RIELLO BURNES 40 G10D Quick start guide

2902508 (0)
Installation, use and maintenance instructions
Kerosene - oil burner
Two stage operation
CODE MODEL TYPE
3746686 G10D 716T81

2508
1
TECHNICAL FEATURES
◆
The burner meets protection level of IP 40, EN 60529.
Thermal power – output 44 / 54 – 120 kW – 3.7 / 4.5 – 10 kg/h
Fuel Kerosene, min. viscosityat 20
° C: 1.6 mm
2
/s
Gas oil, max. viscosity at 20
° C: 6 mm
2
/s
Electrical supply
Single phase, 220V +10% –15%
~
60Hz
Motor Run current 1.1A – 3300 rpm – 345 rad/s
Capacitor
2.5 m F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 7 – 15 bar
Absorbed electrical power 0.2 kW
1– Return line
2– Suction line
3– Gauge connection
4– Pressure regulator, 2nd stage
5– Vacuum gauge connection
6– Hydraulic jacks with air-damper
7– Combustion head adjustment screw
8– Lock-out lamp and reset button
9– Flange with insulating gasket
10 – Regulation pressure, 1st stage
11 – Economizer
EQUIPMENT
Quantity Description
2
1
2
1
1
1
1
Flexible pipes with nipples
Flange with insulating gasket
Screws and nuts for flange
Hinge
Screw with two nuts for flange
7 pin plug
4 pin plug
S7349
Fig. 1

2508
2
WORKING RANGE
(as EN 267)
DIMENSIONS
MOUNTING THE BURNER
0.8
0
0.4
3 4 5 Fuel output - kg/h
40 50 120 Thermal power - kW
D5815 60 70 80 90 100
0.2
0.6
Pressure in the combustion
chamber – mbar
6 7 9 108
110
1.0
1.2
3.7
Flange Burner
305 108 261
140
=
40
45°
262
11
204
D5670
=
189
83 83
170
45°
ø105
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
S7385

2508
3
OIL LINES
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.
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.
PRIMINGTHE 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.
◆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.
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
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), (see figure).
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
Hmax. 4 m
H
H
max. 4 m
min. 0.1 m
D5219
D5220
H=Difference of level.
L= Max.length of the
suction line.
I.D.=Internal diameter of the
oil pipes.
PRIMINGTHE PUMP
Loosen the plug of the vacuum gauge (5, fig. 1,
page 1) and wait until the fuel flows out.
A
D5809

2508
4
BURNER ELECTRICAL WIRING
(50V)
Motor
Capacitor
Regulating thermostat
Neutral
Switch with fuse
6A max.
M
~
220V ~60Hz
L N
Limit thermostat
with manual resetting
Remote lock-out lamp
(230V - 0.5A max.), if required
1 N T1 T2 S3B4
1 2
T
T
D5822
CARRIED-OUT IN THE FACTORY
Burners’s
7 pole socket
34567891112
N L
Yellow/
1st Valve
Hour counter
h
WARNING DO NOT EXCHANGETHE NEUTRAL WITHTHE PHASE
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.
●Connect 2nd stage thermostat between clamps
T6 and T8 removing the bridge.
Boilers’s
7 pin plug
green
C D A E
C
A D
C
DA
C
D
B
2nd Valve
Terminal block of
control-box 530SE*
4
6
3
2
1
5
2061425
Economizer
B5 T6 T7 T8 4 pin plug
4 pole socket
T●2nd stage
thermostat
A= Brown B= White C= Blue D= Black E= Grey

2508 5
To remove the control-box from the burner,
loosen screw (A)
(see figure on the right) and
pull towards the arrow.
RUN OF THE ELECTRICAL CABLES
1- Grommet
2- Cable-clamp
3- Terminal block
4- Clamps for 2nd stage thermostat
5- 4 pole socket for 2nd stage
thermostat
6- 7 pole socket for burner
N- Neutral
- Lock-out lamp
L- Phase
- Burner-earth
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.
S7348
Ignition
transformer
Photoresistance
S7057

2508 6
COMBUSTION ADJUSTMENT
To suit the required appliance output, fit the nozzle, the settings of the combustion head and the air
damper opening in accordance with the following schedule.
NOZZLES RECOMMENDED: Monarch type R
Delavan type B
Steinen type S - Q
Danfoss type S
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 car-
ried 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.
Nozzle Pump
pressure Burner output Comb. head
adjustment Air damper adjustment
bar kg/h ±4% 1st stage 2nd stage
GPH Angle 1st 2nd 1st 2nd Set-point Set-point Set-point
1.35 60°7 11 3.5 4.5 1.5 2.1 2.5
1.50 60°7 11 4.2 5.2 1.5 2.5 3.1
1.75 60°7 11 4.5 5.6 2.0 2.5 3.0
2.00 60°7 11 5.7 7.1 3.0 2.8 3.5
2.25 60°7 11 6.1 7.5 3.0 2.9 3.8
2.50 60°7 11 6.5 8.2 3.5 3.0 4.2
2.75 60°7 11 7.6 9.7 4.0 3.5 8.0
3.00 60°7 10 8.3 10.1 6.0 3.6 8.0
FUEL KEROSENE
3
12
1
2
In the sketch on the left, the combustion
head is set for an output of 2.00 GPH at
7/11 bar, while the shutter is level with
set-point 3, as required by the above
schedule.
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5398
2
135

2508 7
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 advisa-
ble for ignitions at low temperatures).
Turn to the left: (sign –), in order to reduce the vol-
ume of air entering the combustion chamber and thus
increasing its pressure. The CO2improves and the
adhesion of the flame to the diffuser tends to reduce.
(This setting is not advisable for ignitions at low tem-
peratures).
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:
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 sched-
ule (3);
– mount the cover, simply by means of the upper
screw;
– check smoke number;
– should it become necessary to modify the air out-
put, remove the cover by loosening the screw,
adjust the air damper, remount the cover and
finally recheck the smoke number.
NOTE: When the burner works at a firing rate
higher than 9 kg/h remove the panel
fitted inside the metal cover.
(See
figure).
1
2 3
6
D5671
3
PANEL
S7350

2508 8
PUMP PRESSURE AND AIR OUTPUT
The burner is provided with an hydraulic device controlled by the economizer which reduces to
approx. 70% the max. output of gas oil and air.
1st STAGE ADJUSTMENT
Adjustment of air shutter: place the small plug (9) of the economizer (10) into the position I
(Item A) . In this way the burner will remain permanently in the 1st stage.
Unloosen the nut (2), turn the screw (3) until the air shutter (1) reaches the position desired.
Then lock the nut (2).
Pressure regulation: this is set at 7 bar at the factory.
Should such pressure be reset or changed, just turn the screw (4). The pressure gauge must be
mounted in place of cap (5).
2nd STAGE ADJUSTMENT
Adjustment of air shutter: place the small plug (9) of the economizer (10) into the position II
(Item B) . In this way the burner remains permanently in the 2nd stage.
Unloosen the nut (6), turn the screw (7) until the air shutter (1) reaches the position desired. Then
lock the nut (6).
Pressure regulation: this is set at 11 bar at the factory.
Should such pressure be reset or changed, just turn the screw (8). The pressure gauge must be
mounted in place of cap (5).
S7347
S7346
II - I
II
I
9
II - I
II
I
9
Item A Item B

2508 9
ELECTRODE SETTING
BURNER START-UP CYCLE
ECONOMIZER
This economizer showed in fig. on the right can be wired to a
2nd stage thermostat; in this case it performs two functions:
1. Delay of 5 - 6 seconds in the intervention of the 2nd stage valve
against 1st stage valve.
2. In relation of the position of the plug A, it determines the type of
required operation:
4±0.3 mm
D6120 A4.5 ±0.5 mm
MOVE THE ELECTRODE
HOLDER BACKWARDS TO
THE END
Attention:
Before assembling or remov-
ing the nozzle, loosen the
screw (A) and move the elec-
trodes ahead.
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
1st stage valve
2nd stage valve
Lock-out lamp ~12s D5810
~12s ~5s~5s
S7355
II - I
II
I
II - I
II
I
II - I
II
I
Position I - II =Burner operation in 1st or 2nd stage on request
of the 2nd stage thermostat.
Position II =Burner operation only in 2nd stage - compulsorily.
Position I=Burner operation only in 1st stage - compulsorily.
A