Riello Burners RG5S 399T1 Quick start guide

2902623 (2)

Manuel d’entretien

Installation, use and maintenance instructions

Installatie-, gebruiks- en onderhoudsvoorschriften

Montage und Bedienungsanleitung

OδηγÝε÷ εγκατÀσταση÷, χρÜση÷ και συντÜρηση÷

Öl-Gebläsebrenner

Brûleur ﬁoul

Light oil burner

Stookoliebrander

ΚαυστÜρα÷ ΠετρελαÝου

CODE -

Κ¿¢ΙΚΟΣ

MODELL - MODELE

MODEL -

ΜΟΝΤΕΛΟ

TYP -TYPE

ΤΥΠΟΣ

3739950 RG5S 399 T1

Einstuﬁger Betrieb

Fonctionnement à 1 allure

One stage operation

Eentrapsbranders

ΜονοβÀθíιοι

2623

INDEX

1. BURNER DESCRIPTION

One 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

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– Oil pump

2– Control-box

3– Reset button with lock-out

lamp

4– Flange with insulating

gasket

5– Air damper adjustment assembly

6– Nozzle holder assembly

7– Photoresistance

8– Hydraulic jack

9– Start delaying device

■CE Certification No.: 0036 0310/01 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

SW1006

2623

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD

(as EN 267)

TYPE 399T1

Output - Thermal power 13.5

–

26.1 kg/h - 160

–

309.5 kW

Fuel Light oil, viscosity 4 –

6 mm

/s at 20 °C

Electrical supply Single phase,

50Hz 230V

10%

Motor Run current 2.1A – 2730 rpm – 286 rad/s

Capacitor 8

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8

–

15 bar

Absorbed electrical power 0.47 kW

247 155 300 213

160

190

12,5

285

345

127

45°

D5390

ø125

0Fuel output – kg/h

150 170 190 Thermal power – kW

Pressure in combustion

chamber – mbar

D6230

210 230

14 16 18 20

270

22 24 26

250 290 310

2623

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 closing plate

(2)

should be reversed, (see fig. 6).

Fig. 5

D5012

Fig. 4

D5025

Fig. 2

Fig. 3 S7071

D4017

Fig. 6

121

2623

3.3 HYDRAULIC SYSTEMS

= difference of level;

= max. length of the suction line;

I. D.

= internal diameter of the oil pipes.

D4018

Fig. 8

D5745

max. 4 m

■The pump is designed to allow working with two pipes.

In order to obtain one pipe working it is necessary to unscrew

the pin (2), remove the by-pass screw (3) and then screw again

the pin (2), (see fig. 7).

■It is necessary to install a filter on the fuel supply line.

■Before starting the burner make sure that the return pipe-line is

not clogged. An excessive back pressure would cause the dam-

age 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

PRIMING PUMP:

On the system in fig. 8 it is sufficient to loosen the suction gauge connection

(6, fig. 7) 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

required. 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.

SYSTEM NOT PERMITTED

IN GERMANY

max. 4 m

D5744

Fig. 9 Fig. 10

Fig. 7

1- Suction line

2- Return line

3- By-pass screw

4- Gauge connection

5- Pressure adjuster

6- Suction gauge connection

7- Valve

2623

3.4 ELECTRICAL WIRING

D1913

ESEGUITO IN FABBRICA

TESTING

Check the shut-down of the

burner by opening the thermo-

stats and the lock-out by dark-

ening the photoresistance.

NOTES:

– Wires of min. 1 mm2section.

(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.

WARNING

DO NOT EXCHANGE NEUTRAL WITH PHASE

7 pin plug

7 pole socket

Black

White

Capacitor

Main switch

T6A

Motor

Blue

Oil valve

Hour counter

(230V - 0.1A max.)

Limit thermostat Remote lock-out signal

(230V - 0.5A max.)

Ignition

electrodes

Brown

Burner-earth

CARRIED-OUT IN THE FACTORY

552SE

CONTROL BOX

Photoresistance

PE L N

~50Hz 230V

Blue

CONTROL BOX (see ﬁg. 11)

To remove the control-box from the burner, loosen screw (A) 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.

Fig. 11

S7072 A

Safety thermostat

2623 6GB

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

CO2concentration 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% CO2at sea level and with light oil and room temperature of 20 °C.

4.2 RECOMMENDED NOZZLES:

Monarch type R

Delavan type W

(up to 3,00 GPH)

Delavan type B

(over 3,00 GPH)

Steinen type S; Danfoss type S.

TO FIT NOZZLE CARRY OUT THE FOLLOW-

ING ACTIONS, (see fig. 12)

➤Remove nozzle-holder assembly (1) after

loosing screws (2) and nut (3), remove the

small cables (4) from the control box and the

photoresistance (5).

➤Withdraw the small cables (4) from the elec-

trodes, remove the diffuser disc-holder as-

sembly (8) from the nozzle-holder assembly

(1) after loosing screw (3, fig. 13, page 7).

➤Screw the nozzle (9) correctly and tighten it as

shown in fig. 12.

Attention

During the reassembly of the nozzle-holder as-

sembly screw the nut (3) as shown in the figure

below.

Nozzle Start delaying

device pressure Pump

pressure Burner

output

Combustion

head

adjustment

Air damper adjustment

Low-ﬂame High-ﬂame Low-ﬂame High-ﬂame

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

3.00 60° 9 15 13.5 0 0.4 1.3

3.50 60° 9 15 15.7 0 0.5 2.0

4.00 60° 9 15 18.0 2 0.7 2.5

4.50 60° 9 15 20.2 4 0.8 3.0

5.00 60° 9 15 22.4 6 0.9 3.7

5.50 60° 9 15 24.7 8 1.1 5.8

6.00 60° 9 14 26.0 10 1.3 6.0

SW1007

Fig. 12

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

2623 7GB

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 nozzle-holder

assembly (1).

➤In the sketch the combustion head is set for an output of 4.00 GPH at 15 bar.

The set-point 2of the regulating rod (7) is at the same level with the outside plane of the nozzle-holder

assembly (1) as shown in the schedule.

4.4 ELECTRODES ADJUSTMENTS, (see fig. 13)

4.5 PUMP PRESSURE AND AIR OUTPUT

The burner, in order to guarantee good smooth

starts, irrespective of the type of boiler, is fitted

with a hydraulic device which, independently of

the control-box, reduces the fuel- and air-flow.

At ignition, the pressure at the nozzle is 9 bar.

After 3 - 9 seconds, it automatically increases to

15 bar.

The air-flow, initially adjusted to the low setting,

is, at the change-over of pressure, automatically

brought to the air-flow required for the big flame.

■SETTING FOR THE LOW IGNITION-FLAME

(See fig. 14)

ADJUSTMENT OF AIR SHUTTER

Unloosen the screw (8), by approximately one full

turn; in this way, the burner remains permanently

on low flame.

Unloosen the nut (5), turn the screw (4) until the

indicator (6) reaches the position desired.

Then lock the nut (5) and tighten the screw (8).

ADJUSTMENT START DELAYING DEVICE

This is set at 9 bar at the factory.

The pressure gauge must be mounted in place of

plug (4, fig. 7, page 4). Should it be necessary to

re-set or alter such pressure, this can be done,

by adjusting screw (7), always after having loos-

ened screw (8). For the adjustment, follow what

indicated in the table at page 6.

Anyway, it is advised to adjust the content of CO2at values not lower than 12%.

MEASURES MUST BE RESPECTED.

WARNING:

Lean the diffuser disc-holder assembly (1)

on the nozzle-holder (2) and lock it by

screw (3). For prospective adjustments

loosen screw (4) and move the electrodes

assembly (5).

To have access to the electrodes carry

out operation as described in chapter “4.2

RECOMMENDED NOZZLES” (page 6).

D4019

4.5 – 0.5 mm

06 –7 mm

Fig. 13

13 2

5 4

S7161

Fig. 14

2623 8GB

■HIGH-FLAME SETTING, (see fig. 14, page 7)

AIR-DAMPER ADJUSTMENT

Loosen the nut (3), turn the screw (1), until the indicator (2) is in the required position. Then, lock the nut (3).

PUMP-ADJUSTMENT

This is set at 15 bar at the factory.

The pressure gauge must be mounted in place of plug (4, fig. 7, page 4).

Should it be necessary to re-set or alter such pressure, this can be done, by adjusting screw (5, fig. 7, page 4).

When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.

4.6 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (3, 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 BASI CHECK 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, (7, fig. 1, page 1).

➤Check for correct fuel consumption.

➤Replace the nozzle (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 set rightly all the components stated in

this manual. Then carry out a combustion check verifying:

●Smoke temperature at the chimney; ●Contentof CO2(%); ●ContentofCO(ppm);

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

D5544~12s

Thermostat

Motor

Ignition transformer

Valve

Low-flame

Lock-out lamp

~12s 5s

High-flame

3 ÷ 9s

Lock-out due to failure to light

Normal

2623 9GB

6. FAULTS / SOLUTIONS

Here below you can find some causes and the possible solutions for some problems that could cause a fail-

ure 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

(3, 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 doesn’t

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.

Start 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.

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.

This manual suits for next models

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