Riello G5 444T50 User manual

2902381 (2)

Installation, use and maintenance instructions

Light oil - kerosene burners

One stage operation

CODE MODEL TYPE

3744451 G5 444T50

3744452 G5 444T50

2381

TECHNICAL DATA

■Burner with CE marking in conformity with EEC directives: EMC89/336/EEC, Low Voltage 73/23/EEC,

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

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

Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h

Fuel Light oil 35s, max. viscosity at 20 °C: 6 mm2/s

Kerosene 28s

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

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

Capacitor 4 µF

Ignition transformer Secondary 8 kV – 16 mA

Pump Maximum pressure 14 bar (203 psi)

Absorbed electrical power 0.16 kW

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– Lock-out lamp and reset button

9– Flange with insulating gasket

10 – Combustion head adjustment screw

BURNER EQUIPMENT

Quantity Description

Flexible pipe with nipple

Flange with insulating gasket

Screws and nuts for flange

Hinge

Screw of pump by-pass

Grommet

Screw with two nuts for flange

Fig. 1

D5553 12

2381

FIRING RATE, (as EN 267)

OVERALL DIMENSIONS

MOUNTING THE BURNER

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

2,3

272 76 236

130

45°

ø89

233

180

D5554

180

75 72

150

45°

Flange Burner

It is necessary that the insulating gasket

(9, fig. 1) is placed between the boiler door

and the burner flange.

This insulating gasket has six holes,

which, if necessary, can be modified as

shown on the drawing on the right.

D5242

Fig. 2

Verify that the installed

burner is lightly leaned

towards the button.

(See figure 2).

The burner is designed to

allow entry of the flexible

oil-lines on either side of

the burner.

D5572

BURNER FIXING AND

HINGE ASSEMBLY

S7384

2381

OIL LINES

WARNING

The pump is supplied for use with

a one pipe system. For use on a two pipe system, it

is necessary to screw the by-pass screw (A) sup-

plied as burner’s accessory. (See figure).

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 tank 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 possi-

bility of leakage of the valve.

WARNING:

◆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.

PRIMING THE 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.

arning: before starting the burner make sure that the return pipe-line is not clogged: any obstruc-

tion would cause the pump seals to break.

meters

L meters

I. D.

8 mm

I.D.

10 mm

0.5

1.5

100

PRIMING THE PUMP

Loosen the plug of the vacuum

gauge (5, fig. 1) and wait until the

fuel flows out.

meters

Lmeters

I. D.

8 mm

I.D.

10 mm

0.5

1.5

3.5

100

H max. 4 m

max. 4 m

min. 0.1 m

D5219

D5220

D5199

H=Difference of level.

L=Max.length of the

suction line.

I.D.=Internal diameter of the

oil pipes

2381

ELECTRICAL WIRING

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Switch with fuse

6A max.

S7026

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-trans-

former) 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

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

RUN OF THE ELECTRICAL CABLE

1- Cable gland N- Neutral

2- Cable-clamp L- Phase

3- Terminal block - Burner-earth

A321

D5228

Black

2381

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

combustion head and the air damper opening in accordance with the following schedule.

LIGHT OIL FUEL

KEROSENE FUEL

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

Steinen type Q - H ; Danfoss type B - H

Angle: 60° - in most cases.

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

PRESSURE:

8 bar: the pump leaves the factory set at this value, which is suitable only for kerosene.

10 bar: maximum pressure for kerosene.

FOR LIGHT OIL INCREASE PRESSURE

12 bar: in most cases.

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

1 2 34

Nozzle Pump pressure Burner output Comb. head

adjustment

Air damper

adjustment

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

0.60 60°/80° 12 2.6 1.5 2

0.65 60°/80° 12 2.8 2 2.2

0.75 60° 12 3.2 2.5 2.5

0.85 60° 12 3.7 3 3

1.00 60° 12 4.3 4 4.5

1.10 60° 12 4.8 5 6

1.10 60° 13 5.0 6 7

1 2 34

Nozzle Pump pressure Burner output Comb. head

adjustment

Air damper

adjustment

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

0.75 60° 8 2.2 1 2

0.85 60° 8 2.5 1.5 2

1.00 60° 8 2.9 2 2.3

1.10 60° 8 3.2 2.5 2.5

1.25 60° 8 3.7 3 3

1.35 60° 8 4.0 4 4

1.50 60° 8 4.4 5 5

1.50 60° 10 5.0 6 7

2381

COMBUSTION HEAD SETTING

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 0.85 GPH at 12 bar (for light oil) or

1.25 GPH at 8 bar (for kerosene).

The shutter is level with set-point 3, as required by the schedule at page 5.

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:

TURN TO THE RIGHT: (SIGN +)

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

pressure.

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

(Setting advisable for ignitions at low temperatures).

TURN TO THE LEFT: (SIGN –)

In order to reduce the volume of air entering the combustion chamber and thus increasing its pres-

sure. 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.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5232

135

D5551

2381

AIR DAMPER ADJUSTMENT: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 output 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 (4);

– 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.

ELECTRODE SETTING

D5550

1 2

Attention:

Before removing or assembling the

nozzle, loosen the screw (A) and

move the electrodes ahead.

2 – 2.5 mm

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230

2381

BURNER START-UP CYCLE

ONLY FOR LIGHT OIL

ADJUSTMENTS, TO AVOID FLAME - DETACHMENT,

AT BURNER - IGNITION

This inconvenience can occur, when the temperature of the light oil decreases below +8 °C.

1) CORRECT POSITIONING OF THE ELECTRODES

2) PUMP - SETTING

When the temperature of the light oil decreases below +8 °C, increase the pressure to 14 bar.

3) COMBUSTION-HEAD SETTING

Regulate the combustion-head one set-point further ahead than indicated in the instructions.

Example: the instructions require to set the combustion-head on set-point 3.

Instead, the setting is made on set-point 4.

4) FAN - AIR DAMPER ADJUSTMENT

Adjust the air damper of the fan, such as to obtain a smoke number not inferior to 1.

(i.e. a combustion with the lowest possible excess-air).

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp

~12s D5229

~12s ~5s

2 – 2.5 mm

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230

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