC 230V / 50-60Hz 20163106
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L - I2E - I2 (43,46 ÷ 45,3 MJ/m3 (0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E
Model DB 16 LSE
Output (1) min - max kW
kg/h
2600/8000 ÷ 16000
220/678 ÷ 1356
Fuels
– Natural gas: G20 - NCV 10 kWh/Nm3
– Natural gas: G25 - NCV 8.6 kWh/Nm3
– Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5°E - 6 cSt)
Gas pressure at max. output (2)
Gas: G20/G25 mbar 5/24
Operation – FS2 continuous (min. 1 stop in 72 hours)
– Modulanting
Modulating ratio at maximum output Gas
Olio
1 : 5
1 : 4
Nozzles N° 1
Combustion air temperature °C max 150
Ignition Pilot burner with gas
Weight kg 460
Model DB 16 LSE
Electrical supply 230 V / 50-60 Hz
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1.4 A - 30 mA
Electric power consumption Gas
Oil kW max 0.5 0.6
Protection level IP 54

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Technical description of the burner
3.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Tab. E
3.7 Flange dimensions
D
B
C
B1
E
P
I
T
MM
L
G
Fig. 1
20165206
BB1C D E G I L M P T
502 852 250 544 761 641 542 1151 510 1330 839
620 DB20
560 DB16
700
M16
45
22.5
DN 1 0 0
180
18
562
= =
652
= =
11
410
= =
510
= =
520
= =
620
= =
452
= =
542
= =
Fig. 2
Air duct connection
S9313
D3893
D7797
Boiler fixing Gas feeding