Riello RG5D Burner Manual

2902312 (5)
Manuel dentretien
Installation, use and maintenance instructions
Installatie-, gebruiks- en onderhoudsvoorschriften
Montage und Bedienungsanleitung
,
Instrucciones de instalacin, uso y mantenimiento
l-Geblsebrenner
Brleur fioul domestique
Light oil burner
Stookoliebrander
Quemadores de gasleo

CODE - CDIGO

MODELL - MODELE
MODEL - MODELO -
TYP - TYPE
TIPO -
3739850 RG5D 398T1
D
F
GB
NL
E
GR
Zweistufiger Betrieb
Fonctionnement 2 allures
Two stage operation
Tweetrapsbranders
Funcionamiento de dos llamas

2312
1 GB
INDEX
1. BURNER DESCRIPTION
Two stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket . . . .No. 1 Screw and nuts for flange to be fixed to boiler . . . No. 4
Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples . . . . . . . . . . . . . . . . No. 2
7 pin plug . . . . . . . . . . . . . . . . . . .No. 1 4 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions . . . . . . . . . . . . . . . . 2
2.3 Working field . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Recommended nozzles . . . . . . . . . . . . . . 6
4.3 Combustion head setting. . . . . . . . . . . . . 7
4.4 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.5 Pump pressure and air output . . . . . . . . . 7
4.6 Burner start-up cycle . . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
1 Pump
2 Electronic start delaying
device
3 Control-box
4 Reset button with lock-out
lamp
5 Flange with insulating
gasket
6 2
nd
stage air damper
adjustment assembly
7 Nozzles holder assembly
8 Photoresistance
9 Hydraulic jack
10 4 pole socket
11 2
nd
stage valve
12 1
st
stage valve
13 Valve casing assembly
CE Certification No.: 0036 0325/01 as 92/42/EEC.
The burner meets protection level of IP 40, EN 60529.
Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
Fig. 1
S7111
10
1
9
2
7
6
12
3
4
5
13
8
11
2312
2 GB
4
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD (as EN 267)
TYPE 398T1
Output - Thermal power 8 / 12 25 kg/h 95 / 142 296 kW
Fuel Light oil, viscosity 4 6 mm
2
/s at 20 C
Electrical supply Single phase,
~
50Hz 230V 10%
Motor Run current 2.1 A - 2730 rpm - 286 rad/s
Capacitor 8 F
Ignition transformer Secondary 8 kV - 16 mA
Pump Pressure: 8 15 bar
Absorbed electrical power 0.47 kW
247 159 300 213
160
190
12,5
36
2
8
5
3
4
5
1
1
9
9
9
9
127
4
5
4
5
D5390

1
2
5
8 10 12 14 Fuel output kg/h
100 Thermal power kW
2.4
2.0
1.2
0.4
0
P
r
e
s
s
u
r
e

i
n

c
o
m
b
u
s
t
i
o
n
c
h
a
m
b
e
r

m
b
a
r
D5391
16 18
120
3.2
20
140 160 180 220 240 200
0.8
1.6
2.8
22 24 26
260 280 300
2312
3 GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
Put on the flange (1) the screw and two nuts, (see fig. 3).
Widen, if necessary, the insulating gasket holes (4), (see fig. 4).
Fix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the
insulating gasket (4), (see fig. 2).
After installation ensure that burner is lightly inclined as in fig. 5.
3.2 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and cable clamp (2) should be reversed, (see fig. 6).
Fig. 5
D5012
Fig. 4
D5025
Fig. 2
Fig. 3
S7112
4
3
2
1
5
D5392
1 1
Fig. 6
2
2312
4 GB
3.3 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
H = difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes.
PRIMING PUMP:
On the system in fig. 7 it is
sufficient to loosen the suction gauge
connection (6, fig. 8) and wait until oil flows out.
On the systems in fig. 9 and 10 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds
before repeating the operation.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 10) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not re-
quired. Should however the return line arrive over the fuel level, a non-return
valve is required.
This solution however is less safe than previous one, due to the possibility of
leakage of the valve.
D5395
H
Fig. 7
m
a
x
.

4

m
5 - 2
nd
stage pressure adjuster
6 - Suction gauge connection
7 - 1
st
stage valve
8 - Valve casing assembly
9 - 2
nd
stage valve
10 - Auxiliary pressure test point
SYSTEM NOT PERMITTED
IN GERMANY

The pump is designed to allow working with

two pipes. In order to obtain one pipe working
it is necessary to unscrew the return plug (2),
remove the by-pass screw (3) and then screw
again the plug (2), (see fig. 8).
Before starting the burner make sure that the
return pipe-line is not clogged. An excessive
back pressure would cause the damage of
the pump seal.
WARNING:
1 - Suction line
2 - Return line
3 - By-pass screw
4 - Gauge connection
H
meters
L meters
i
8 mm
i
10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
D5405
Fig. 8
5
4
2
3
6
9
7
10
8
1
H
m
a
x
.

4

m
m
a
x
.

4

m
H
H
H
D5393
Fig. 9 Fig. 10
H
meters
L meters
i
8 mm
i
10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
2312
5 GB
3.4 ELECTRICAL WIRING

DO NOT EXCHANGE
NEUTRAL WITH PHASE

WARNING
CONTROL BOX
To remove the control-box from the burner, loosen screw (A, fig. 11) and pull
to the arrow direction, after removing all components, the 7 pin plug and
earth wire.
In case of disassembly of the control box, retighten the screw (A) with a
torque wrench setting of 1 1.2 Nm.
7 pin plug
7 pole socket
h
L1 B4 S3 T2 T1 N
Black
White
Blue
C
a
p
a
c
i
t
o
r
Burner-earth
Main switch
T6A
N
e
u
t
r
a
l
CONTROL BOX
552SE
~50Hz 230V
N
1
2
3
Photoresistance
T
Blue
Ignition
electrodes
Brown
L
T
h
T
2
nd
stage oil valve
T8 T7 T6 B5
4 pin plug
4 pole socket
B
l
u
e
B
l
a
c
k
W
h
i
t
e
B
l
u
e
B
r
o
w
n
2 1 3 2 1
M
~
ELECTRONIC
DELAYING DEVICE
2
nd
stage
M
o
t
o
r
thermostat
M
1
2
1
2
3
M
C
A
R
R
I
E
D
-
O
U
T

I
N

T
H
E

F
A
C
T
O
R
Y
1
st
stage oil valve
D5336
Limit thermostat
Remote lock-out signal
(230V - 0.5A max.)
Safety thermostat
1
st
stage
hour counter
(230V - 0.1A max.)
2
nd
stage hour counter
(230V - 0.1A max.)
Brown
Blue
S7120
Fig. 11
A
NOTES:
Wires of min. 1 mm
2
section. (Unless requested otherwise
by local standards and legislation).
The electrical wiring carried out by the installer must be in
compliance with the rules in force in the Country.
Connect 2nd stage thermostat between clamps T6 - T8
by removing the bridge.
TESTING: Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
2312
6 GB
4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and
testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO
2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of
the combustion head, and the air damper opening in accordance with the following schedule.
The values shown in the table are measured on a CEN boiler (as per EN 267).
They refer to 12.5% CO
2
at sea level and with light oil and room temperature of 20 C.
4.2 RECOMMENDED NOZZLES
Delavan type W - B
Steinen type Q
Danfoss type S
N.B.: If necessary the 1
st
stage nozzle can
have an output exceeding 50 % of the
total output.
TO FI T NOZZLES CARRY OUT THE FOL-
LOWING ACTIONS: (see fig. 12)
Remove nozzle-holder assembly (1) after loos-
ing screws (2) and nuts (3), remove the small
cables (4) from the control box and the pho-
toresistance (5).
Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc assembly (8)
from the nozzle-holder assembly (1) after loos-
ing screws (9).
Screw the nozzles (10) correctly and tighten
it as shown in figure.
ATTENTION
During the reassembly of the nozzle-holder assem-
bly screw the nuts (3) as shown in the figure below.
Nozzles
Pump
pressure
Burner
output
Combustion
head
adjustment
Air damper
adjustment
GPH
Angle
kg/h 4% 1
st
stage 2
nd
stage
1
st
stage 2
nd
stage bar 1
st
stage 2
nd
stage Set-point Set-point Set-point
2.00 1.00 60 12 8.0 12.4 0 0.25 2.1
2.00 2.00 60 12 8.0 16.4 3 0.15 3.0
2.50 2.50 60 12 10.3 20.5 6 0.3 4.4
3.00 3.00 60 12.5 12.6 25,0 8 0,6 6,0
5
3
4
2
6
7
9
8
10
0 2 4 6 8
1
S7118
Fig. 12
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684
2312
7 GB
4.3 COMBUSTION HEAD SETTING (see fig. 12, page 6)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting
screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the nozzles-
holder assembly (1).
In the sketch the combustion head is set for an output of 2.00 + 2.00 GPH at 12 bar.
The set-point 3 of the regulating rod is at the same level with the outside plane of the nozzles-holder as-
sembly as shown in the schedule.
4.4 ELECTRODES ADJUSTMENT
1 1

MEASURES MUST BE RESPECTED.
For prospecti ve adj ustments loosen
screws (1) and move the electrodes as-
sembly (2), (see fig. 13).
WARNING
To have access to the electrodes carry
out operation as described in chapter
4. 2 RECOMMENDED NOZZLES
(page 6).
Fig. 13
3 m
m
4
.
5

0
.
5

m
m
0
D5406
2
4.5 PUMP PRESSURE AND AIR OUTPUT
1
st
STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER
Unloosen the nut (1), turn the screw (2) until the indicator (3)
reaches the position desired. Then lock the nut (1), (see fig. 14).
2
nd
STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER
Unloosen the nut (4), turn the screw
(5) until the indicator (6) reaches the
position desired.
Then lock the nut (4), (see fig. 14).
PRESSURE REGULATION
This is set at 12 bar at the factory.
Should it be necessary to re-set or al-
ter such pressure, this can be done,
by adjusting screw (8).
The pressure gauge must be mount-
ed in place of cap (7), (see fig. 15).
When burner shuts down the ai r
damper automatically closes till a
max. chi mney depr essure of
0.5 mbar.
Fig. 15
D5407
5
6
4
2
1
3
Fig. 14
7
8
S7119
2312
8 GB
4.6 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (4, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the
burner acting on the main switch of the system.
THE BASIC CHECKS ARE:
Check that there are not obstructions or dents in the supply or return oil pipes.
Clean the filter in the oil suction line and in the pump.
Clean the photoresistance, (8, fig. 1, page 1).
Check for correct fuel consumption.
Replace the nozzles (see fig. 12, page 6) and check the correct position of electrodes (fig. 13, page 7).
Clean the combustion head in the fuel exit area, on the diffuser disc.
Leave the burner working without interruptions for 10 min. and check the right settings at 1
st
and 2
nd
stage of all components stated in this manual. Then carry out a combustion check verifying:
Smoke temperature at the chimney;
Content of CO2 ( %);

Content of CO (ppm);
Smoke value according to opacity smokes index according to Bacharach scale.

D6040
Lock-out due to failure to light
B
Normal
3 28s ~12s 5s
1
st
stage thermostat
2
nd
stage thermostat
Motor
Ignition transformer
1
st
stage valve
1
st
stage flame
2
nd
stage valve
2
nd
stage flame
Lock-out lamp
~12s
B
2312
9 GB
6. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for problems that could cause a failure to
start or a bad working of the burner.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box
(4, fig. 1, page 1).
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the
burner functions correctly, the lock-out can be attributed to a temporary fault.
If however the lock out continues the cause must be determined and the solution found.
WARNING
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error
in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the
technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
The burner doesnt
start when the limit
thermostat closes.
Lack of electrical supply.
Check presence of voltage in the
L1 - N clamps of the 7 pin plug.
Check the conditions of the fuses.
Check that safety thermostat is not
lock out.
The photoresistance sees false light. Eliminate the light.
Thermostats are faulty. Replace them.
The connections in the control box
are wrongly inserted.
Check and connect completely all the
plugs.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve
1
st
stage.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned.
Adjust them according to the
instructions of this manual.
Air output is too high.
Set the air output according to the
instructions of this manual.
Nozzle dirty or worn. Replace it.

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2902312 (5)

The pump is designed to allow working with

Smoke temperature at the chimney;

Content of CO2 ( %);

Smoke value according to opacity smokes index according to Bacharach scale.

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