Riello G3BF 490T53 Quick start guide

2902136 (6)

Installation, use and maintenance instructions

Kerosene burners

One stage operation

CODE MODEL TYPE

3749053 G3BF 490T53

3749257 G5BF 492T57

3748953 G5BF 489T53

2136

TECHNICAL FEATURES

TYPE - Boiler Model 490T53 – 50 / 70 492T57 – 70 / 90 489T53 – 90 / 120

Thermal power – output

(with air at 20

19 – 35 kW 17 – 42 kW 28 – 60 kW

1.6 – 3 kg/h 1.5 – 3.5 kg/h 2.3 – 5 kg/h

Fuel kerosene, 28 sec.

Electrical supply single phase, 230V

10%

50Hz

Motor run current 0.85A – 2850 rpm – 298 rad/s

Capacitor 4

Ignition transformer secondary, 8 kV – 16 mA

Pump maximum pressure 14 bar (203 psi)

Absorbed electrical power 0.15 kW 0.16 kW 0.16 kW

◆

urner w

mar

n con

orm

ty w

EEC

rect

ves:

EMC89/336/EEC

tage

73/23/EEC

Machines 89/392/EEC and Efﬁciency 92/42/EEC.

◆The intake air temperature must not be over 70°C.

◆The burner meets protection level of IP 54, EN 60529.

◆Kit for two pipes system code 3000970

410

10 – Relief valve

11 – Air socket from the outside

12 – Combustion head adjustment screw

1– Suction line

2– Gauge connection

3– Pump pressure regulator

4– Vacuum gauge connection

5– Air-damper

6– Regulating air-damper rod

7– Lock-out lamp and reset button

8– Flange with insulating gasket

9– Wiring loom ﬁtting

Fig. 1

D5422

489T53

490 T53 - 492T57

D5423

2136

EQUIPMENT

DIMENSIONS

MOUNTING THE BURNER

Quantity Description

Flexible pipe with nipple

Flange with insulating gasket

Screw with two nuts for ﬂange

Nuts for ﬂange

TYPE A B C D E F G H I

490T53

271 249 288 193 90 93 207 75 21

492T57

271 249 288 191 90 93 226 75 26

489T53

271 249 288 191 89 79 237 75 37

Flange Burner

C F G

130

45°

øE

D5305

180

72 72

150

45°

øH

It is necessary that the insulating gasket (A) is

placed between the boiler door and the burner

ﬂange.

D5306

BURNER FIXING

S7386

2136

WORKING RANGE

(as EN 267)

0.8

0.4

Pressure in the combustion

chamber – mbar

2 2.5 3 Fuel output - kg/h

20 40 Thermal power - kW

D5426 25 30 35

0.2

0.6

0.2

0.4

Pressure in the combustion

chamber – mbar

1.5 2 2.5 Fuel output - kg/h

20 25 30 Thermal power - kW

D5425

0.8

0.4

Pressure in the combustion

chamber – mbar

2 3 4 5 Fuel output - kg/h

25 30 60 Thermal power - kW

D5226 35 40 45 50 55

0.2

0.6

489T53

2.3

492T57

490T53

1.5 3.5

0.8

2136

OIL LINES

meters

L meters

I. D.

8 mm I.D.

10 mm

0.5

1.5

100

PRIMINGTHE PUMP

Loosen the plug of the vacuum gauge (4, fig. 1, page 1)

and wait until the fuel flows out.

meters

L meters

I. D.

8 mm I.D.

10 mm

0.5

1.5

3.5

100

max. 4 mH H

max. 4 m

min. 0.1 m

D5307

D5308

The pump vacuum should not exceed a maximum of 0.4 bar (30 cm Hg).Beyond this limit gas is released

from the oil. Oil lines must be completely airtight. The return line should terminate in the oil tan

at the same level as the suction line; in this case a non-return valve is not required.

Should however the return line arrives over the fuel level, the non-return valve is indispensable.

This solution however is less safe than previous one, due to the possibility of leakage of the valve.

PRIMINGTHE PUMP:

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.

WARNING: Before starting the burner make sure that the return pipe-line is not clogged: an

obstruction would cause the pump seals to break.

■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.

WARNING

D5199

The pump is supplied for use with a one pipe system.

For use on a two pipes system, it is necessary to screw the

BY-PASS SCREW (A) supplied with kit code 3000970.

WARNING

H=Difference of level.

L= Max.length of the suction line.

I.D.=Internal diameter of the oil pipes.

2136

BURNER ELECTRICAL WIRING

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Switch with fuse

6A max.

Black

NOTES

– Wires of 1 mm2section.

–The electrical wiring carried out by the

installer must be in compliance with the

rules in force in the Country.

– To remove the control-box from the

burner, loosen screw (A)

(see ﬁgure)

and

pull towards the arrow.

–The photoresistance is ﬁtted directly into

the control-box (underneath the ignition-

transformer) on a plug-in support.

TESTING

Check the shut-down of the burner by opening

the thermostats.

CARRIED-OUT IN THE FACTORY

WARNING

Do not exchange the neutral with the phase.

230V ~50Hz

N L

Limit thermostat

with manual resetting

Remote lock-out lamp

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

123456789

Blue

Brown

Terminal block of

control-box 530SE*

Valve

D5228

Black

RUN OF THE ELECTRICAL CABLE

1- Terminal block N- Neutral

L- Phase

- Burner-earth

1S7130

2136 6

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 nozzle then adjust the pump pressure, (the setting of the com-

bustion head for type 489 T53) and the air damper opening in accordance with the following schedule.

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.

NOZZLES RECOMMENDED: Monarch type R - NS ; Delavan type W - A - E - B

Steinen type Q - H ; Danfoss type B - H - S

Angle: 60°- in most cases.

80°- in case of ﬂame detachment, during ignitions at low temperatures.

PRESSURE: 8bar : the pump leaves the factory set at this value.

10bar : maximum pressure for kerosene.

TYPE

Nozzle Pump pressure Burner

output Comb. head

adjustment Air damper

adjustment

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

490T53

0.50 60°8 1.5 2.5

0.60 60°8 1.7 3.0

0.65 60°8 1.9 3.3

0.75 60°8 2.2 3.9

0.85 60°8 2.5 4.2

1.00 60°8 2.9 6.0

1.00 60°9 3.0 8.0

For 1.00 GPH nozzles it is advisable to use , if possible, full cones.

492T57

0.50 60°8 1.5 2.2

0.60 60°8 1.7 2.4

0.65 60°8 1.9 2.6

0.75 60°8 2.2 3.0

0.85 60°8 2.5 3.2

1.00 60°8 2.9 3.9

1.10 60°8 3.4 5.2

For 1.00 - 1.10 GPH nozzles it is advisable to use , if possible, full cones.

489T53

0.75 60°8 2.2 0 2.8

0.85 60°8 2.5 0.5 3.0

1.00 60°8 2.9 1.5 3.2

1.10 60°8 3.2 2.0 3.5

1.25 60°8 3.7 3.0 4.0

1.35 60°8 4.0 4.0 4.2

1.50 60°8 4.4 5.0 4.9

1.50 60°10 5.0 6.0 6.5

1 2 3

2136 7

THE BURNERS LEAVE THE FACTORY SET AT THESE VALUES

COMBUSTION HEAD SETTING (Only type 489T53)

This is done when ﬁtting the nozzle, with the blast tube removed.

It depends on the output of the burner and is carried out by rotating the regulating rod, till the terminal

plane of the blast tube is level with the set-point, as indicated in the schedule.

In the sketch below, the combustion head is set for an output of 1.25 GPH at 8 bar

The shutter is level with set-point 3, as required by the schedule at page 6.

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

The setting of the fan output according to the installation should normally be done only through the air

damper. Should one subsequently want to retouch also the setting of the combustion head, with the

burner running, operate on the rod (1) with a 6 mm spanner (2) as follows:

TURNTOTHE RIGHT : (sign +)

In order to increase the volume of air entering the combustion chamber and thus diminishing its pres-

sure.

There is a reduction of CO2and the adhesion of the ﬂame to the air diffuser disc improves. (Setting

advisable for ignitions at low temperatures).

TURNTOTHE LEFT : (sign –)

In order to reduce the volume of air entering the combustion chamber and thus increasing its pressure.

The CO2improves and the adhesion of the ﬂame to the diffuser tends to reduce. (This setting is not

advisable for ignitions at low temperatures).

In any case do not bring the combustion head setting more than one point away from that indicated in

the schedule. One set-point corresponds to 3 turns of the rod;a hole (3) at its end facilitates counting

the number of turns.

TYPE Nozzle Pump

Pressure Comb. head

adjustment Air damper

adjustment

bar Set-point Set-point

490T53 Danfoss 0.60 GPH - 80°H 8 – 3.8

492T57 Danfoss 0.75 GPH - 80°H 8 – 4.0

489T53 Danfoss 1.00 GPH - 80°H 8 2.5 3.9

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

2 3

D5232 D5233

135

2136 8

AIR DAMPER ADJUSTMENT

The air-output setting can be carried out acting with the rod

(2) on the screw (1) that makes the air-damper (3) turn.

Further retouchs can be carried out without removing the

cover but unscrewing the plug (A) as shown in the figure on

the below.

ELECTRODE SETTING

BURNER START-UP CYCLE

D5141

Turn to the right (sign +) to increase the

air quantity in the combustion chamber,

turn to the left (sign –) to decrease it.

S7021

Attention:

Before assembling or removing the

nozzle, loosen the screw (A) and

move the electrodes ahead.

2 – 2.5 mm

4±0.3 mm

D5230 A

MEASURES

MUST BE RESPECTED

WARNING

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

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