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2903266

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Start-up, calibration and operation of the burner

8.8.3

Fuel pre-heating function (for burners 
equipped with heater)

If the burner is equipped with the fuel pre-heating function, in the

presence of a start request from the heat request thermostat of

the boiler, the burner awaits the closure of the start-up thermostat

(or pre-heating, K) positioned on the nozzle holder. 
If the start-up thermostat (or the pre-heating one) does not close

within 600 seconds, the burner goes into lockout mode.
If the flame goes out during operation, the burner carries out re-

cycling if the contact of the start-up thermostat (or the pre-heating

one, K) is closed.
If the flame goes out during operation and the contact of the start
up thermostat (or the pre-heating one, K) is open, the purging
stops and the burner waiting for the closure of the contact of the
start up thermostat (or the pre-heating one, K) to restart with the
pre-purging time.

8.8.4

Shutdown test

If, during operations, the reset push-button is pressed for longer

than 5 seconds and less than 10 seconds, (so as not to go to the

next menu) the burner switches off, the oil valve closes, the flame

is extinguished and the starting sequence restarts.
If the switch off test is enabled, the number of repetitions of the

start up sequence (see section 8.8.7) and the number of possible

resets (see section 8.8.11), are reset.

8.8.5

Diagnosis of the flame signal quality

The burner allows a light diagnosis of the flame during the burner

run operation.

NOTE:

If the detected signal is more than 6 times the minimum threshold

value (approximately 3 lux), the green LED will be constant. Oth-

erwise, the number of blinks will indicate the quantity of signal

coming from the sensor (no. of blinks * approx. 3 lux). The detect-

ed signal depends on the sensitivity of the sensor used, and its

tolerance; if the sensor is highly sensitive, the signal level will be

high (for the same flame).

NOTE:
With 2 lux, the burner goes into lockout after 3 cycle repeats

8.8.6

Intermittent operation 

After (at the most) 24 hours of continuous operation, the control
box starts the automatic switch off sequence, followed by a re-
start, in order to check for a possible fault with the flame sensor.
It is possible to set up this automatic switch off to 1 hour, (see the
section 8.10).

8.8.7

Recycle and limit of repetitions

The control box allows a recycle, i.e. complete repetition of the
start-up sequence, making up to 3 attempts, in the event the
flame failure during operation.
If the flame failure 4 times during operations, this will cause a
burner lockout. If there is a new demand for heat during the recy-
cle, the 3 attempts are reset when the limit thermostat (TL)
switches. 

NOTE:
After 510 seconds of continuous operation, a new attempt of

possibility is added. 

By disconnecting the power supply, when a new heat request oc-

curs (power supply is applied to the burner) all possible attempts

at re-ignition are reset (maximum 3).

8.8.8

Presence of an extraneous light or parasite 

flame

If when the fan motor starts, during the pre-purging, an extrane-

ous light or parasite flame is detected the burner remains in purg-

ing until it disappears or the lockout condition is reached 25

seconds.

If the parasite flame or the extraneous light are detected during

the pre-purging, the pre-purging time of 15 seconds is reset and

the time for checking for the presence of a parasite flame or ex-

traneous light begins (the motor continues to purge).

The function is cumulative and can be carried out a maximum of

2 times. If at the 24th second the parasite flame or the extraneous

light disappears, the pre-purging time starts and if the parasite

flame or the extraneous light reappear the pre-purging time is re-

set and the countdown of 25 seconds for checking for the pres-

ence of the parasite flame or the extraneous light restarts.

The third time that the parasite flame or the extraneous light ap-

pears the burner goes into lockout.

If during the recycle due to flame disappearance while operating

and the consequent repetition of the start-up sequence the para-

site flame or the extraneous light is detected, the countdown of

25 seconds starts for checking for the presence of the parasite

flame or the extraneous light. 

The presence of the parasite flame or extraneous light is also de-

tected in the “t2” state (the burner does not start). The fault is in-

dicated by way of the blinking LED (see section 8.8.2). 

8.8.9

Pre and post spark ignition

In the pre-spark ignition time the ignition device starts 2 seconds

before the oil valve opens.

In the post-spark ignition time, the ignition device stops 3 sec-

onds after safety time.
The spark ignition is present during all safety time.

NOTE:
In case of continuous recycling or heat requests close to
one another, the maximum permissible number of cycle rep-
etitions of the ignition transformer is one attempt every min-
ute.

8.8.10 Reset protection and remote reset

The system will only unlock after the button has been released.
The unit can also be reset via an external button (remote reset)
which connects the L terminal (LINE) to the RESET terminal (re-
fer to the wiring diagrams). Max length of external remote reset
cable is 3 meters.

8.8.11 Reset push-button anomaly

if the reset push-button or the remote reset breaks or is kept
pressed for more than 60 seconds, the fault is indicated by the
blinking of the led (see section 8.8.2) as long as the fault is pres-

Flame quality 

Number of green LED blinks

Acceptable

1 - 2 blinks

Good

3 - 4 blinks

Excellent

5 blinks, or always ON 

Flame detection

Parameters

Type of sensitive element

Photo-conductive cell

Functioning principle

Detection of visible light

Sensitivity to the flame during the
pre-purging

> 1 Lux

Typical sensitivity to the flame
during normal operation

> 3 Lux

Typical sensitivity to the flame
failure

< 2 Lux

Summary of Contents for 20015255

Page 1: ...se 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 2 WO...

Page 2: ...Original instructions...

Page 3: ...4 4 Burner dimensions 9 4 5 Firing rates 9 5 Installation 10 5 1 Notes on safety for the installation 10 5 2 Handling 10 5 3 Preliminary checks 10 5 4 Installer Servicer notes for the use of Gas oil w...

Page 4: ...23 8 8 11 Reset push button anomaly 23 8 8 12 External lockout indicator 24 8 8 13 Frequency main supply anomaly 24 8 8 14 Internal voltage anomaly 24 8 8 15 Checking the fan motor 24 8 8 16 Checking...

Page 5: ...th the following Technical Standards EN 12100 EN 267 According to the European Directives MD 2006 42 EC Machine Directive LVD 2014 35 EU Low Voltage Directive EMC 2014 30 EU Electromagnetic Compatibil...

Page 6: ...ied 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 wi...

Page 7: ...ance and care of those burner components most likely to be subject to wear and tear the use of non original components including spare parts kits accessories and optional force majeure The manufacture...

Page 8: ...quality bio compatible oil filter at the tank and then a second ary filter of 60 Microns protecting the burner from contamina tion If an existing oil storage tank is to be used then in addition to the...

Page 9: ...d maintenance errors or to improper use 3 3 Basic safety rules Children or inexpert persons must not use the appliance Under no circumstances must the intake grids dissipation grids and ventilation ve...

Page 10: ...el Kerosene viscosity 1 6 6 mm2 s at 20 C Hi 11 97 kWh kg Electrical supply Single phase 50Hz 230V 10 Motor Run current 0 7A 2700 rpm 283 rad s Capacitor 4 5 F Ignition transformer Secondary 18 kV 25...

Page 11: ...line from the desired delivery and a horizontal line from the pressure in the combustion chamber The intersection of these two lines is the work point which must lie within the firing rates Fig 2 204...

Page 12: ...s 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 handl...

Page 13: ...at the tank and a secondary 60 micron filter are used to protect the burner pump and nozzle from con tamination The burner hydraulic components and flexible oil lines must be suitable for bio fuel use...

Page 14: ...ll be met if you use flues for pressure exhaust of flue gases the condensation kind Make sure the air intake tube s inlet is positioned so that it is not likely to be obstructed by foreign matter and...

Page 15: ...line 3 By pass screw 4 Gauge connection 5 Pressure adjuster 6 Vacuum gauge connection 7 Valve 8 Auxiliary pressure test point 2 1 3 4 5 6 7 8 D10934 Fig 9 WARNING Where gas oil containing bio diesel i...

Page 16: ...ength of the suction line I D internal diameter of the oil pipes NOTE The Tab B and Tab C show the maximum approximate lengths for the supply line depending on the difference in level length and the d...

Page 17: ...L max length of the suction line I D internal diameter of the oil pipes NOTE The Tab D shows the maximum approximate lengths for the sup ply line depending on the difference in level length and the d...

Page 18: ...operation This means they should compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start up efficiency Normally the boiler s thermostat press...

Page 19: ...ables and thermostat as well 7 1 2 Motor capacitor The proper positioning of motor capacitor cover is shown in the detail of Fig 15 To remove the motor capacitor cover from the burner loosen the screw...

Page 20: ...Hz 230V Main switch White WARNING Do not invert the neutral with the phase in the electrical supply line Check that the electrical supply of the burner corresponds to that shown on the identifica tion...

Page 21: ...urner WARNING 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 regula tions of the laws in force WARNING...

Page 22: ...her of two positions To set the positions of the damper proceed as follows remove the secondary air damper B Fig 19 loosing the screws 1 Loosen the screw 2 and rotate the main air damper A to the requ...

Page 23: ...tion time Only 3 consecutive re ignition attempts are permitted Fig 21 Loss of flame during operation R ecycle max 3 attempts t1 t3 t4i ts t5i t4l HT FM ID V1 F LED F LED P M t3i POW ERSUPPLY Signal n...

Page 24: ...eset 0 8 tr Re cycles Max no 3 repetitions of complete start up sequence if there is a flame failure during operation the final action at the last attempt following flame failure is a lock out 3 re cy...

Page 25: ...hen a new heat request oc curs power supply is applied to the burner all possible attempts at re ignition are reset maximum 3 8 8 8 Presence of an extraneous light or parasite flame If when the fan mo...

Page 26: ...burner restarts 8 8 15 Checking the fan motor The control box automatically detects the presence of the fan mo tor and in the event of a fault it performs a lockout The lockout is indicated by the bl...

Page 27: ...number of times programmed 0 5 sec ON 0 5 sec OFF 8 10 3 Intermittent operation Sequence for enable disable Programming allowed in OPERATION Press the button for 20 sec t 25 sec GREEN led flashing 3...

Page 28: ...heat demand Pre heating not terminated if there is a heater After 600 seconds fault in the resistor of the oil pre heater fault in the switch or start up thermostat the short circuit socket is not co...

Page 29: ...to either the suction line or the pump If the problem lies in the suction line check to make sure that the filter is clean and that air is not entering the piping Hoses Check periodically the flexibl...

Page 30: ...ts Allow the burner to work for 10 min and then check the combustion readings with the parameters indicated within the appliance instruction manual Then carry out a combustion check verifying Smoke te...

Page 31: ...are wrongly inserted OFF Check and connect all the plugs and sockets prop erly The heater is faulty or the P short cir cuit socket is not connected if there is not a heater Replace them The burner go...

Page 32: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com...

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