Riello G5R MC Quick start guide

20013743 (3) - 04/2011

Installation, use and maintenance instructions

安装 , 使用以及维护说明书

Light oil burner

轻油燃烧器

CODE - 编码 MODEL - 型号 TYPE - 类型

20013623 G5R MC 447T1

One stage operation

一段火运行

20013743

INFORMATION ABOUT THE INSTRUCTION MANUAL

INTRODUCTION

The instruction manual supplied with the burner:

- is an integral and essential part of the product and must not be sepa-

rated from it; it must therefore be kept carefully for any necessary

consultation and must accompany the burner even if it is transferred

to another owner or user, or to another system. If the manual is lost

or damaged, another copy must be requested from the Technical

Assistance Service of the area;

- is designed for use by qualified personnel;

- offers important indications and instructions relating to the installation

safety, start-up, use and maintenance of the burner.

DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-

UAL

When the system is delivered, it is important that:

- The instruction manual is supplied to the user by the system manu-

facturer, with the recommendation to keep it in the room where the

heat generator is to be installed.

- The instruction manual shows:

- the serial number of the burner;

- the address and telephone number of the nearest Assistance

Centre;

- The system supplier carefully informs the user about:

- the use of the system,

- any further tests that may be necessary before the system is

started up,

- maintenance and the need to have the system checked at least

once a year by the manufacturer or another specialised techni-

cian.

To ensure a periodic check, recommends the drawing up

of a Maintenance Contract.

..................................................................................

1 20013743

TECHNICAL DATA

BURNER DESCRIPTION

OBurner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,

Machines 2006/42/EC.

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

HYDRAULIC JACK OPERATION 7)(Fig. 1)

TYPE 447T1

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

Fuel Light oil, viscosity 4 – 6 mm2/s at 20 °C

(Hi= 11.86 kWh/kg)

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

Motor Run current 0.75A – 2800 rpm – 294 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure 7 – 15 bar

Absorbed electrical power 0.185 kW

It is strongly recommended a periodic check of the pump pressure operation (annually or better 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 restorable, please replace the pump, in order to guarantee that the

pump pressure during the pre-purge time is at least 3.7 bar.

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

Fig. 1

D4645 1243

108

DANGER

20013743 2

BURNER EQUIPMENT

Flexible pipes with nipples . . . . . . . . . . . No. 2 Cover . . . . . . . . . . . . . . . . . . . . . . . No. 1

Screws and nuts for flange . . . . . . . . . . . No. 4 Hinge . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Screw with two nuts for flange . . . . . . . . No. 1 Insulating gasket . . . . . . . . . . . . . . . No. 3

FIRING RATE

OVERALL DIMENSIONS

0.8

0.4

Pressure in the combustion

chamber – mbar

2 3 4 5 Light oil output - kg/h

25 30 60 Thermal power - kW

D5226 35 40 45 50 55

0.2

0.6

2.3

270 122 224

130

45°

ø80

228

175

D4646

180

75 72

150

45°

Flange Burner

3 20013743

MOUNTING THE 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).

D5572

BURNER FIXING AND

HINGE ASSEMBLY

S7384

20013743 4

HYDRAULIC SYSTEMS

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

would cause the pump seals to break.

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.

When the return line arrives over the

fuel level, a non-return valve must be

used.

This solution however is less safe than

previous one, due to the possibility of

leakage of the valve.

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.

A filter must be installed on the suction fuel line.

meters

Lmeters

I. D.

8 mm I.D.

10 mm

0.5

1.5

100

WARNING

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

For use on a one pipe system, it is necessary to remove the by-pass

screw (A, fig. 3).

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.

PRIMING THE PUMP

Loosen the plug of the vacuum gauge (5, fig. 1,

page 1) and wait until the fuel flows out.

Fig. 3

5 20013743

ELECTRICAL WIRING

ATTENTION:

Do not swap neutral and phase over, follow the diagram

shown carefully and carry out a good earth connection.

The section of the conductors must be at least 1mm². (Unless re-

quested 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.

CONTROL BOX, (see fig. 4)

To remove the control box (1) from the burner:

Unscrew the fissing screws on the burner cover and remove it.

Unscrew the fissing screws (2) on the plate and remove the

control box (1).

Screw the two fissing screws (2) and reassemble the burner

cover.

Fix the control box (1) with plate far from the burner.

TESTING

Check the shut-down of the burner by opening the thermostats.

D4677

Key to lay-out

A- Control box 531SE

C- Capacitor

E- Electrode

F-Fuse

FR -P.E.Cell

H- Lock-out signal

I- Main switch

M-Motor

PE - Burner-earth

R- Heater

TL - Limit thermostat

TS - Safety thermostat

Y- Oil valve

Fig. 4

20013743 6

COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjust-

ment and testing must be carried out observing the instruction manual of the boiler, including verifica-

tion 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 table.

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.

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

Steinen type H - Q; Danfoss type H.

Angle:60°:in most cases.

80° : in case of flame detachment, during ignitions at low temper-

atures.

PUMP PRESSURE 12 bar : the pump leaves the factory set at this value

14 bar : improves flame retention; it is therefore suitable for ignitions

at low temperatures.

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 table.

In the figure 5, the combustion head is set for an

output of 0.75 GPH at 12 bar, while the shutter is

level with set-point 2.5, as required by the above

table.

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° 11 2.3 1.5 2

0.65 60°/80° 12 2.6 2 2.2

0.75 60° 12 3.0 2.5 2.5

0.85 60° 12 3.4 3 3

1.00 60° 12 4.0 4 4.5

1.10 60° 12 4.4 5 6

1.25 60° 12 5.0 6 7

SETTINGS CARRIED OUT IN THE FACTORY

0.75 60° S 12 3.0 2.5 2.5

D5582

135

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

Fig. 5

7 20013743

Combustion head settings indicated in the table 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 (fig. 6), with the

burner running, operate on the rod (1) with a 6 mm span-

ner (2) as follows:

Turn to the right: (sign +):

In order to increase the volume of air entering the com-

bustion 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 combus-

tion chamber and thus increasing its pressure. The CO2

improves and the adhesion of the flame to the diffuser

tends to reduce. (This setting is not advisable for igni-

tions 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.

AIR DAMPER ADJUSTMENT, (fig. 7)

The mobile air damper (A) operated by the jack (B) as-

sures the complete opening of the air intake.

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

fixed air damper (C), after loosing the screws (D).

When the optimal regulation is reached, screw tight the screws (D) to assure a free movement of

the mobile air damper (A).

The settings indicated in the table 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 table;

– 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.

D5551

D5555

Fig. 6

Fig. 7

20013743 8

FUEL HEATING

In order to obtain smooth starting and operation across

its output range the burner is fitted with an electric

resistance, which heats up the gas oil in the nozzle

line. This resistance is energized when the thermostat

calls for heat and after a delay of approximately two

minutes depending on room temperature, the motor

will start. The resistance remains inserted and locks-

out on the shut-down of the burner.

Attention

Should you want to cut off the electric resistance (on

setting the burner or when the ambient temperature

does not require it, etc. . .), take the plug off the panel

of the control box and plug it into the “Resistance

OFF” (see fig. 8). In this case the burner starts

up when the thermostats close.

NOTE

The warning light (LED) is ON but when the resist-

ance works. It is OFF when the resistance is discon-

nected or broken.

FAILURE DETECTION ON HEATING

DEVICE - Only for type 447T1

The plug fitted in the panel is placed in the position corre-

sponding to “Resistance ON” (see fig. 8).

When the remote control closes, the LED lights up and,

after about two minutes, the burner starts up.

1) If the LED is OFF, the heating resistance placed

in the nozzle-holder is off.

2) If the LED is ON and nevertheless the burner does not run, place the plug in the position corre-

sponding to “Resistance OFF” (see fig. 9). If the motor runs, the delaying device inside

the control box is out of order.

3) If the motor does not run, it means that the failure is neither in the panel nor in the resistance, but

elsewhere.

ELECTRODE SETTING, (see fig. 10)

PLUG

Resistance ON

Resistance OFF LED

S7059

Control box

531SE B

PLUG

Resistance OFF

S7060

LED

Fig. 8

Fig. 9

NORMAL OPERATION

BURNER DOES NOT OPERATE

IMPORTANT:

THESE DIMENSIONS MUST BE

OBSERVED

Before removing or assembling the

nozzle, loosen the screw (A) and

move the electrodes ahead.

2 – 2.5 mm

4± 0.3 mm

D5230 A

Fig. 10

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