Riello Burners CAMRAY5 150 Quick start guide

2902785 (4)

Installation, use and maintenance instructions

Kerosene and light oil burners

One stage operation

CODE BOULTER CODE MODEL TYPE

3748960 8-716-108-334 CAMRAY5 150/200 490 T51

3748961 8-716-108-333 CAMRAY5 200/240 490 T51

3748962 8-716-111-556 COH 280 490 T51

2785 1

INDEX

1. BURNER DESCRIPTION

One stage kerosene and light oil burner.

1.1 BURNER EQUIPMENT

By-pass screw (clipped on the pump). . . . . . . . . . . . . . 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 Firing rate . . . . . . . . . . . . . . . . . . . . . . . 2

3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3

3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Mounting the burner . . . . . . . . . . . . . . . . 3

3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . 4

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . 5

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Combustion adjustment. . . . . . . . . . . . . . 6

4.2 Nozzles recommended . . . . . . . . . . . . . . 6

4.3 Pump pressure . . . . . . . . . . . . . . . . . . . . 6

4.4 Maintenance position . . . . . . . . . . . . . . . 7

4.5 Diffuser disc and electrodes setting . . . . 7

4.6 Combustion head setting. . . . . . . . . . . . . 8

4.7 Air damper adjustment . . . . . . . . . . . . . . 8

4.8 Burner start-up cycle . . . . . . . . . . . . . . . . 8

5. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9

6. SAFETY WARNINGS . . . . . . . . . . . . . . . 10

6.1 Burner identification . . . . . . . . . . . . . . . . 10

6.2 Basic safety rules . . . . . . . . . . . . . . . . . . 10

®In case of BF applications the intake air temperature must not be over 70°C.

®CE Certification No.: 0036 0332/02 as 92/42/EEC.

®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.

®The burner meets protection level of IP 40, EN 60529.

1– Reset button with lock-out lamp

2– Photoresistance

3– Snorkel (BF)

4– Blast tube

5– Control-box

6 – Pump pressure adjustment screw

7 – Pressure gauge port

8 –Pump

9 –Flange

10 – Air damper adjustment screw

D4266

Fig. 1

2 4

2785 2

2. TECHNICAL DATA

2.1 TECHNICAL DATA

◆Light oil is not permitted on low level discharge of flue gas products.

2.2 OVERALL DIMENSIONS

2.3 FIRING RATE, (as EN 267)

TYPE 490 T51

Output - Thermal power

(with air at 20°C) 4 – 10 kg/h – 47.45 – 120 kW

Fuel Kerosene, viscosity 1.6 – 6 mm2/s at 20 °C (Hi= 11.97 kWh/kg)

Light oil, viscosity 4 – 6 mm2/s at 20 °C ◆(Hi= 11.86 kWh/kg)

Electrical supply Single phase, ~ 50Hz 230V ± 10%

Motor Run current 1.3A – 2750 rpm – 288 rad/s

Capacitor 5 µF

Ignition transformer Secondary 8 kV – 16 mA

Pump Kerosene, maximum pressure 10 bar (145 psi)

Light oil, maximum pressure 15 bar (218 psi)

Absorbed electrical power 0.16 kW

BurnerFlange

167 69.5 253

204

D4267

83 83

268

163

45°

189

168

140

106

Ø 95

0.4

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

Thermal power - kW

D4351

0.2

0.6

0.8

1.0

1.2

1.4

1.6

45678

45 65 75 85 9555

910

105 115 125

2785 3

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. 2).

®Widen, if necessary, the insulating gasket holes (5), (see fig. 3).

®Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nu ts (3) interposing the

insulating gasket (5), (see fig. 4).

3.2 MOUNTING THE BURNER

E9188

Fig. 2

D5012

Fig. 3

E9187

Fig. 4

In case of BF applications, the combustion air

supply is trough a flexible tube connected at the

socket (A).

E1557

Fig. 5

2785 4

3.3 HYDRAULIC SYSTEMS

H = difference of level L = Max. lenght of the suction line I.D. = Interminal diameter of the oil pipes.

F i g . 6

D5912

®Check periodically the flexible pipes conditions. Using kerosene, they

have to be replaced at least every 2 years.

®A metal bowl filter with replaceable micronic filter must be fitted in the oil

supply pipe.

®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), screw the by-pass screw (3) and then screw again the

plug (2). (See fig. 6).

®In the two pipes systems, 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:

meters

L meters

I. D.

8 mm

I. D.

10 mm

0.5

1.5

100

meters

L meters

I. D.

8 mm

I. D.

10 mm

0.5

1.5

3.5

100

1- Suction line

2- Return line

3- By-pass screw

4- Gauge connection

5- Pressure adjuster

6- Suction gauge connection

7- Valve

8- Auxiliary pressure test point

PRIMING PUMP:

On the system in fig. 7 it is sufficient to loosen the suction gauge

connection (6, fig. 6) and wait until oil flows out.

On the systems in fig. 8 and 9 start the burner and wait for the priming.

Should lock-out occur prior to the arrival of the fuel, await at least 20 sec-

onds 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. 9) 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 required. Should however the return line arrive over the fuel level, a

non-return valve is required. This solution however is less safe than previ-

ous one, due to the possibility of leakage of the valve.

max. 4 m

min. 0.1 m

D1559

F i g . 7

max. 4 m

D1560

F i g . 8

D1558

max. 4 m

F i g . 9

2785 5

3.4 ELECTRICAL WIRING

E9154

CONTROL BOX (see fig. 10)

To remove the control box from the burner follow of the istruction:

®Loosen the screw (1), open the protection (2) an d remove all com-

ponents.

®Remove the coil (3).

®Loosen the two screws (4).

®Move a little the control box and remove the high voltage leads.

Fig. 10

Capacitor

~50Hz - 230V

Oil valve

D4218

CONTROL BOX

Photoresistance

535SE/LD

Motor

Main switch

T6A

Black

White

Blue

Ignition

electrodes

4 pin plug

4 pole socket

Burner-earth

TESTING:

Check the shut-down of the burner by open-

ing the thermostats and the lock-out by dark-

ening the photoresistance.

Limit

Safety

Remote lock-out signal

(230V - 0.5A max.)

thermostat

ATTENTION:

®Do not swap neutral and phase over, follow the dia-

gram shown carefully and carry out a good earth con-

nection.

®The section of the conductors must be at least 1mm².

(Unless requested otherwise by local standards and legis-

lation).

®The electrical wiring carried out by the installer must be in

compliance with the rules in force in the country.

2785 6

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 CO2

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% CO2 at sea

level and with fuel and room temperature of 20°C.

4.2 NOZZLES RECOMMENDED

Hago type ES - B ; Delavan type W - B (not for 45° light oil); Steinen type S; Danfoss type S;

Use Delavan type W CSA.

4.3 PUMP PRESSURE

The pump leaves the factory set for kerosene working.

10 bar: maximum pressure for kerosene.

FOR LIGHT OIL INCREASE PRESSURE

12 bar: pressure suitable for light oil in most cases.

14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.

FUEL

Nozzle Pump

pressure

Burner

output

Combustion head

adjustment

Air damper

adjustment

GPH Angle bar kg/h ± 4% Set-point Set-point

KEROSENE

1.35 60° W 8 4.04 0 2.2

1.50 60° W 8 4.49 1 2.8

1.65 60° W 8 4.93 2 3.1

1.75 60° W 8 5.23 2 3.5

2.00 60° W 8 5.98 2 4.3

2.25 60° W 8 6.73 3 5

2.50 60° - 45° W 8 7.48 5 6

2.75 60° - 45° W 8 8.22 5 8

3.00 60° - 45° W 10 10.03 6 10

LIGHT OIL

1.00 60° W 12 4.0 0 2.3

1.10 60° W 12 4.4 1 2.7

1.25 60° W 12 5.0 2 3.3

1.35 60° W 12 5.4 2 4

1.50 60° W 12 6.0 2 4.7

1.65 60° W 12 6.6 3 5

1.75 60° W 12 7.0 4 6

2.00 60° - 45° W 12 8.0 5 7

2.25 60° - 45° W 12 9.0 6 8.4

2.50 60° - 45° W 12 10.0 6 10

2785 7

4.4 MAINTENANCE POSITION

Access to the combustion head, the diffuser disc-holder assembly, electrodes and nozzle (see fig. 11).

®Loosing the fixing nut to the flange and remove the burner out of the boiler.

®Hook the burner to the flange (1), by removing the blast tube (2) after loosing the fixing screws (3).

®Remove the small cables (4) from the electrodes (5) and the diffuser disc-holder assembly from the nozzle-

holder (6) after loosing its fixing screw (7).

®Once replacement of the nozzle has been made, screw it and tighten it as shown in the figure 11.

4.5 DIFFUSER DISC AND ELECTRODES SETTING, see fig. 12

E9189

E9191

Fig. 11

To ad just the diffu ser dis c u nit, p roceed as

follows:

®Loosen the screw (1, fig. 12).

®Move the diffuser disc unit up to level .

®Tighten the screw (1).

To adjust the electrodes unit, proceed as fol-

lows:

®Loosen the screw (2, fig. 12).

®Move the electrodes unit up to level .

®Tighten the screw (2).

THESE DIMENSIONS MUST BE OBSERVED

IMPORTANT

D4269

Fig. 12

+ 0.5

- 0.2

5.75

B4 ± 0.5

+ 0.7

- 0.5

7.5

2785 8

4.6 COMBUSTION HEAD SETTING, (see fig. 13)

To adjust the combustion head, proceed as follows:

Loosen the two screws in the ring slots.

Turn the blast tube to regulate it, until the end of the

slotted r ing c entres up with t he n otch s hown i n the

table on page 6.

Turn in a clockwise direction:

in or der t o i ncrease t he v olume of a ir ent ering t he

combustion chamber and thu s d iminishing i ts pre s-

sure. There is a reduction of CO2 and the adhesion of

the flame to the air diffuser disc improves.

(Setting advisable for ignitions at low temperatures).

Turn in an anticlockwise direction:

in order to reduce the volume of air entering the com-

bustion chamber a nd thu s i ncreasing i ts p ressure.

The CO2 improves and the adhesion of the flame to

the diffuser tends to reduce. (This setting is not advis-

able for ignitions at low temperatures).

Tighten the two screws.

In the sketch on the right, the combustion head is adjusted at set-point 3.5.

Combustion head settings indicated in the schedule at page 6 are valid for most cases.

4.7 AIR DAMPER ADJUSTMENT

The settings indicated in the schedule refer to the combustion-chamber with “zero” depression. These reg-

ulations are p urely i ndicative. Eac h in stallation ho wever, ha s it s o wn un predictable w orking co nditions:

actual nozzle output; positive or negative pressure in the combustion-chamber, the need of excess air, etc.

All these conditions may require a different air-damper setting.

4.8 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (1, fig. 1, page 1).

Blast tube

Shutter

D4268

Screw

Slotted ring

Fig. 13

Screw

Normal

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp

~ 12s D5229

~ 12s ~ 5s

Lock-out due to failure to light

2785 9

5. FAULTS / SOLUTIONS

Here below you can find some causes and the possible solutions for some 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

(1, 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 will not

start when the limit

thermostat closes.

Lack of electrical supply.

Check presence of voltage in the

L - N clamps of the control box.

Check the conditions of the fuses.

Check that safety thermostat is not

lock out.

The photoresistance sees false light. Eliminate the light.

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.

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.

Nozzle dirty or worn. Replace it.

This manual suits for next models

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