Riello Burners CAMRAY5 150 Quick start guide

2902785 (4)
Installation, use and maintenance instructions
Kerosene and light oil burners
One stage operation
CODE BOULTER CODE MODEL TYPE
3748960 8-716-108-334 CAMRAY5 150/200 490 T51
3748961 8-716-108-333 CAMRAY5 200/240 490 T51
3748962 8-716-111-556 COH 280 490 T51

2785 1
INDEX
1. BURNER DESCRIPTION
One stage kerosene and light oil burner.
1.1 BURNER EQUIPMENT
By-pass screw (clipped on the pump). . . . . . . . . . . . . . No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions . . . . . . . . . . . . . . . . 2
2.3 Firing rate . . . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Mounting the burner . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Nozzles recommended . . . . . . . . . . . . . . 6
4.3 Pump pressure . . . . . . . . . . . . . . . . . . . . 6
4.4 Maintenance position . . . . . . . . . . . . . . . 7
4.5 Diffuser disc and electrodes setting . . . . 7
4.6 Combustion head setting. . . . . . . . . . . . . 8
4.7 Air damper adjustment . . . . . . . . . . . . . . 8
4.8 Burner start-up cycle . . . . . . . . . . . . . . . . 8
5. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
6. SAFETY WARNINGS . . . . . . . . . . . . . . . 10
6.1 Burner identification . . . . . . . . . . . . . . . . 10
6.2 Basic safety rules . . . . . . . . . . . . . . . . . . 10
®In case of BF applications the intake air temperature must not be over 70°C.
®CE Certification No.: 0036 0332/02 as 92/42/EEC.
®Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73 /23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
®The burner meets protection level of IP 40, EN 60529.
1– Reset button with lock-out lamp
2– Photoresistance
3– Snorkel (BF)
4– Blast tube
5– Control-box
6 – Pump pressure adjustment screw
7 – Pressure gauge port
8 –Pump
9 –Flange
10 – Air damper adjustment screw
8
D4266
Fig. 1
9
3
10
5
1
6
7
2 4

2785 2
2. TECHNICAL DATA
2.1 TECHNICAL DATA
◆Light oil is not permitted on low level discharge of flue gas products.
2.2 OVERALL DIMENSIONS
2.3 FIRING RATE, (as EN 267)
TYPE 490 T51
Output - Thermal power
(with air at 20°C) 4 – 10 kg/h – 47.45 – 120 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 1.3A – 2750 rpm – 288 rad/s
Capacitor 5 µF
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 0.16 kW
BurnerFlange
167 69.5 253
32
11
204
D4267
83 83
268
163
45°
45°
189
168
140
106
Ø 95
0.4
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
D4351
0.2
0.6
0.8
1.0
1.2
0
1.4
1.6
45678
45 65 75 85 9555
910
105 115 125

2785 3
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
®Put on the flange (1) the screw and two nuts, (see fig. 2).
®Widen, if necessary, the insulating gasket holes (5), (see fig. 3).
®Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nu ts (3) interposing the
insulating gasket (5), (see fig. 4).
3.2 MOUNTING THE BURNER
5
1
2
4
3
E9188
Fig. 2
D5012
Fig. 3
E9187
1
Fig. 4
In case of BF applications, the combustion air
supply is trough a flexible tube connected at the
socket (A).
E1557
A
Fig. 5

2785 4
3.3 HYDRAULIC SYSTEMS
H = difference of level L = Max. lenght of the suction line I.D. = Interminal diameter of the oil pipes.
F i g . 6
D5912
2
3
4
7
6
5
18
®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. 6).
®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:
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
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. 7 it is sufficient to loosen the suction gauge
connection (6, fig. 6) and wait until oil flows out.
On the systems in fig. 8 and 9 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. 9) 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.
H
max. 4 m
min. 0.1 m
D1559
F i g . 7
max. 4 m
H
H
D1560
F i g . 8
D1558
max. 4 m
H
H
F i g . 9

2785 5
3.4 ELECTRICAL WIRING
E9154
4
4
3
12
CONTROL BOX (see fig. 10)
To remove the control box from the burner follow of the istruction:
®Loosen the screw (1), open the protection (2) an d remove all com-
ponents.
®Remove the coil (3).
®Loosen the two screws (4).
®Move a little the control box and remove the high voltage leads.
Fig. 10
Capacitor
NL
~50Hz - 230V
Oil valve
D4218
CONTROL BOX
Photoresistance
535SE/LD
Motor
Main switch
T6A
Black
White
Blue
PE
Ignition
electrodes
4 pin plug
4 pole socket
Burner-earth
TESTING:
Check the shut-down of the burner by open-
ing the thermostats and the lock-out by dark-
ening the photoresistance.
Limit
Safety
Remote lock-out signal
(230V - 0.5A max.)
thermostat
thermostat
ATTENTION:
®Do not swap neutral and phase over, follow the dia-
gram shown carefully and carry out a good earth con-
nection.
®The section of the conductors must be at least 1mm².
(Unless requested otherwise by local standards and legis-
lation).
®The electrical wiring carried out by the installer must be in
compliance with the rules in force in the country.

2785 6
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 CO2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of the
combustion head, 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% CO2 at sea
level and with fuel and room temperature of 20°C.
4.2 NOZZLES RECOMMENDED
Hago type ES - B ; Delavan type W - B (not for 45° light oil); Steinen type S; Danfoss type S;
Use Delavan type W CSA.
4.3 PUMP PRESSURE
The pump leaves the factory set for kerosene working.
10 bar: maximum pressure for kerosene.
FOR LIGHT OIL INCREASE 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.
FUEL
Nozzle Pump
pressure
Burner
output
Combustion head
adjustment
Air damper
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
KEROSENE
1.35 60° W 8 4.04 0 2.2
1.50 60° W 8 4.49 1 2.8
1.65 60° W 8 4.93 2 3.1
1.75 60° W 8 5.23 2 3.5
2.00 60° W 8 5.98 2 4.3
2.25 60° W 8 6.73 3 5
2.50 60° - 45° W 8 7.48 5 6
2.75 60° - 45° W 8 8.22 5 8
3.00 60° - 45° W 10 10.03 6 10
LIGHT OIL
1.00 60° W 12 4.0 0 2.3
1.10 60° W 12 4.4 1 2.7
1.25 60° W 12 5.0 2 3.3
1.35 60° W 12 5.4 2 4
1.50 60° W 12 6.0 2 4.7
1.65 60° W 12 6.6 3 5
1.75 60° W 12 7.0 4 6
2.00 60° - 45° W 12 8.0 5 7
2.25 60° - 45° W 12 9.0 6 8.4
2.50 60° - 45° W 12 10.0 6 10

2785 7
4.4 MAINTENANCE POSITION
Access to the combustion head, the diffuser disc-holder assembly, electrodes and nozzle (see fig. 11).
®Loosing the fixing nut to the flange and remove the burner out of the boiler.
®Hook the burner to the flange (1), by removing the blast tube (2) after loosing the fixing screws (3).
®Remove the small cables (4) from the electrodes (5) and the diffuser disc-holder assembly from the nozzle-
holder (6) after loosing its fixing screw (7).
®Once replacement of the nozzle has been made, screw it and tighten it as shown in the figure 11.
4.5 DIFFUSER DISC AND ELECTRODES SETTING, see fig. 12
E9189
E9191
1
2
3
2
5
4
Fig. 11
7
6
To ad just the diffu ser dis c u nit, p roceed as
follows:
®Loosen the screw (1, fig. 12).
®Move the diffuser disc unit up to level .
®Tighten the screw (1).
To adjust the electrodes unit, proceed as fol-
lows:
®Loosen the screw (2, fig. 12).
®Move the electrodes unit up to level .
®Tighten the screw (2).
A
B
THESE DIMENSIONS MUST BE OBSERVED
IMPORTANT
D4269
1
Fig. 12
2B
A
+ 0.5
0
3
0
- 0.2
5.75
A
B4 ± 0.5
+ 0.7
- 0.5
7.5

2785 8
4.6 COMBUSTION HEAD SETTING, (see fig. 13)
To adjust the combustion head, proceed as follows:
®
Loosen the two screws in the ring slots.
®
Turn the blast tube to regulate it, until the end of the
slotted r ing c entres up with t he n otch s hown i n the
table on page 6.
Turn in a clockwise direction:
in or der t o i ncrease t he v olume of a ir ent ering t he
combustion chamber and thu s d iminishing i ts pre s-
sure. There is a reduction of CO2 and the adhesion of
the flame to the air diffuser disc improves.
(Setting advisable for ignitions at low temperatures).
Turn in an anticlockwise direction:
in order to reduce the volume of air entering the com-
bustion chamber a nd thu s i ncreasing i ts p ressure.
The CO2 improves and the adhesion of the flame to
the diffuser tends to reduce. (This setting is not advis-
able for ignitions at low temperatures).
®
Tighten the two screws.
In the sketch on the right, the combustion head is adjusted at set-point 3.5.
Combustion head settings indicated in the schedule at page 6 are valid for most cases.
4.7 AIR DAMPER ADJUSTMENT
The settings indicated in the schedule refer to the combustion-chamber with “zero” depression. These reg-
ulations are p urely i ndicative. Eac h in stallation ho wever, ha s it s o wn un predictable w orking co nditions:
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.
4.8 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (1, fig. 1, page 1).
Blast tube
Shutter
D4268
Screw
Slotted ring
Fig. 13
0
Screw
Normal
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
~ 12s D5229 ~ 12s ~ 5s
Lock-out due to failure to light
A
A

2785 9
5. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for some problems that could cause a
failure to start or a bad working of the burner.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box
(1, fig. 1, page 1).
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the
burner functions correctly, the lock-out can be attributed to a temporary fault. If however the lock out
continues the cause must be determined and the solution found.
WARNING
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error
in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the
technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
The burner will not
start when the limit
thermostat closes.
Lack of electrical supply.
Check presence of voltage in the
L - N clamps of the control box.
Check the conditions of the fuses.
Check that safety thermostat is not
lock out.
The photoresistance sees false light. Eliminate the light.
The connections in the control box
are wrongly inserted.
Check and connect completely all the
plugs.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective. Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned.
Adjust them according to the
instructions of this manual.
Air output is too high. Set the air output.
Nozzle dirty or worn. Replace it.

2785 10
6. SAFETY WARNINGS
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guarantee a
combustion with the lowest polluting emissions rate.
The Technical Service Personnel will be glad to give you all the imformation for a correct matching of this
burner to the boiler.
This burner must only be used for the application it was designed for.
The manufacturer accepts no liability within or without the contract for any damage caused to people, ani-
mals and property due to installation, adjustment and maintenance errors or to improper use.
6.1 BURNER IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and performance
data. If the Identification Plate is tampered with, removed or missing, the product cannot be clearly identi-
fied thus making any installation or maintenance work potentially dangerous.
6.2 BASIC SAFETY RULES
®Children or inexpert persons must not use the appliance.
®Under no ci rcumstances must the intake grids, dissipation grids and ventilation vents in the installation
room be covered up with cloths, paper or any other material.
®Unauthorised persons must not attempt to repair the appliance.
®It is dangerous to pull or twist the electric leads.
®Cleaning operations must not be performed if the appliance is not disconnected from the main power supply.
®Do not clean the burner or its parts with inflammable substances (e.g. petrol, alcohol, etc.). The cover
must be cleaned with soapy water.
®Do not place anything on the burner.
®Do not block or reduce the size of the ventilation vents in the installation room.
®Do not leave containers and inflammable products in the installation room.

2907893 (3)
Catalogo ricambi
Spare parts list
Catalogue pièces détachées
Ersatzteile Katalog
Catálogo recambios
MOD. COD. BOULTER COD. TIPO/TYPE/TYP
CAMRAY5 150/200 3748960 8-716-108-334 490 T51
CAMRAY5 200/240 3748961 8-716-108-333 490 T51
COH 280 3748962 8-716-111-556 490 T51
Bruciatori di kerosene - gasolio • Kerosene - light oil burners • Brûleurs kérosène - fioul
Kerosin/Öl - Gebläsebrenner • Quemadores de kerosene/gasóleo

13008637 FLANGIA FLANGE BRIDE KESSELFLANSCH BRIDA
23002572 GRUPPO BOCCAGLIO BLAST TUBE ASSEMBLY GROUPE GUEULARD FLAMMROHRSYSTEM CONJUNTO CABEZAL B
33002571 GRUPPO ELICA - ELETTRODI DIFFUSER DISC - ELECT. ASSEM. ACCR. FLAM. - GROUPE ELECTR. STAUSCHEIBE - ELEKTRODENBL DISCO ESTABIL. - CONJUNTO ELECT. A
43002570 PORTAUGELLO NOZZLE HOLDER PORTE-GICLEUR DÜSENSTOCK PORTABOQUILLA B
53008794 COLLEGAMENTO A.T. HIGH VOLTAGE LEAD CABLE HAUTE TENSION KABEL ZÜNDELEKTRODEN CABLES ELECTRODOS A
63008957 COLLARE COLLAR COLLIER BRENNERFLANSCH COLLA RÍN
73008963 KIT GUARNIZIONI KIT SEALS KIT JOINTS DICHTUNG ERSATZ KIT JUNTAS A
83008839 GRUPPO SERRANDA ARIA AIR DAMPER ASSEMBLY SYSTEME REGLAGE D’AIR LUFTREGULIERUNG CONJUNTO REGISTRO DEL AIRE
93008958 FONOASSORBENTE DEADENING ISOLATION ACOUSTIQUE GERÄUSCHDAMMUNG AISLAMIENTO ACÚSTICO
10 3005799 GIRANTE FAN TURBINE GEBLÄSERAD TURBINA C
11 3008646 FOTORESISTENZA P.E. CELL CELLULE PHOTORESISTANCE FOTOWIDERSTAND FOTORESISTENCIA A
12 3008962 COFANO COVER CAPOT BRENNERHAUBE ENVOLVENTE
13 3008863 COLLEGAMENTO LEAD CABLE DE CONNEXION VERBINDUNG CABLE CONEXIÓN
14 3008960 CONDENSATORE 5 µF CAPACITOR 5 µF CONDENSATEUR 5 µF KONDENSATOR 5 µF CONDENSADOR 5 µF B
15 3003602 RACCORDO CONNECTOR MAMELON ANSCHLUßNIPPEL RACORD C
16 3005720 TUBO FLESSIBILE FLEXIBLE FLEXIBLE ÖLSCHLAUCH TUBO FLEXIBLE A
17 3008964 MOTORE MOTOR MOTEUR MOTOR MOTOR C
18 3008876 PRESA DI PRESSIONE PRESSURE GAUGE PRISE DE PRESSION DRUCKANSCHLUß ENCHUFE
19 3008961 TUBO TUBE TUYAU DRUCKROHR TUBO
20 3000443 GIUNTO JOINT ACCOUPLEMENT PUMPENKUPPLUNG ACOPLAMIENTO A
21 3008648 BOBINA - MANTELLO E POMELLO COIL - SHELL AND KNOB BOBINE V.M. - ETRIER ET ECROU M.V. - SPULE - HALTEBÜG. MIT SCHRAUBE BOBINA - PROTECCIÓN BOBINA A
22 3008851 COLLEGAMENTO LEAD COIL CABLE DE CONNEXION ANSCHLUßKABEL MAGNETSPULE CABLES ELECTROVÁLVULA
23 3008654 POMPA PUMP POMPE ÖLPUMPE BOMBA C
24 3000439 ORGANO DI TENUTA PUMP SEAL ORGANE D’ETANCHEITE DICHTUNGSEINSATZ ANTRIEBSWELLE CONJUNTO ESTANQUIDAD A
25 3008653 FILTRO - ANELLO OR FILTER - O-RING FILTRE - JOINT TORIQUE FILTEREINSATZ – O-RING-DICHTUNG FILTRO – JUNTA TÓRICA A
26 3008651 REGOLATORE REGULATOR REGULATEUR DRUCKREGULIERSCHRAUBE REGULADOR A
27 3007582 VALVOLA NEEDLE VALVE VANNE MAGNETIQUE MAGNETVENTIL KÖRPER VÁLVULA A
28 3008652 APPARECCHIATURA 535SE/LD CONTROL BOX 535SE/LD BOITE DE CONTROLE 535SE/LD STEUERGERÄT 535SE/LD CAJA DE CONTROL 535SE/LD B
29 3008649 PROTEZIONE PROTECTION PROTECTION SCHUTZ PROTECCIÓN
30 3020119 ELICA DIFFUSER DISC ACCROCHE FLAMME STAUSCHEIBE DISCO ESTABILIZADOR A
31 3020121 ELETTRODO ELECTRODE ELECTRODE ZÜNDELEKTRODE ELECTRODO A
N. COD. DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DENOMINACIÓN
7893
RICAMBI CONSIGLIATI
ADVISED SPARE PARTS
RECHANGE CONSEIL
EMPFOHLENE ERSATZTEILE
RECAMBIOS ACONSEJADOS
A = Ricambi per dotazione minima - Spare parts for minimum fittings - Pièces détachées pour équipement mimimum - Erzatzteile für minimale Ausstattung - Recambios para equipamiento mínimo.
A+B = Ricambi per dotazione base di sicurezza - Spare parts for basic safety fittings - Pièces détachées pour équipement standard de sécrité - Erzatzteile für Sicherheitsgrundausstattung - Recambios para equipamiento básico de seguridad.
A+B+C
=
Ricambi per dotazione estesa di sicurezza
-
Spare parts for extended safety fittings
-
Pièces détachées pour équipement complet
de sécurité
-
Erzatzteile für erweiterte Sicherheitsausstattung
-
Recambios para equipamiento general de seguridad