Riello R40 G7 140-160 Kurzanleitung

Installation, use and maintenance instructions

2902374 (5) - 06/2015

Light oil and kerosene burners

One stage operation

CODE MODEL TYPE

3745959 R40 G7 140 - 160 459T55

3745961 R40 G7 160 - 200 459T55

2374 1

TECHNICAL DATA

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

OBurner with CE marking in conformity with EEC Directives: Machine Directive 2006/42/EC, Low Voltage

Directive 2006/95/EC and Electromagnetic Compatibility 2004/108/EC.

TYPE 459T55

Thermal power – output 29 – 69 kW – 2.45 – 5.8 kg/h

Fuel Kerosene, viscosity 1.5 – 6 mm2/s at 20 °C

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

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

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

Capacitor 4 F

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– Lock-out lamp and reset button

6– Screws fixing air-damper

7– Flange with insulating gasket

8– Vacuum gauge connection

EQUIPMENT

Quantity Description

Flange with insulating gasket

Screw of by-pass pump

Screw with two nuts for flange

Screws

Screws with washer, nuts

Flexible pipe with nipple

D5534

Fig. 1

123

2374 2

WORKING RANGE (as EN 267)

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

D5236 35 40 45 50 55

0.2

0.6

1.0

1.2

1.4

2.45

65 70

Flange Burner

305 73 261

140

45°

ø89

262

204

D5235

189

83 83

170

45°

It is necessary that the insulating gasket

(7, 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.

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-line on either side of

the burner.

D5242

Fig. 2

D5572

S7389

BURNER FIXING

2374 3

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:

OCheck periodically the flexible pipes conditions. Using kerosene, they have to be replaced at

least every 2 years.

OA 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.

Warning: 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 (8, 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

Hmax.4m

max. 4 m

min. 0.1 m

D5219

D5220

D5199

H=Difference of level.

L=Max. length of the suc-

tion line.

I.D.=Internal diameter of the

oil pipes.

2374 4

BURNER ELECTRICAL WIRING

S7029

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Main switch

T6A

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

D5228

Black

2374 5

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. The values

in the table refer to 12.5% CO2at sea level and to “zero” pressure in the combustion chamber.

FUEL LIGHT OIL

FUEL KEROSENE

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

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

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 2.50 1 1.2

0.65 60°/80° 12 2.80 1.5 1.4

0.75 60° 12 3.10 2 1.8

0.85 60° 12 3.60 2.5 2.2

1.00 60° 12 4.29 3 2.6

1.10 60° 12 4.72 4 3

1.25 60° 12 5.30 5 3.5

1.35 60° 12 5.80 6 4.2

Angle: 60° in most cases.

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

Nozzle Pump pressure Burner output Comb. head

adjustment Air damper

adjustment

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

0.85 60° 8 2.51 1 1.2

1.00 60° 8 2.95 1.5 1.4

1.10 60° 8 3.25 2 1.8

1.25 60° 8 3.69 3 2.2

1.35 60° 8 3.99 3.5 2.4

1.50 60° 8 4.43 4.5 2.7

1.75 60° 8 5.20 6 3.2

2.00 60° 8 5.80 6 4.2

2374 6

PRESSURE:

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

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

FOR KEROSENE DECREASE PRESSURE

8 bar: pressure suitable for kerosene in most cases.

10 bar: maximum pressure for kerosene.

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.

AIR DAMPER ADJUSTMENT

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

damper (1), after loosing the screws (2).

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: actu-

al 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.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5244

135

In the sketch on the left, the combustion

head is set for an output of 1.00 GPH at

12 bar (for gas-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

D5514

2374 7

ELECTRODE SETTING

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 gas-oil decreases below +8 °C.

1) CORRECT POSITIONING OF THE ELECTRODES (see figure above)

2) PUMP - SETTING

When the temperature of the gas-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 damper, reducing the excess air until the Bacharach number is not near 1.

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

Attention:

Before removing or assembling the

nozzle, loosen the screw (A) and

move the electrodes ahead.

2 – 2.3 mm

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 A

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

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