Riello RL 300/B MZ Installation, Use And Maintenance Instructions Download

Page: 33 / 44

20035745

Faults - Possible causes - Solutions

The burner does
not pass to 2nd
stage

Control device TR does not close

Adjust or replace

Defective control box

Replace

2nd stage solenoid valve coil defective

Replace

Piston jammed in valve unit

Replace entire unit

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

Low pump pressure

Increase

2nd stage operation of cylinder is faulty

Change cylinder

Burner stops at
transition between
1st and 2nd stage.
Burner repeats
starting cycle.

Nozzle dirty

Renew nozzle

Photocell dirty

Clean

Excess air

Reduce

Uneven fuel supply Check if cause is in pump from tank or fuel sup-

ply system

Feed burner located near burner

Internally rusted
pump

Water in tank

Suck water from tank bottom with sepa-
rate pump

Noisy pump, unsta-
ble pressure

Air has entered the suction line

Tighten connectors

- Depression value too high (higher than 35 cm Hg):
Tank/burner height difference too great

Feed burner with loop circuit

Piping diameter too small

Increase

Suction filters clogged

Clean

Suction valves closed

Open

Paraffin solidified due to low temperature

Add additive to fuel

Pump unprimes
after prolonged
pause

Return pipe not immersed in fuel

Bring to same height as suction pipe

Air enters suction piping

Tighten connectors

Pump leaks fuel

Leakage from sealing organ

Replace pump

Smoke in flame
- dark Bacharach

- yellow Bacharach

Not enough air

Adjust head and fan air damper

Nozzle worn or dirty

Replace

Nozzle filter clogged

Clean or replace

Erroneous pump pressure

Adjust to between 10 - 14 bar

Flame stability disc dirty, loose, or deformed

Clean, tighten in place, or replace

Boiler room air vents insufficient

Increase

Too much air

Adjust head and fan air damper

Dirty combustion
head

Nozzle or filter dirty

Replace

Unsuitable nozzle delivery or angle

See recommended nozzles

Loose nozzle

Tighten

Impurities on flame stability spiral

Clean

Erroneous head adjustment or not enough air

Adjust; open gate valve

Blast tube length unsuited to boiler

Contact boiler manufacturer

10 pulses




Connection or internal fault
Presence of electromagnetic disturbance

Use the radio disturbance protection kit

SIGNAL

FAULT

POSSIBLE CAUSE

SOLUTION

Summary of Contents for RL 300/B MZ

Page 1: ...20035745 4 04 2012 Installation use and maintenance instructions Kerosene and gas oil burners Two stage operation CODE MODEL TYPE 20034242 RL 300 B MZ 966 T 20034244 RL 400 B MZ 967 T GB ...

Page 2: ......

Page 3: ...12 4 8 1 Description of panel board 13 4 8 2 Entry for power cables and external leads 13 4 9 Standard equipment 13 5 Installation 14 5 1 Notes on safety for the installation 14 5 2 Handling 14 5 3 Preliminary checks 14 5 4 Installer Servicer notes for the use of Gas oil with Bio blends up to 10 15 5 5 Operating position 15 5 6 Removal of the locking screws from the shutter 15 5 7 Boiler plate 16 ...

Page 4: ...t oil pressure switch 24 7 7 Air pressure switch CO check 25 7 8 Burner operation 25 7 8 1 Burner starting 25 7 8 2 Steady state operation 26 7 8 3 Firing failure 26 7 8 4 Undesired shutdown during operation 26 7 9 Final checks 26 8 Maintenance 27 8 1 Notes on safety for the maintenance 27 8 2 Maintenance programme 27 8 2 1 Maintenance frequency 27 8 2 2 Checking and cleaning 27 8 3 Burner start u...

Page 5: ...6 42 EC Machine Directive LVD 2006 95 EC Low Voltage Directive EMC 2004 108 EC Electromagnetic Compatibility The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001 Manufacturer s Declaration RIELLO S p A declares that the following products comply with the NOx emission limits specified by German standard 1 BImSchV reliese 26 01 2010 Product Type M...

Page 6: ...elivered 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 Assist ance Centre The system supplier must carefully inform the user about the use of the system any further tests that may be required before activati...

Page 7: ...pump safety value and nozzle The Riello war ranty is dependent upon the use of Riello genuine compo nents including the oil lines being used 3 Riello warranty does not cover defects arising from incorrect commissioning or servicing by non Riello employed service engineers and any issues impacting the burner arising from external site related issues 2 3 Guidance for the use of bio fuel blends up to...

Page 8: ...pliance applica tion and commissioned checking that all combustion param eters are as recommended in the appliance technical manual Riello recommends that the in line and burner oil pump filters are inspected and if required replaced at least every 4 months during burner use before the burner start up follow ing a long period of discontinue operation and even more frequently where contamination ha...

Page 9: ...nd 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 vents in the installation room be cov ered up with cloths paper or any other material Unauthorised persons must not attempt to repair the appli ance It is dangerous to pull or twist the electric leads ...

Page 10: ...working 1 stop every 72 h Electrical supply to the system 1 230 50 3 230 50 Auxiliary voltage 230 50 60 R L 300 TC Emission Class 1 EN267 EN676 MZ Class 2 EN267 Class 2 EN676 BLU Class 3 EN267 EN676 MX Class 2 EN267 Class 3 EN676 FS1 3 400 50 230 50 60 BASIC DESIGNATION EXTENDED DESIGNATION 1 230V 50Hz 3 230V 50Hz 230V 50 60Hz Heavy oil B Two stage M Modulating 1 Single stage S L LS N Head TC Stan...

Page 11: ...oil and Blends of gas oil and bio fuel FAME in accordance with EN 14214 up to 10 Kerosene net calorific value density viscosity at 20 C kWh kg Mcal kg kg dm3 mm2 s max 11 97 10 3 10 300 kcal kg 0 77 0 83 6 1 5 E 6 cSt Gas oil net calorific value density viscosity at 20 C kWh kg Mcal kg kg dm3 mm2 s max 11 86 10 2 10 200 kcal kg 0 82 0 85 6 1 5 E 6 cSt Operation Intermittent min 1 stop in 24 hours ...

Page 12: ...Pomp motor W V A 1100 220 380 4 7 2 7 Ignition transformer V1 V2 I1 I2 230 V 2 x 5 kV 1 9 A 35 mA Electrical power consumption W max 7300 11700 Electrical protection IP 54 Model RL 300 B MZ RL 400 B MZ Electrical supply V Ph Hz 230 400 3 50 400 3 50 Auxiliary power supply V Ph Hz 230 1 50 Electric motors rpm W V A 2900 4500 230 400 15 8 7 2900 7500 400 690 13 8 8 0 Pomp motor W V A 1100 220 380 4 ...

Page 13: ...s the maximum delivery of the burner in relation to the pressure in the combustion chamber mm A B D E G H L R RL 300 B MZ 1325 510 313 605 720 890 1175 1055 RL 400 B MZ 1325 510 313 605 775 890 1175 1055 Fig 1 E D B A G H R L R D3319 WARNING The firing rate value Fig 2 has been obtained considering an ambient temperature of 20 C an atmospheric pressure of 1013 mbar approx 0 m above sea level and w...

Page 14: ...13 Shutter 14 Lever for movement of combustion head 15 Gears for movement of air damper 16 Air pressure test point 17 Pump 18 Photoelectric cell 19 Pump motor 20 Minimum oil pressure switch The burner can be opened either on the right or left sides irre spective of the side from which fuel is supplied When the burner is closed the hinge can be re positioned on the opposite side WARNING The burner ...

Page 15: ...Control box lock out if the control box 9 Fig 5 pushbutton red led and the reset button 8 Fig 5 light up it indicates that the burner is in lock out To reset hold the pushbutton down for between 1 and 3 seconds Motors trip release by pressing the push button of the relevant thermal cutout relay 4 8 2 Entry for power cables and external leads Key Fig 6 1 Electrical supply 2 Fan motor 3 Triggering S...

Page 16: ...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 handling Check also that the area in which you are working is empty and that there is an adequate escape area i e a free safe area to which you can quick ly move if the burner should fall When handling keep the load at not mor...

Page 17: ...xible oil lines must be suitable for bio fuel use check with Riello if in doubt Riello have carefully chosen the specification of the bio compatible components including the flexible oil lines to protect the pump safety value and nozzle The Riello war ranty is dependent upon the use of Riello genuine compo nents including the oil lines being used The burner must be commissioned and combustion para...

Page 18: ...actory fettling 2 5 is not required unless it is expressly requested by the boiler manufacturer 5 9 Securing the burner to the boiler Prepare an adequate system of hoisting by hooking onto the rings 3 Fig 11 Slip the thermal protection standard equipment onto the blast tube 4 Fig 11 Place entire burner on the boiler hole arranged previously see Fig 10 and fasten with the screws given as standard e...

Page 19: ...ozzle assembly Fit two nozzles with the box spanner 1 Fig 13 16 mm after having removed the plastic plugs 2 fitting the spanner through the central hole in the flame stability disk 3 The nozzles must be screwed into place tightly but not to the maximum torque value provided by the wrench The nozzle for the 1st stage of operation is the one lying beneath the firing electrodes Fig 14 Tab F WARNING I...

Page 20: ...20035745 18 GB Installation 5 11 Position of electrodes Make sure that the electrodes are positioned as shown in Fig 14 WARNING Measures must be respected mm 4 4 5 mm 8 1 0 16 Fig 14 D3323 ...

Page 21: ...ovide clearance to the burner only if there ispressure Key Fig 15 H Pump Foot valve height difference L Piping length ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Manual on off valve 5 Suction line 6 Foot valve 7 Rapid closing manual valve remote controlled only Italy 8 On off solenoid valve only Italy 9 Return line 10 Check valve only Italy 11 Tank filter Tab G WARNING Where gas oil containi...

Page 22: ...urner with the by pass closed by screw 6 Fig 17 It is therefore necessary to connect both hoses to the pump The pump will break immediately if it is run with the return line closed and the by pass screw inserted Remove the plugs from the suction and return connections of the pump Insert the hose connections with the supplied seals into the con nections and screw them down Install the hoses where t...

Page 23: ...to cool Do not illuminate the UV cell or the burner will lock out the burner should lock out anyway about 10 seconds after it starts WARNING In case of use with gas oil containing up to 10 Bio blend it will be essential to use flexible oil lines suitable for bio fuel use Please contact Riello for further information Suntec TA2 Min delivery rate at 12 bar pressure kg h 480 Delivery pressure range b...

Page 24: ...ly the boiler s thermostat pressure switch ensures the stopping of the burner If this is not the case it is necessary to apply in series with IN a timer switch that turns off the burner at least once every twenty four hours Refer to the wiring diagrams The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system made according to current stand...

Page 25: ...es and 12 bar pump pressure Find the delivery of the two 30 GPH nozzles in Tab F at page 17 1455 9 1455 9 2911 8 kW Diagram Fig 21 indicates that for a delivery of 2911 8 kW the burner requires the combustion head to be set to approx 3 notch es 7 3 2 1st and 2nd stage nozzles See the information listed at page 17 7 3 3 Pump pressure 12 bar this is the pressure calibrated in the factory which is us...

Page 26: ...ake and close grille 1 progressively until you achieve the required output The only time reducing intake to a partial setting is not necessary is when the burner is working at the top of the operating range given on page 11 7 6 Low limit oil pressure switch The low limit oil pressure switch inhibits burner ignition at a pres sure below the pump s setting See Tab F to page 17 it comes with a factor...

Page 27: ... onds Control device TL closes After about 3s 0 s the control box starting cycle begins 2 s the fan motor starts Servomotor 12 Fig 27 starts air damper opens in 1st stage position 3 s the ignition transformer is connected The pump 3 Fig 26 sucks the fuel from the tank through the piping 1 and the filter 2 and pumps it under pressure to delivery The piston 4 rises and the fuel returns to the tank t...

Page 28: ...led The burner is fired as described in the case above If the temperature or pressure increase until control device TL opens the burner shuts down Section A A in the diagram Fig 27 7 8 3 Firing failure If the burner does not fire it goes into lock out within 5 s of the opening of the 1st stage valve and 30 s after the closing of control device TL The control box red pilot light will light up 7 8 4...

Page 29: ...cell Clean the glass cover from any dust that may have accumulated Photocell 1 Fig 29 can be removed by pulling it outward force fully Filters Check the filtering baskets on line and at nozzle present in the system Clean or replace if necessary If rust or other impurities are observed inside the pump use a separate pump to lift any water and other impurities that may have deposited on the bottom o...

Page 30: ...ction through which any causes of malfunctioning are easily identified indicator RED LED To use this function you must wait at least 10 seconds once it has entered the safety condition lock out and then press the re set button The control box generates a sequence of pulses 1 second apart which is repeated at constant 3 second intervals Once you have seen how many times the light pulses and identi ...

Page 31: ...d LED will flash intermit tently with a higher frequency only now can the optical link be activated Once the operations are done the control box s initial state must be restored using the resetting procedure described above The sequence of pulses issued by the control box identifies the possible types of malfunction which are listed in the table on page 30 BUTTON PRESSED FOR CONTROL BOX STATUS Bet...

Page 32: ...tage cable defective or grounded Replace High voltage cable deformed by high tempera ture Replace and protect Ignition transformer defective Replace Erroneous valves or transformer electrical con nections Check Defective control box Replace Pump unprimed Prime pump Pump motor coupling broken Replace Pump suction line connected to return line Correct connection Valves up line from pump closed Open ...

Page 33: ... Suction filters clogged Clean Suction valves closed Open Paraffin solidified due to low temperature Add additive to fuel Pump unprimes after prolonged pause Return pipe not immersed in fuel Bring to same height as suction pipe Air enters suction piping Tighten connectors Pump leaks fuel Leakage from sealing organ Replace pump Smoke in flame dark Bacharach yellow Bacharach Not enough air Adjust he...

Page 34: ...lengths of the thermostat connections is over 20 meters this specific pro tection kit is available as an interface between the thermostatic controls and the burner PC INTERFACE KIT To connect the control box to a personal computer for the trans mission of operation fault signals and detailed service informa tion an interface adapter with PC software are available SPACER KIT If burner head penetrat...

Page 35: ... 2 References layout 3 Layout of unifilar output RL 300 B MZ RL 400 B MZ 4 Functional diagram RL 300 B MZ Star delta starter operational layout RL 400 B MZ 5 RMO 88 operational layout 6 RMO 88 operational layout 7 Electrical connections set by installer 1 2 Sheet no 1 A1 Coordinates Reference layout ...

Page 36: ...20035745 34 GB Appendix Electrical panel layout 0 1 2 30 0 0 1 2 30 0 1 2 2 4 4 0 4 0 5 4 6 4 0 4 0 0 4 4 4 4 4 74 7 7 4 4 0 5 4 0 0 0 0 0 0 0 RL 300 B MZ ...

Page 37: ...35 20035745 GB Appendix Electrical panel layout 0 0 1 2 30 0 0 0 1 2 30 0 1 2 2 4 4 0 4 0 5 4 6 4 0 4 0 0 4 4 4 4 4 74 7 7 4 4 0 5 4 0 0 0 0 0 0 0 0 RL 400 B MZ ...

Page 38: ...20035745 36 GB Appendix Electrical panel layout RL 300 B MZ ...

Page 39: ...37 20035745 GB Appendix Electrical panel layout RL 400 B MZ ...

Page 40: ...20035745 38 GB Appendix Electrical panel layout ...

Page 41: ...39 20035745 GB Appendix Electrical panel layout ...

Page 42: ...20035745 40 GB Appendix Electrical panel layout 01123 0 3 112 01453 6 7 0 3 8 9 0 3 112 01453 6 7 8 9 8 8 9 8 9 76 76 A ...

Page 43: ...ltage free contact relay K6 Burner on voltage free contact relay MP Pump motor MV Fan motor PE Burner ground PA Air pressure switch PO Oil pressure switch RS Remote lock out reset button S1 Emergency stop push button S2 Switch for following operations off automatic manual SH3 Burner reset button and lockout warning S4 1st 2nd stage selector SM Servomotor TA Ignition transformer TL Load limit remot...

Page 44: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www rielloburners com ...

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Riello RL 300/B MZ, Installation, Use And Maintenance Instructions

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