Installation, use and maintenance instructions Kerosene burners One stage operation CODE MODEL TYPE 3516010 RDB1 WORCESTER GREENSTAR 12/18 484LD2X 3516020 RDB2.2 WORCESTER GREENSTAR 18/25 744LD2SX 20015255 RDB2.
Contents 1 Declaration.................................................................................................................................................................................. 3 2 Information and general warnings............................................................................................................................................ 4 2.1 Information about the instruction manual.....................................................................................
Contents 8.7.3 Fault diagnostics ...........................................................................................................................................................22 8.7.4 Recycle function ............................................................................................................................................................23 8.7.5 Flame failure at the end of safety time .............................................................................................
Declaration 1 Declaration Declaration of conformity in accordance with ISO / IEC 17050-1 Manufacturer: RIELLO S.p.A. Address: Via Pilade Riello, 7 37045 Legnago (VR) Product: Kerosene and gas oil burners Model: RDB1 WORCESTER GREENSTAR 12/18 RDB2.2 WORCESTER GREENSTAR 18/25 RDB2.
Information and general warnings 2 Information and general warnings 2.1 Information about the instruction manual 2.1.1 Introduction 2.1.3 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.
Information and general warnings 2.2 Guarantee and responsibility The manufacturer guarantees its new products from the installation 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.
Information and general warnings 2.3.1 Information and general instructions 2.3.2 To ensure consistency, the supplier of the fuel must be able to demonstrate compliance with a recognised Quality Control and management system to ensure high standards are maintained within the storage, blending and delivery processes. The installation oil storage tank and its ancillaries must also be prepared BEFORE liquid Bio fuel is introduced.
Safety and prevention 3 3.1 Safety and prevention 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.
Technical description of the burner 4 4.1 Technical description of the burner Technical data Type Output - Thermal power (with air at 20 °C) 3516010 3516020 20015255 1.0 – 1.5 kg/h 12 – 18 kW 1.5 – 2.1 V 18 – 25 kW 2.1 – 2.7 kg/h 25 – 32 kW Fuel Kerosene, viscosity 1.6 – 6 mm2/s at 20 °C (Hi = 11.97 kWh/kg) Electrical supply Single phase, Motor Run current 0.7A ~ 50Hz 230V ± 10% – 2700 rpm – 283 rad/s 4.
Technical description of the burner 4.4 Burner dimensions B 204 A ø 254 169 225.5 68 ø 90 136 A B 3516010 3516020 158 68 20015255 168 98 D7354 12 Fig. 2 4.5 Firing rates The MAXIMUM OUTPUT is chosen from within the diagram area (Fig. 3). The MINIMUM OUTPUT must not be lower than the minimum limit of the diagram. The work point may be found by plotting a vertical line from the desired delivery and a horizontal line from the pressure in the combustion chamber.
Installation 5 5.1 Installation 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 environment, proceed with the installation operations. All the installation, maintenance and disassembly operations must be carried out with the electricity supply disconnected.
Installation 5.4 Installer/Servicer notes for the use of Gas oil with Bio blends up to 10% where gas oil use is permitted by the appliance Manufacturer During the burner installation, check that the gasoil and bio fuel blends are in accordance with Riello specifications (please refer to the chapters "Technical Data" and "Guidance for the use of bio fuel blends up to 10%" within the burner technical manual).
Installation 5.6 Boiler fixing Align burner combustion head (1) interposing the insulating gasket (2), into the boiler housing tube (3). Push firmly down to compress the gasket (2). Tighten the two screw (4) sufficiently to ensure a good seal. Make sure any electrical cable and flexible oil line are routed away from hot surfaces. The seal between burner and boiler must be airtight. WARNING 3 D7383 4 1 D7419 Fig. 7 2 Fig. 6 5.
Installation NOTE: Burner installation must comply with one of the installations illustrated in the figures below. WARNING Under no circumstances should the air’s entry in the hose intake area be obstructed. The hose must not be blocked in any way or feature a shutting device (valves, membranes etc.). Coaxial tubes must not be installed for any reason. S7851 S7876 S7853 13 GB Fig. 9 Fig. 10 Fig.
Hydraulic systems 6 6.1 6.1.1 Hydraulic systems Fuel supply Pump Where gas oil containing bio diesel is in use, it is recommended to avoid over oxygenation of the blended fuels. The pump is designed to allow working with one pipe. In order to obtain two pipes working it is necessary to unscrew the return plug 2)(Fig. 12), screw the by-pass screw 3),supplied as burner equipment and then screw the return hose.
Hydraulic systems 6.2 One pipe system max. 4 m H Pressurised one pipe systems (Fig. 13) have a positive fuel pressure on intake to the burner. Usually the tank is higher than the burner, or the fuel pumping systems are on the outside of the boiler. Vacuum one pipe systems (Fig. 14) have a negative fuel pressure (depression) on intake to the burner. Usually the tank is lower than the burner. You are advised to use additional filters on the fuel supply line.
Hydraulic systems 6.3 Two pipe system max. 4 m H Vacuum two pipe systems (Fig. 15) have a negative fuel pressure (depression) on intake to the burner. Usually the tank is lower than the burner. The return line should terminate in the oil tank at the same level as the suction line; in this case a non-return valve is not required. Should however the return line arrives over the fuel level, the non-return valve is indispensable.
Electrical system 7 7.1 Electrical system Notes on safety for the electrical wiring DANGER The electrical wiring must be carried out with the electrical supply disconnected. Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. Refer to the wiring diagrams. The manufacturer declines all responsibility for modifications or connections different from those shown in the wiring diagrams.
Electrical system 7.2 Electrical wiring TESTING: ~ 50Hz - 230V L Check the shut-down of the burner by opening the thermostats and the lock-out by darkening the photoresistance. N 7.2.1 Control box T6A This operation must be performed with the burner turned off and mains power disconnected. DANGER TS To remove the control box (Fig. 17) from the burner follow of the istruction: Loosen the screw (1) and remove protection (6) of the electrical connections and coil.
Start-up, calibration and operation of the burner 8 Notes on safety for the first start-up WARNING 8.2 The first start-up of the burner must be carried out by qualified personnel, as indicated in this manual and in compliance with the standards and regulations of the laws in force. Check the correct working of the adjustment, command and safety devices.
Start-up, calibration and operation of the burner 8.4 Pump pressure The pump leaves the factory set for kerosene working. 10 bar: maximum pressure for kerosene. 8.5 Air damper adjustment The air damper is set in factory. This regulation is purely indicative. Each installation however, has its own unpredictable working conditions: actual nozzle output; positive or negative pressure in the combustion-chamber, the need of excess air, etc.
Start-up, calibration and operation of the burner 8.7 Operation programme Lock-out for flame failure in running position Normal operation TL TL M MV I M MV I I * V V F F SB A SB A tpri tpv I M I tpri – tpstv – tpti – tpv – ts – – V F SB A * tpri tpv 8.7.1 tpri tpstv tpv ts Fig. 25 Key to lay-out F – Flame detector I – Ignition transformer MV – Fan motor SB – Remote lock-out signal TL – Limit thermostat V – Oil valve TL MV tpv Fig.
Start-up, calibration and operation of the burner 8.7.
Start-up, calibration and operation of the burner 8.7.4 Recycle function 8.7.7 The control box allows a recycle, i.e. complete repetition of the start-up programme, making up to 3 attempts, in the event the flame failure during operation. If the flame failure 4 times during operations, this will cause the burner to lock out. If there is a new demand for heat during the recycle, the 3 attempts are reset when the limit thermostat (TL) switches.
Start-up, calibration and operation of the burner 8.7.12 Lock-out types The control box display causes of malfunctioning any time that lock-out occure, identified by the reset button color. The sequence of led pulses in the reset button issued by the control box identifies the possible types of malfunction, which are listed in the table below. Description Lock-out time The flame is not detected Immediate after the safety time Presence of extraneous After max.
Maintenance 9 9.1 Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, safety, yield and duration of the burner. Before carrying out any maintenance, cleaning or checking operations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.
Faults / Solutions 10 Faults / Solutions Below is a list of some of the causes and possible solutions to a series of problems that might be encountered and could cause a failure to start or irregular burner operation. The burner will attempt to a new ignition only after pushing the reset button. After this if the burner functions correctly, the lock-out can be attributed to a temporary fault. A fault turn-on the led into the reset button of the control box (1, Fig. 1 to page 8).
Faults / Solutions 10.1.1 Operating faults Fault Digital fault diagnostics Possible cause The burner goes into Flame failure. lockout mode during operation. R,(-),R,(-) Fast blinking Solution Clean or replace the flame detector. Replace the dirty or deteriorated nozzle. Check the efficiency of the flame detector. Check the efficiency of the piston on the pressure adjuster. Check the efficiency of the pump cut off valve.
RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.rielloburners.
