Riello Burners RG5S 399T1 Quick start guide

2902623 (2)
Manuel d’entretien
Installation, use and maintenance instructions
Installatie-, gebruiks- en onderhoudsvoorschriften
Montage und Bedienungsanleitung
OδηγÝε÷ εγκατÀσταση÷, χρÜση÷ και συντÜρηση÷
Öl-Gebläsebrenner
Brûleur fioul
Light oil burner
Stookoliebrander
ΚαυστÜρα÷ ΠετρελαÝου
CODE - Κ¿¢ΙΚΟΣ
MODELL - MODELE
MODEL - ΜΟΝΤΕΛΟ
TYP -TYPE
ΤΥΠΟΣ
3739950 RG5S 399 T1
D
F
GB
NL
GR
Einstufiger Betrieb
Fonctionnement à 1 allure
One stage operation
Eentrapsbranders
ΜονοβÀθíιοι

2623
1
GB
INDEX
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . .No. 1 Screw and nuts for flange to be fixed to boiler . No. 4
Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . No. 2
7 pin plug. . . . . . . . . . . . . . . . . . .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 Working field . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Recommended nozzles. . . . . . . . . . . . . . 6
4.3 Combustion head setting. . . . . . . . . . . . . 7
4.4 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.5 Pump pressure and air output . . . . . . . . . 7
4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9
1– Oil pump
2– Control-box
3– Reset button with lock-out
lamp
4– Flange with insulating
gasket
5– Air damper adjustment assembly
6– Nozzle holder assembly
7– Photoresistance
8– Hydraulic jack
9– Start delaying device
■CE Certification No.: 0036 0310/01 as 92/42/EEC.
■The burner meets protection level of IP 40, EN 60529.
■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.
Fig. 1
SW1006

2623
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4
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD
(as EN 267)
TYPE 399T1
Output - Thermal power 13.5
–
26.1 kg/h - 160
–
309.5 kW
Fuel Light oil, viscosity 4 –
6 mm
2
/s at 20 °C
Electrical supply Single phase,
~
50Hz 230V
±
10%
Motor Run current 2.1A – 2730 rpm – 286 rad/s
Capacitor 8
µ F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8
–
15 bar
Absorbed electrical power 0.47 kW
247 155 300 213
160
190
12,5
36
285
345
11
99
99
127
45°
45°
D5390
ø125
0Fuel output – kg/h
150 170 190 Thermal power – kW
4
3
2
1
Pressure in combustion
chamber – mbar
D6230
12
210 230
14 16 18 20
270
22 24 26
250 290 310

2623
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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. 3).
➤
Widen, if necessary, the insulating gasket holes (4), (see fig. 4).
➤
Fix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the
insulating gasket (4)
, (see fig. 2).
➤
After installation ensure that burner is lightly inclined as in fig. 5.
3.2 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and closing plate (2) should be reversed, (see fig. 6).
Fig. 5
D5012
Fig. 4
D5025
Fig. 2
Fig. 3 S7071
D4017
Fig. 6
121

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3.3 HYDRAULIC SYSTEMS
H = difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes.
2
D4018
3
4
5
6
7
1
4
Fig. 8
D5745
H
max. 4 m
■The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to unscrew
the pin (2), remove the by-pass screw (3) and then screw again
the pin (2), (see fig. 7).
■It is necessary to install a filter on the fuel supply line.
■Before starting the burner make sure that the return pipe-line is
not clogged. An excessive back pressure would cause the dam-
age 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
PRIMING PUMP:
On the system in fig. 8 it is sufficient to loosen the suction gauge connection
(6, fig. 7) and wait until oil flows out.
On the systems in fig. 9 and 10 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.
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. 10) 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 previous one,
due to the possibility of leakage of the valve.
SYSTEM NOT PERMITTED
IN GERMANY
H
max. 4 m
max. 4 m
H
H
H
D5744
Fig. 9 Fig. 10
Fig. 7
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve

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3.4 ELECTRICAL WIRING
D1913
ESEGUITO IN FABBRICA
TESTING
Check the shut-down of the
burner by opening the thermo-
stats and the lock-out by dark-
ening the photoresistance.
NOTES:
– Wires of min. 1 mm2section.
(Unless requested 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.
WARNING
DO NOT EXCHANGE NEUTRAL WITH PHASE
7 pin plug
7 pole socket
Black
White
Capacitor
Main switch
T6A
Motor
Blue
Oil valve
Hour counter
(230V - 0.1A max.)
Limit thermostat Remote lock-out signal
(230V - 0.5A max.)
Ignition
electrodes
Brown
Burner-earth
CARRIED-OUT IN THE FACTORY
552SE
CONTROL BOX
Photoresistance
PE L N
~50Hz 230V
Blue
CONTROL BOX (see fig. 11)
To remove the control-box from the burner, loosen screw (A) and
pull to the arrow direction, after removing all components, the
7 pin plug and earth wire.
In case of disassembly of the control box, retighten the screw
(A) with a torque wrench setting of 1 – 1.2 Nm.
Fig. 11
S7072 A
Safety thermostat

2623 6GB
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
CO2concentration 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% CO2at sea level and with light oil and room temperature of 20 °C.
4.2 RECOMMENDED NOZZLES:
Monarch type R
Delavan type W
(up to 3,00 GPH)
Delavan type B (over 3,00 GPH)
Steinen type S; Danfoss type S.
TO FIT NOZZLE CARRY OUT THE FOLLOW-
ING ACTIONS, (see fig. 12)
➤Remove nozzle-holder assembly (1) after
loosing screws (2) and nut (3), remove the
small cables (4) from the control box and the
photoresistance (5).
➤Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc-holder as-
sembly (8) from the nozzle-holder assembly
(1) after loosing screw (3, fig. 13, page 7).
➤Screw the nozzle (9) correctly and tighten it as
shown in fig. 12.
Attention
During the reassembly of the nozzle-holder as-
sembly screw the nut (3) as shown in the figure
below.
Nozzle Start delaying
device pressure Pump pressure Burner
output
Combustion
head
adjustment
Air damper adjustment
Low-flame High-flame Low-flame High-flame
GPH Angle bar bar kg/h ± 4% Set-point Set-point Set-point
3.00 60° 9 15 13.5 0 0.4 1.3
3.50 60° 9 15 15.7 0 0.5 2.0
4.00 60° 9 15 18.0 2 0.7 2.5
4.50 60° 9 15 20.2 4 0.8 3.0
5.00 60° 9 15 22.4 6 0.9 3.7
5.50 60° 9 15 24.7 8 1.1 5.8
6.00 60° 9 14 26.0 10 1.3 6.0
SW1007
Fig. 12
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684

2623 7GB
4.3 COMBUSTION HEAD SETTING, (see fig. 12, page 6)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting
screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the nozzle-holder
assembly (1).
➤In the sketch the combustion head is set for an output of 4.00 GPH at 15 bar.
The set-point 2of the regulating rod (7) is at the same level with the outside plane of the nozzle-holder
assembly (1) as shown in the schedule.
4.4 ELECTRODES ADJUSTMENTS, (see fig. 13)
4.5 PUMP PRESSURE AND AIR OUTPUT
The burner, in order to guarantee good smooth
starts, irrespective of the type of boiler, is fitted
with a hydraulic device which, independently of
the control-box, reduces the fuel- and air-flow.
At ignition, the pressure at the nozzle is 9 bar.
After 3 - 9 seconds, it automatically increases to
15 bar.
The air-flow, initially adjusted to the low setting,
is, at the change-over of pressure, automatically
brought to the air-flow required for the big flame.
■SETTING FOR THE LOW IGNITION-FLAME
(See fig. 14)
ADJUSTMENT OF AIR SHUTTER
Unloosen the screw (8), by approximately one full
turn; in this way, the burner remains permanently
on low flame.
Unloosen the nut (5), turn the screw (4) until the
indicator (6) reaches the position desired.
Then lock the nut (5) and tighten the screw (8).
ADJUSTMENT START DELAYING DEVICE
This is set at 9 bar at the factory.
The pressure gauge must be mounted in place of
plug (4, fig. 7, page 4). Should it be necessary to
re-set or alter such pressure, this can be done,
by adjusting screw (7), always after having loos-
ened screw (8). For the adjustment, follow what
indicated in the table at page 6.
Anyway, it is advised to adjust the content of CO2at values not lower than 12%.
MEASURES MUST BE RESPECTED.
WARNING:
Lean the diffuser disc-holder assembly (1)
on the nozzle-holder (2) and lock it by
screw (3). For prospective adjustments
loosen screw (4) and move the electrodes
assembly (5).
To have access to the electrodes carry
out operation as described in chapter “4.2
RECOMMENDED NOZZLES” (page 6).
D4019
4.5 – 0.5 mm
06 –7 mm
Fig. 13
13 2
5 4
S7161
Fig. 14

2623 8GB
■HIGH-FLAME SETTING, (see fig. 14, page 7)
AIR-DAMPER ADJUSTMENT
Loosen the nut (3), turn the screw (1), until the indicator (2) is in the required position. Then, lock the nut (3).
PUMP-ADJUSTMENT
This is set at 15 bar at the factory.
The pressure gauge must be mounted in place of plug (4, fig. 7, page 4).
Should it be necessary to re-set or alter such pressure, this can be done, by adjusting screw (5, fig. 7, page 4).
When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.
4.6 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the
burner acting on the main switch of the system.
THE BASI CHECK ARE:
➤Check that there are not obstructions or dents in the supply or return oil pipes.
➤Clean the filter in the oil suction line and in the pump.
➤Clean the photoresistance, (7, fig. 1, page 1).
➤Check for correct fuel consumption.
➤Replace the nozzle (fig. 12, page 6) and check the correct position of electrodes (fig. 13, page 7).
➤Clean the combustion head in the fuel exit area, on the diffuser disc.
➤Leave the burner working without interruptions for 10 min. and set rightly all the components stated in
this manual. Then carry out a combustion check verifying:
●Smoke temperature at the chimney; ●Contentof CO2(%); ●ContentofCO(ppm);
●Smoke value according to opacity smokes index according to Bacharach scale.
D5544~12s
Thermostat
Motor
Ignition transformer
Valve
Low-flame
Lock-out lamp
~12s 5s
High-flame
3 ÷ 9s
Lock-out due to failure to light
B
Normal
B

2623 9GB
6. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for some problems that could cause a fail-
ure 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
(3, 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 doesn’t
start when the limit
thermostat closes.
Lack of electrical supply.
Check presence of voltage in the
L1 - N clamps of the 7 pin plug.
Check the conditions of the fuses.
Check that safety thermostat is not
lock out.
The photoresistance sees false light. Eliminate the light.
Start thermostats are faulty. Replace them.
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 according to the
instructions of this manual.
Nozzle dirty or worn. Replace it.