Riello G3B FIREBIRD 70K Quick start guide

Installation, use and maintenance instructions

2902809 (2) - 05/2011

Kerosene and light oil burners

One stage operation

CODE MODEL TYPE

3743757 G3B FIREBIRD 70K 510 T1K

3743771 G3B FIREBIRD 90K 510 T3K

3743772 G3B FIREBIRD 90D 510 T3K

2809

INDEX

1. BURNER DESCRIPTION

One stage kerosene and light oil burner.

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

1.1 Burner equipment . . . . . . . . . . . . . . . . . . . 2

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

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Overall dimensions . . . . . . . . . . . . . . . . . . 2

2.3 Working field . . . . . . . . . . . . . . . . . . . . . . . 3

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

3.1 Mounting the burner . . . . . . . . . . . . . . . . . . 3

3.2 Hydraulic systems . . . . . . . . . . . . . . . . . . . 4

3.3 Electrical wiring . . . . . . . . . . . . . . . . . . . . . 5

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

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

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

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

4.4 Electrodes setting . . . . . . . . . . . . . . . . . . . 6

4.5 Air damper adjustment . . . . . . . . . . . . . . . 7

4.6 Burner start-up cycle . . . . . . . . . . . . . . . . . 7

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . 8

5.1 Maintenance position . . . . . . . . . . . . . . . . 8

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9

OBurner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 2004/108/EC, Low

Voltage 2006/95/EC, Machines 2006/42/EC and Efficiency 92/42/EEC.

OCE Certification No.: 0036 0315/01 as 92/42/EEC.

OThe burner meets protection level of IP 40, EN 60529.

1– Return line

2– Suction line

3– Gauge connection

4– Pump pressure regulator

5– Vacuum gauge connection

6 – Screws fixing air damper

7 – Hydraulic jack with air damper

8 – Reset button with lock-out lamp

9 – Flange with insulating gasket

10 – Control box

D5506

Fig. 1

HYDRAULIC JACK OPERATION 7)(Fig. 1)

It is strongly recommended a periodic check of

the pump pressure operation (annually or bet-

ter every six months, if the burner operation is

continuous).

If the value is lower than 1 bar, compared to

that one of the initial setting, please check the

cleaning of the pump and line filters.

In case the pressure setting was not restora-

ble, please replace the pump, in order to guar-

antee that the pump pressure during the pre-

purge time is at least 3.7 bar.

DANGER

2809

1.1 BURNER EQUIPMENT

Flange with insulating gasket . . . . . . . . . No. 1 4 pole socket . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Screw and nut for flange . . . . . . . . . . . . . No. 4 Cable grommet . . . . . . . . . . . . . . . . . . . . . . No. 1

Flexible pipe with nipple . . . . . . . . . . . . . No. 1 Screw with two nuts for flange . . . . . . . . . . . No. 1

Screw of by-pass pump . . . . . . . . . . . . . . No. 1 4 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

TYPE 510 T1K 510 T3K

Output

Thermal power

1.4 – 2.2 kg/h

16.8 – 26.3 kW

2 – 3 kg/h

24 – 35.9 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 0.7A – 2850 rpm – 298 rad/s

Capacitor 4 F

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 0.115 kW

Flange Burner

252 86 203

130

45°

215

164

D6253

180

75 72

150

45°

ø89

2809

2.3 WORKING FIELD (as EN 267)

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

3.1 MOUNTING THE BURNER

Fix the flange (1) to the boiler door using screw and nuts, interposing the insulating gasket (see fig. 2).

The insulating gasket has six holes, which, if necessary, can be modified as shown in the figure 3.

Verify that the installed burner is lightly leaned towards the button (see fig. 4).

The burner is designed to allow entry of the flexible oil-lines on either side of the burner.

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

Thermal power - kW

0.8

0.2

0.4

0.6

510T1K 510T3K

01.2

D4361

1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3

16 18 20 22 24 26 28 30 32 34 36

S7386

Fig. 4

D5242

Fig. 3Fig. 2

D5574

2809

3.2 HYDRAULIC SYSTEMS

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

F i g . 5

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. 6 it is sufficient to loosen the suction gauge connec-

tion (6, fig. 5) and wait until oil flows out.

On the systems in fig. 7 and 8 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. 8) 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

F i g . 6

max. 4 m

D4348

Fig . 7

D5300

max. 4 m

Fig. 8

D5299

D5199

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. 5).

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

2809

3.3 ELECTRICAL WIRING

S7026

CONTROL BOX (see fig. 9)

– To remove the control box from the burner,

loosen screw (A) and pull towards the arrow.

– The photoresistance is fitted directly into the control-

box (underneath the ignition-transformer) on a plug-

in support.

3.4 RUN OF THE ELECTRICAL

CABLE

1- Cable grommet N- Neutral

2- Cable clamp L- Phase

3- Terminal block - Burner-earth

A321

Brown

White (50V)

Blue

Motor

Capacitor

Limit thermostat

Neutral

Main switch

T6A

Black

WARNING

Do not exchange the neutral with the phase.

230V ~50Hz

Safety thermostat

Remote lock-out signal

(230V - 0.5A max.), if required

123456789

Blue

Brown

Terminal block of

control-box 530SE*

Valve

D5228

Black

3.5 NOTES

– Wires of min. 1 mm2section.

(Unless requested otherwise by local stand-

ards and legislation).

– The electrical wiring carried out by the

installer must be in compliance with the

rules in force in the Country.

3.6 TESTING

Check the shut-down of the burner by open-

ing the thermostats.

Burner-earth

CARRIED OUT

IN THE FACTORY

Fig. 9

2809

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, fit the proper nozzle, then adjust the pump pressure 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 NOZZLES RECOMMENDED

Monarch type R - NS; Delavan type W - E; Steinen type Q - H; Danfoss type H - S.

4.3 PUMP PRESSURE

8 bar: pressure suitable for kerosene in most cases.

10 bar: maximum pressure for kerosene.

INCREASE PRESSURE

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

14 bar: maximum pressure light oil.

4.4 ELECTRODES SETTING, (see fig. 10)

TYPE

Nozzle Pump

pressure Burner

output Air damper

adjustment

GPH Angle bar kg/h ± 4% Set-point

510 T1K

0.50 60° 7 1.40 1.6

0.50 60° 8 1.50 1.7

0.60 60° 8 1.79 2.2

0.65 60° 8 1.94 2.4

0.75 60° 8 2.20 3.3

510 T3K

0.65 60° 8.5 2.00 2.3

0.75 60° 8 2.24 2.6

0.85 60° 8 2.54 3.4

1.00 60° 8 3.00 8

KEROSENE

LIGHT OIL

Before removing or assembling the

nozzle, loosen the screw (A) and

move the electrodes ahead.

ATTENTION

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 A

Fig. 10

2 – 2.5 mm

2809

4.5 AIR DAMPER ADJUSTMENT, (see fig. 11)

The mobile air damper (1) operated by the jack (2) assures the

complete opening of the air intake.

The regulation of the air-rate is made by adjusting the fixed air

damper (3), after loosing the screws (4). When the optimal

regulation is reached, screw tight the screws (4) to assure a

free movement of the mobile air damper (1).

The settings indicated in the schedule refer to the burner with

its metal cover fitted and the combustion chamber with “zero”

depression.

These regulations are purely indicative.

Each installation however, has its own unpredictable working

conditions: 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.

It is important to take account of the fact that the air out-

put of the fan differs according to whether the burner has

its metal cover fitted or not.

Therefore we recommended to proceed as follows:

– adjust the air damper as indicated in the schedule;

– mount the cover, simply by means of the upper screw;

– check smoke number;

– should it become necessary to modify the air output, remove the cover by loosening the screw, adjust

the air damper, remount the cover and finally recheck the smoke number.

4.6 BURNER START-UP CYCLE

Fig. 11

D5550

Normal

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp

~12s D5229

~12s ~5s

Lock-out due to failure to light

2809

5. MAINTENANCE

The burner requires periodic maintenance carried out by a qualified and authorised technician in conform-

ity 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 BASIC CHECKS ARE:

Leave the burner working without interruption for 10 min., checking the right settings of all the components

stated in this manual.

Then carry out a combustion check verifying:

CO2(%) content Smoke temperature at the chimney CO content (ppm).

5.1 MAINTENANCE POSITION

Insert in the hole (1) the pin (2) and fix the burner with the nut (3) fitted wrong-side up.

312

FLANGE

D5325

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