Riello 629 T80 Stücklistenhandbuch

2916203 (2) - 06/2012

Instrucciones de instalación, uso y mantenimiento

Instruções para instalação, uso e manutenção

Instruction for installation, use and maintenance

Fuel-oil-fired burner

Quemador de aceite pesado

Queimador de nafta

CODE

CÓDIGO MODEL

MODELO TYPE

TIPO

3436081 PRESS 100 N/ECO 629 T80

3436082 PRESS 100 N/ECO 629 T80

Two-stage operation

Funcionamiento biestadio

Funcionamento bifásico

6203

1GB

INDEX

1. BURNER DESCRIPTION

Two stage heavy oil burner.

1.1 EQUIPMENT

Flexible tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples . . . . . . . . . . . . . . . . . . . . . . . No. 2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 2 Screws . . . . . . . . . . . . . . . . . . . . . . . . . No. 4

Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . No. 2

Guide extensions (for the lengthened head version).No. 2 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Fitting for operation with emulsified

fuel oil (see page 10) . . . . . . . . . . . . . . . . . . . . . . . No. 1

1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1

1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2

2.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Field of operation . . . . . . . . . . . . . . . . . . . . 3

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 4

3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 4

3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 5

3.3 Electrical connections . . . . . . . . . . . . . . . . 6

4. OPERATION. . . . . . . . . . . . . . . . . . . . . . . 7

4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 7

4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 7

4.3 Combustion head setting . . . . . . . . . . . . . . . 7

4.4 Adjustment of the air damper motor . . . . . . . 7

4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . 8

4.6 Atomisation temperature adjustment . . . . . . . 8

4.7 Start-up programme . . . . . . . . . . . . . . . . . . . 9

4.8 Ecological oil burners . . . . . . . . . . . . . . . . . 10

4.9 Emulsified fuel oil functioning . . . . . . . . . . . 10

4.10 Start-up programme diagnostics . . . . . . . . . 10

4.11 Operating fault diagnostics . . . . . . . . . . . . . 11

2895

OThe burner meets protection level IP 40, EN 60529.

OBurner with CE marking in conformity with EEC directives: EMC 2004/108/EC, Low Voltage

2006/95/EC and Machines 2006/42/EEC.

1 - Suction line

2 - Return fitting

3 - Pump pressure adjustment

4 - Manometer fitting (G1/8)

5 - Vacuometer fitting (G1/2)

6 - Air damper opening motor

7 - Control box reset push-button and

lock-out indicator

8 - Fan overload cutout reset

9 - Regulating screw for combustion head

10 - Double filter

11 - Valve assembly

12 - Manometer with protection valve

13 - Adjustment thermostat

14 - Preheater contact maker

15 - Transformer

16 - Terminal strip

17 - Cable glams

18 - Antigas valve

19 - Thermometer

20 - Pump motor starter with reset

21 - Air pressure switch

Fig. 1

6203 2GB

2. TECHNICAL DATA

2.1 ELECTRICAL DATA

Motor IE1

Motor IE2

Type 629 T80

Thermal power - Capacity 285/490 ÷ 1140 kW – 25/43 ÷ 100 kg/h

Fuel Oil with max. viscosity at 50° C 115 sq.mm/s (15° E)

Pump 150 kg/h at 20 bar

Electrical supply Three-phase, 230V ±10% ~60Hz without neutral

400V ±10% ~60Hz with neutral

Fan motor rpm

2850

1.5

220 - 380

5.5 - 3.2

Pump motor kW

220 - 380

0.37

2.1 - 1.2

Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA

Heaters 7 kW

Electrical intake power kW max 9.4

Electrical supply Three-phase, 230V ±10% ~60Hz without neutral

400V ±10% ~60Hz with neutral

Fan motor rpm

2930

1.5

220 - 380

6.2 - 3.6

Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA

Heaters 7 kW

Electrical intake power kW max 9.4

6203 3GB

2.2 DIMENSIONS

2.3 FIELD OF OPERATION (2 nozzles in operation)

D2715

BurnerBoiler plate

NOTE

The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised

to hold the burner while it is being extracted so as not damage the flame disc and the said guides.

For long - head version.

Use the pin extensions supplied to move the burner back.

876 250

410 625 290

Diam.195

370

D2710

Thermal power

Pressure in combustion

chamber – mbar

When the burner operates with only one nozzle, the pressurization conditions are improved and no prob-

lems arise. Minimal fuel capacity with one only nozzle: 25 kg/h - 285 kW.

kg/h

D2709

6203 4GB

3. INSTALLATION

3.1 FUEL OIL SUPPLY SYSTEMS

GRAVITY SYSTEM

SUCTION SYSTEM

LOOP SYSTEM (max loop system 3 bar)

Pump priming:

loosen the cap of the vacuometer fitting

(5, fig. 1) and wait for the fuel flow.

H: Difference in height

L: Length of the suction tube

For fuel oil with viscosity max. 7°E at 50°C.

D2727

max. 30m

metres

L metres

diam.

1” gas diam. 1

1/4” gas

035

0.5 6 10

1915

1.5 12 20

21525

Not advised, to be used only when

there is a previously existing system.

Never exceed the max. vacuum of 0.5 bar

(38 cm Hg) measured at the vacuometer

fitting (5, fig. 1 ).

The pipes should be perfectly airtight.

When the tank is placed below of the burn-

er level, the return pipe should arrive at the

same level as the suction pipe.

In this case the foot valve is not required.

For fuel oil with viscosity max. 7°E at 50°C.

D2728

metres

L metres

diam. 1

1/4” gas diam. 1

1/2”

01226

0.5 10 22

1918

1.5 7 15

2512

2.5 4 9

3–6

max. 30m

1- Tank (properly heated for heavy oil) 5- Transfer pump

2- Filter (with resistor for oil > 7°E / 50°C) 6- Manometer

3- Burner 7- Burner pump

4- Air damper for eliminating burner (coupled) 8- Pressure adjuster

For heavy oil with viscosity up to 50°E/50°C.

Important note: to let the fuel flow properly all the pipes have to be properly sized, insulated and heated

(elec. resistor or steam or hot water).

Warning: before starting up the burner verify that there is no obstruction in the pipes.

any obstruction may damage the sealing of the pump.

D2729

6203 5GB

3.2 ELECTRICAL SYSTEMBURNER (carried out in the factory)

531

624

789123456

531

642

MV2HS1ST0

ST1

ST2R1

411 85918 13 17 10

1612 15

RT1

531

642

TAV

RMO88.53A2

L1R

L2R

L3R

N L1L2L3 LNS3 T130 T2T6T8

V21

V22

L1P

L2P

L3P

CMP

CMV

CMP Pump motor contact maker

CR Preheater contact maker

FSuppressor

FR Photocell

MB Burner terminal strip

MP Pump motor

MV Fan motor

PA Air pressure switch

R1 Atomiser holder resistor

R2 Pump resistor

R3 Valve assembly resistor

RMO Electrical control box

RT Fan motor thermal relay

RT1 Pump motor thermal relay

SPre-heater tank

SM Servomotor

TA Ignition transformer

TB Burner earth

TE Regulation thermostat and start-up enabling

signal

Tm Minimum contact thermostat

Tm Maximum contact thermostat

V1 Oil valve for 1st stage

V2 Oil valve for 2nd stage

2615

6203 6GB

3.3 ELECTRICAL CONNECTIONS TOTHETERMINAL STRIP(to be carried out by the installer)

FASTENING OF THE ELECTRICAL WIRES

All the wires, which have to be connected to the burner terminal strip (16, fig. 1) shall pass through the cable

glams (17, fig. 1), see the figure below.

Any other signals or controls can be connected to the burner terminal strip by removing the presheared disc pre-

sheared hole and inserting a common cable glam for the passage and the clamping of the leads. To ensure the

IP 40 degree of protection in compliance with EN 60529 close the passage holes of the cables and any unused

cable entries with appropriate discs.

NOTES

- Make a safe earth connection.

- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.

CONNECTIONS

PRE-HEATER

230V 400V

A Ampere 16 10

B Ampere 6 4

C Ampere 25 16

D sq.mm 1.5 1.5

E sq.mm 2.5 1.5

F sq.mm 6 4

RESISTORS

NOTE

Wire section: min. 1 sq.mm.

(Unless required otherwise by local standards and legis-

lation).

For 230V supply make the triangle connection on the

pre-heater and on the motor (the original connection is

“star-type” for 400V).

TWO STAGE OPERATION

It is achieved by the remote control device connected to ter-

minals 5-6 (removing the jumper), that controls the 2nd valve.

D2711

IN Manual switch

MB Burner terminal strip

HLock-out signal

TL Limit remote control

TR Regulation remote control

TS Safety control device system

D3742

D2635

1-Single phase pre-heated resistor

power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21

2 - Motor three phase supply:. . . . . . . . . . . . .cable entry Pg 16

3 - Single phase power supply and

safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

4-Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

5-2nd stage thermostat:. . . . . . . . . . . . . . . . .cable entry Pg 13.5

6203 7GB

4. OPERATION

4.1 CHOICE OF NOZZLES

Recommended nozzle:

- Monarch F 80 H0.

4.2 PUMP PRESSURE

Recommended pressure:

- Fluid oil: 20 bar

- Heavy oil: 25 bar

The flow rated of the nozzles indicated on the tables are

nominal, and are obtained for a light fuel oil having viscosity

from 3 to 5°E at 50° C pre-heated at 100°C. The actual flow

rate may vary by ± 5% of the nominal flow rate.

if flow rate values between those indicated in the table are

required, it is possible to vary the pump pressure or arrange

the nozzles differently.

The pump leaves the factory set at 20 bar.

4.3 COMBUSTION HEAD ADJUSTMENT

Turn the screw A, fig. 2 till the set-point, shown in the diagram,

is in line with the sleeve B, fig. 2.

4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR

PARKING - Blue lever

This lever leaves the factory vertically positioned and corre-

sponds to the complete closure of the air damper.

A partial opening of the air damper might be obtained by

moving this lever leftwards (+on the plate).

The new position of the air damper is detectable when the

burner is off.

Do not exceed the position of the orange 1st stage lever.

1st STAGE - Orange lever

The orange lever controls the air damper position for the first

flame, it is adjustable both for opening and closing.

2nd STAGE - Red and black levers

The red lever controls the air damper position for the second

flame, it is adjustable both for closing and opening.

The black lever controls the opening of the second oil valve

and it must always be slightly earlier than the red lever, but

never the orange one.

D2638

Black lever

Red lever

Orange lever

Blue lever

Opening +–Closure

Nozzle

GPH (45° - 60°) 20 bar

kg/h 25 bar

kg/h

3.50 + 3.50 42.00 47.40

4.00 + 4.00 48.00 54,20

4.50 + 4.50 54.00 61.00

5.00 + 5.00 60.00 67,80

5.50 + 5.50 66.10 74.50

6.00 + 6.00 72.10 81.40

6.50 + 6.50 78.10 88.10

7.00 + 7.00 84.10 95.00

7.50 + 7.50 90.10 101.60

8.00 + 8.00 96.10 –

8.50 + 8.50 100.00 –

kg/h

Set-points

D2712

D2637

Set-point 4

Fig. 2

6203 8GB

4.5 AIR PRESSURE SWITCH

4.6 ATOMISATION TEMPERATURE ADJUSTMENT

Thermostat for adjustment - maximum value - minimum value

Adjustment thermostat prevents the burner start up if the fuel temperature has not reached the required value

for good atomisation as indicated in the diagram below.

Example

Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.

The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob

to get approximately 100°C at the nozzles).

The value has to be read after some minutes of operation and later the necessary adjustments must be carried

out.

Minimum value contact thermostat cuts in and stops the burner if the fuel temperature falls below the val-

ue necessary for a good combustion.

The maximum value contact thermostat switches off the resistors when, if the adjustment thermostat fails,

the temperature increases inside the pre-heater. In case of abnormal temperature, make sure of the regular

functioning of the control thermostat and of the resistor in contact with the thermostat probe. The thermostat

is calibrated by the factory at 180 °C.

D521

Carry out the regulation of the air pressure switch after

carrying out all the other regulations of the burner with

the air pressure switch adjusted at the beginning of the

scale.

With the burner operating at the MIN power increase

the pressure of the adjustment by slowly turning the

appropriate knob clockwise until the burner locks out.

Then turn the knob counterclockwise to a value equal

to about 20% of the regulated value and then check

the correct turning on of the burner. If the burner locks

out again turn the knob a bit further in a counterclock-

wise direction.

D2719

Thermostat

adjustment knob

Pre-heater

Purge

Atomisation temperature

Viscosity at 50° C

sq.mm °E D2694

6203 9GB

IMPORTANT NOTES

Pre-heater thermostats substitution.

Replace the probe of the new thermostat, after loosen-

ing the fixing screws of the plate pack, making sure

there is a good contact between the probe and the

pipes and the resistor, see the drawing opposite. The

same precautions should be taken when renewing the

resistors in contact with the thermostat probes.

Should exceptional changes or excessive tempera-

tures be detected during operation, verify the continuity

of the resistor in contact with the temperature probe us-

ing an ohmmeter (approximately 35 Ohm).

Only use filters with a groove on the tightening hex

head.

NOTE

The pre-heater might be fitted with a second maximum value thermostat with a manual reset.

This thermostat can be used to act as a switch on an external contact maker to cut off the current to the pre-

heater if the temperature is too high (kit code no. 3000800).

Before the burner start-up, verify that the pump is filled with fuel in order to prevent it functioning while empty

for too long.

Filter cleaning:

periodically clean the filters so the burner always works properly.

Supply line filter:

positioned on the suction line, it causes the increase of the vacuum in the pump making it noisier. Do not ex-

ceed the vacuum of 45 cm Hg (6 m W.c.) (5, fig. 1).

Pre-heater filter (10, fig. 1):

positioned in the delivery line, it causes a decrease in the atomisationing pressure which is monitored

with a manometer (12, fig. 1).

MANOMETER PROTECTION VALVE

After the atomisation pressure check, turn off the manometer (12, fig. 1) to avoid pressure shocks that it might

be subject to each time the burner is started up.

For this reason close the protection valve when the burner is not working and the manometer indicates 0 bar.

4.7 BURNER START-UP PROGRAMME

Motor lock-out

It is caused by the thermal motor overload relay if an overload occurs or there is no phase.

Thermostat probe

Resistor

Pipes into aluminium plate

Plate

D2751

Lock-out because of no ignitionNormal

Thermostat

Motors

Ignition transformer

1st flame valve

2nd flame valve

Lock-out indicator

2894

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