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Riello RL Series User Manual

Riello RL Series
68 pages
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20111051 (1) - 09/2015
Istruzioni per installazione, uso e manutenzione
Installation, use and maintenance instructions
Bruciatori di gasolio
Light oil burners
Funzionamento bistadio
Two stage operation
CODICE - CODE MODELLO - MODEL TIPO - TYPE
3475032 RL 70 660 T1
3475033 RL 70 660 T1
3475232 RL 100 661 T1
3475233 RL 100 661 T1
3475432 RL 130 662 T1
3475433 RL 130 662 T1
I
GB

Table of Contents

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Riello RL Series Specifications

General IconGeneral
OperationSingle-stage, Two-stage, Modulating
ControlElectronic
EmissionsLow NOx
WeightVaries by model
DimensionsVaries by model

Summary

Declarations

Declaration of conformity in accordance with ISO / IEC 17050-1

Details compliance with international standards and European directives for product safety and performance.

Manufacturer's Declaration

States compliance with specific emission limits and lists product types, models, and output ranges.

Information and general instructions

2.1 Information about the instruction manual

Explains the importance of the manual, its intended audience, and guidance for safe installation and use.

2.1.2 Danger: live components

Highlights operations that could lead to electric shocks with lethal consequences.

2.2 Guarantee and responsibility

Details RIELLO's guarantee terms and conditions, and user responsibilities for maintaining warranty validity.

Safety and prevention

3.1 Introduction

Highlights burner safety design and potential risks from improper use or inattention.

3.2 Personnel training

Emphasizes the user's responsibility for training personnel and ensuring safe operation.

Technical description of the burner

4.1 Technical data

Provides detailed technical specifications for the burner models, including output, fuel, and operating parameters.

4.2 Electrical data

Details electrical specifications such as power supply, motor type, ignition transformer, and consumption.

4.2.1 Variants

Lists different burner variants based on power supply and blast tube length, with associated codes.

4.2.2 Accessories (optional)

Describes optional accessories like radio disturbance protection and degassing units.

4.3 Burner description (Fig. 1)

Identifies and explains the function of various burner components shown in Figure 1.

4.3.1 Weight (Tab. A)

Provides the weight of the burner complete with packaging in Table A.

4.3.2 Max. dimensions (Fig. 2)

Presents the maximum external dimensions of the burner as illustrated in Figure 2.

4.3.3 Standard equipment

Lists the standard equipment and parts included with the burner.

4.4 Firing rates (Fig. 3)

Illustrates firing rate curves for different models, showing operating ranges for stage 1 and 2.

4.4.1 Test boiler (Fig. 4)

Explains the test boiler configuration and methodology used for setting firing rates.

Installation

Notes on safety for the installation

Provides essential safety precautions that must be followed during installation procedures.

5.1 Handling

Details safe handling procedures for the burner, emphasizing attention and proper equipment.

5.2 Preliminary checks

Outlines checks to perform on the consignment and the burner's identification label.

5.3 Boiler plate (Fig. 6)

Describes how to prepare the boiler plate by drilling and marking for burner mounting.

5.4 Blast tube length (Fig. 7)

Explains the selection of the correct blast tube length based on boiler specifications.

5.5 Securing the burner to the boiler (Fig. 8)

Provides step-by-step instructions for physically attaching the burner to the boiler.

5.6 Choice of nozzles for 1st and 2nd stage

Guides the selection of appropriate nozzles for stage 1 and 2 based on delivery requirements.

5.7 Nozzle assembly

Details the procedure for installing the chosen nozzles into the burner assembly.

5.8 Combustion head setting

Explains how to adjust the combustion head setting according to the selected nozzle delivery.

Electrical system

Notes on safety for the electrical wiring

Highlights crucial safety precautions for electrical wiring, including disconnection and qualified personnel.

6.1 Electrical connections

Provides guidelines for making electrical connections, including cable types and terminal strip usage.

Hydraulic system

7.1 Fuel supply

Explains the fuel supply circuit, including double-pipe systems and tank configuration.

7.2 Hydraulic connections (Fig. 17)

Details the process of connecting hoses to the pump and burner for the hydraulic system.

7.3 Pump (Fig. 18)

Describes the pump components, their functions, and specifications.

7.3.1 Pump priming

Guides the user through the crucial process of priming the fuel pump before operation.

Burner calibration

8.1 Firing

Covers the initial firing procedure, safety checks, and expected burner behavior.

8.2 Operation

Explains how to adjust settings like fan air gate valve and pump pressure for optimal calibration.

8.2.1 Burner starting (Fig. 23) - (Fig. 24)

Details the burner's starting phases with time intervals and control device interactions.

8.2.2 Steady state operation

Describes how the burner operates in steady state, switching between stages based on demand.

8.2.3 Firing failure

Explains the burner's behavior and lock-out conditions during firing failures.

8.2.4 Undesired shutdown during operation

Covers the burner's response to flame loss and automatic restart attempts.

8.2.5 Final checks

Outlines essential checks to perform after calibration to ensure correct operation and safety.

Maintenance

Notes on safety for the maintenance

Emphasizes safety precautions required before performing any maintenance operations.

Filters (Fig. 25)

Instructs on checking and cleaning the fuel filters located within the burner system.

Combustion

Recommends analyzing flue gases for optimal calibration and identifying maintenance needs.

Pump

Details checks for pump pressure, depression, and noise, and troubleshooting for suction issues.

Fan

Specifies checking the fan for dust accumulation that can affect performance and combustion.

Combustion head

Advises checking the combustion head for condition, positioning, and freedom from impurities.

Nozzles

Provides guidance on cleaning, replacing, and checking nozzles for optimal performance.

Photoresistor (Fig. 26)

Explains how to clean the photoresistor's glass cover for accurate flame detection.

Flame inspection window (Fig. 27)

Recommends cleaning the flame inspection window glass as needed.

Flexible hoses

Instructs to check flexible hoses for good condition, ensuring they are not crushed or deformed.

Fuel tank

Advises on periodically removing water or impurities from the fuel tank.

Boiler

Refers to the boiler's manual for cleaning instructions to maintain combustion characteristics.

To open the burner (Fig. 28)

Details the steps required to open the burner casing for maintenance access.

9.1 Burner start-up cycle diagnostics

Explains how to interpret the color code table for burner start-up sequences and potential issues.

9.2 Resetting the control box and using diagnostics

Describes how to use the control box's diagnostic function and reset procedures.

9.3 Resetting the control box

Provides step-by-step instructions to reset the control box after a malfunction.

9.4 Visual diagnostics

Explains how to view diagnostic codes via LED pulses to identify the cause of burner lock-out.

9.5 Software diagnostics

Details how to use software diagnostics via PC for detailed burner operation and malfunction analysis.

7 led blinks

Lists probable causes and suggested remedies for burner lock-out indicated by 7 LED blinks.

The burner does not pass to 2nd stage

Identifies causes and solutions for the burner failing to transition to the second stage of operation.

Fuel passes to 2nd stage but air remains in 1st

Addresses issues where fuel enters the 2nd stage, but air persists in the 1st stage.

Burner stops at transition between 1st and 2nd stage or vice versa.

Explains causes and remedies for the burner stopping during stage transitions.

Burner repeats starting cycle

Details potential causes and fixes for the burner repeatedly attempting to start.

Uneven fuel supply

Covers issues related to uneven fuel supply and their potential causes.

Rusty pump internal parts

Addresses problems arising from rusty internal pump parts and suggests solutions.

Noisy pump, unstable pressure

Guides on diagnosing and resolving noisy pump operation and unstable pressure.

Pump unprimes after prolonged pause

Explains why the pump might unprime after a long pause and how to fix it.

Pump leaks light oil

Details issues related to light oil leakage from the pump and potential causes.

Smoke in flame - dark Bacharach

Addresses issues causing dark smoke (poor combustion) and potential causes.

Dirty combustion head

Covers causes and remedies for a dirty combustion head affecting performance.

10 led blinks

Lists probable causes and suggested remedies for burner lock-out indicated by 10 LED blinks.

Appendix - Electrical panel layout

1 Index of layouts

Provides an index to navigate through the different electrical layout diagrams.

2 Indication of references

Explains the system used for sheet numbering and coordinate references within diagrams.

3 Functional layout

Presents a functional electrical layout diagram for understanding system operation.

4 Functional layout

Shows another functional electrical layout diagram illustrating system connections.

5 Electrical connection set by installer

Illustrates the electrical connections that are to be made by the installer.

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