Riello G3B FIREBIRD 70K Quick start guide

Installation, use and maintenance instructions
2902809 (2) - 05/2011
Kerosene and light oil burners
One stage operation
CODE MODEL TYPE
3743757 G3B FIREBIRD 70K 510 T1K
3743771 G3B FIREBIRD 90K 510 T3K
3743772 G3B FIREBIRD 90D 510 T3K

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INDEX
1. BURNER DESCRIPTION
One stage kerosene and light oil burner.
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . 2
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . 2
2.3 Working field . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . 3
3.1 Mounting the burner . . . . . . . . . . . . . . . . . . 3
3.2 Hydraulic systems . . . . . . . . . . . . . . . . . . . 4
3.3 Electrical wiring . . . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . . 6
4.2 Nozzles recommended . . . . . . . . . . . . . . . 6
4.3 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6
4.4 Electrodes setting . . . . . . . . . . . . . . . . . . . 6
4.5 Air damper adjustment . . . . . . . . . . . . . . . 7
4.6 Burner start-up cycle . . . . . . . . . . . . . . . . . 7
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . 8
5.1 Maintenance position . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9
OBurner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 2004/108/EC, Low
Voltage 2006/95/EC, Machines 2006/42/EC and Efficiency 92/42/EEC.
OCE Certification No.: 0036 0315/01 as 92/42/EEC.
OThe burner meets protection level of IP 40, EN 60529.
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 – Reset button with lock-out lamp
9 – Flange with insulating gasket
10 – Control box
5
D5506
Fig. 1
1
2
3
4
8
6
6
7
9
10
HYDRAULIC JACK OPERATION 7)(Fig. 1)
It is strongly recommended a periodic check of
the pump pressure operation (annually or bet-
ter 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 restora-
ble, please replace the pump, in order to guar-
antee that the pump pressure during the pre-
purge time is at least 3.7 bar.
DANGER

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1.1 BURNER EQUIPMENT
Flange with insulating gasket . . . . . . . . . No. 1 4 pole socket . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screw and nut for flange . . . . . . . . . . . . . No. 4 Cable grommet . . . . . . . . . . . . . . . . . . . . . . No. 1
Flexible pipe with nipple . . . . . . . . . . . . . No. 1 Screw with two nuts for flange . . . . . . . . . . . No. 1
Screw of by-pass pump . . . . . . . . . . . . . . No. 1 4 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
TYPE 510 T1K 510 T3K
Output
Thermal power
1.4 – 2.2 kg/h
16.8 – 26.3 kW
2 – 3 kg/h
24 – 35.9 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 0.7A – 2850 rpm – 298 rad/s
Capacitor 4 F
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 0.115 kW
Flange Burner
252 86 203
130
=
19
45°
215
11
164
D6253
=
180
75 72
150
45°
ø89

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2.3 WORKING FIELD (as EN 267)
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 MOUNTING THE BURNER
Fix the flange (1) to the boiler door using screw and nuts, interposing the insulating gasket (see fig. 2).
The insulating gasket has six holes, which, if necessary, can be modified as shown in the figure 3.
Verify that the installed burner is lightly leaned towards the button (see fig. 4).
The burner is designed to allow entry of the flexible oil-lines on either side of the burner.
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
0.8
0.2
0.4
0.6
510T1K 510T3K
01.2
D4361
1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3
16 18 20 22 24 26 28 30 32 34 36
S7386
Fig. 4
D5242
Fig. 3Fig. 2
1
D5574

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3.2 HYDRAULIC SYSTEMS
H= difference of level; L= Max. lenght of the suction line; I.D. = Interminal diameter of the oil pipes.
F i g . 5
2
3
4
7
6
5
18
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. 6 it is sufficient to loosen the suction gauge connec-
tion (6, fig. 5) and wait until oil flows out.
On the systems in fig. 7 and 8 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. 8) 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
F i g . 6
max. 4 m
H
H
D4348
Fig . 7
D5300
max. 4 m
H
H
Fig. 8
D5299
D5199
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. 5).
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

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3.3 ELECTRICAL WIRING
S7026
CONTROL BOX (see fig. 9)
– To remove the control box from the burner,
loosen screw (A) and pull towards the arrow.
– The photoresistance is fitted directly into the control-
box (underneath the ignition-transformer) on a plug-
in support.
3.4 RUN OF THE ELECTRICAL
CABLE
1- Cable grommet N- Neutral
2- Cable clamp L- Phase
3- Terminal block - Burner-earth
A321
Brown
White (50V)
Blue
Motor
Capacitor
Limit thermostat
Neutral
Main switch
T6A
NL
M
~
Black
WARNING
Do not exchange the neutral with the phase.
230V ~50Hz
NL
Safety thermostat
Remote lock-out signal
(230V - 0.5A max.), if required
123456789
Blue
Brown
Terminal block of
control-box 530SE*
Valve
T
T
D5228
Black
3.5 NOTES
– Wires of min. 1 mm2section.
(Unless requested otherwise by local stand-
ards and legislation).
– The electrical wiring carried out by the
installer must be in compliance with the
rules in force in the Country.
3.6 TESTING
Check the shut-down of the burner by open-
ing the thermostats.
Burner-earth
CARRIED OUT
IN THE FACTORY
Fig. 9

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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, fit the proper nozzle, then adjust the pump pressure 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 NOZZLES RECOMMENDED
Monarch type R - NS; Delavan type W - E; Steinen type Q - H; Danfoss type H - S.
4.3 PUMP PRESSURE
8 bar: pressure suitable for kerosene in most cases.
10 bar: maximum pressure for kerosene.
INCREASE PRESSURE
12 bar: pressure suitable for light oil in most cases.
14 bar: maximum pressure light oil.
4.4 ELECTRODES SETTING, (see fig. 10)
TYPE
Nozzle Pump
pressure Burner output Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point
510 T1K
0.50 60° 7 1.40 1.6
0.50 60° 8 1.50 1.7
0.60 60° 8 1.79 2.2
0.65 60° 8 1.94 2.4
0.75 60° 8 2.20 3.3
510 T3K
0.65 60° 8.5 2.00 2.3
0.75 60° 8 2.24 2.6
0.85 60° 8 2.54 3.4
1.00 60° 8 3.00 8
KEROSENE
LIGHT OIL
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
ATTENTION
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230 A
Fig. 10
2 – 2.5 mm

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4.5 AIR DAMPER ADJUSTMENT, (see fig. 11)
The mobile air damper (1) operated by the jack (2) assures the
complete opening of the air intake.
The regulation of the air-rate is made by adjusting the fixed air
damper (3), after loosing the screws (4). When the optimal
regulation is reached, screw tight the screws (4) to assure a
free movement of the mobile air damper (1).
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 out-
put 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;
– 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.
4.6 BURNER START-UP CYCLE
Fig. 11
4
3
D5550
4
12
Normal
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
~12s D5229 ~12s ~5s
Lock-out due to failure to light
A

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5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conform-
ity 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 BASIC CHECKS ARE:
Leave the burner working without interruption for 10 min., checking the right settings of all the components
stated in this manual.
Then carry out a combustion check verifying:
CO2(%) content Smoke temperature at the chimney CO content (ppm).
5.1 MAINTENANCE POSITION
Insert in the hole (1) the pin (2) and fix the burner with the nut (3) fitted wrong-side up.
312
FLANGE
D5325

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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 gas which is situated inside the reset button of the control box
(8, 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 connections in the control box
are wrongly inserted.
Check and connect completely all the
plugs.
Burner works only in
the prepurge. The photoresistance sees false light. Eliminate the light.
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.

Subject to modifications
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com