Riello G3BF 490T53 Quick start guide

2902136 (6)
Installation, use and maintenance instructions
Kerosene burners
One stage operation
CODE MODEL TYPE
3749053 G3BF 490T53
3749257 G5BF 492T57
3748953 G5BF 489T53

2136
1
TECHNICAL FEATURES
TYPE - Boiler Model 490T53 – 50 / 70 492T57 – 70 / 90 489T53 – 90 / 120
Thermal power – output
(with air at 20
°
C)
19 – 35 kW 17 – 42 kW 28 – 60 kW
1.6 – 3 kg/h 1.5 – 3.5 kg/h 2.3 – 5 kg/h
Fuel kerosene, 28 sec.
Electrical supply single phase, 230V
± 10%
~
50Hz
Motor run current 0.85A – 2850 rpm – 298 rad/s
Capacitor 4
m F
Ignition transformer secondary, 8 kV – 16 mA
Pump maximum pressure 14 bar (203 psi)
Absorbed electrical power 0.15 kW 0.16 kW 0.16 kW
◆
B
urner w
i
t
h
CE
mar
ki
ng
i
n con
f
orm
i
ty w
i
t
h
EEC
di
rect
i
ves:
EMC89/336/EEC
,
L
ow
V
o
l
tage
73/23/EEC
,
Machines 89/392/EEC and Efficiency 92/42/EEC.
◆The intake air temperature must not be over 70°C.
◆The burner meets protection level of IP 54, EN 60529.
◆Kit for two pipes system code 3000970
410
8
12
10 – Relief valve
11 – Air socket from the outside
12 – Combustion head adjustment screw
1– Suction line
2– Gauge connection
3– Pump pressure regulator
4– Vacuum gauge connection
5– Air-damper
6– Regulating air-damper rod
7– Lock-out lamp and reset button
8– Flange with insulating gasket
9– Wiring loom fitting
Fig. 1
11
D5422
1
3
7
6
2
5
9
489T53
490 T53 - 492T57
D5423

2136
2
EQUIPMENT
DIMENSIONS
MOUNTING THE BURNER
Quantity Description
1
1
1
2
Flexible pipe with nipple
Flange with insulating gasket
Screw with two nuts for flange
Nuts for flange
TYPE A B C D E F G H I
490T53 271 249 288 193 90 93 207 75 21
492T57 271 249 288 191 90 93 226 75 26
489T53 271 249 288 191 89 79 237 75 37
Flange Burner
C F G
130
I
45°
øE
A
11
D
D5305
180
72 72
150
45°
øH
B
It is necessary that the insulating gasket (A) is
placed between the boiler door and the burner
flange.
D5306
A
BURNER FIXING
S7386

2136
3
WORKING RANGE
(as EN 267)
0.8
0
0.4
Pressure in the combustion
chamber – mbar
2 2.5 3 Fuel output - kg/h
20 40 Thermal power - kW
D5426 25 30 35
0.2
0.6
0.6
0
0.2
0.4
Pressure in the combustion
chamber – mbar
1.5 2 2.5 Fuel output - kg/h
20 25 30 Thermal power - kW
D5425
0.8
0
0.4
Pressure in the combustion
chamber – mbar
2 3 4 5 Fuel output - kg/h
25 30 60 Thermal power - kW
D5226 35 40 45 50 55
0.2
0.6
489T53
2.3
3
35
492T57
490T53
1.5 3.5
0.8

2136
4
OIL LINES
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
PRIMINGTHE PUMP
Loosen the plug of the vacuum gauge (4, fig. 1, page 1)
and wait until the fuel flows out.
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
max. 4 mH H
max. 4 m
min. 0.1 m
D5307
D5308
H
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 tan
k
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 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.
WARNING: Before starting the burner make sure that the return pipe-line is not clogged: an
y
obstruction would cause the pump seals to break.
■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.
WARNING
A
D5199
The pump is supplied for use with a one pipe system.
For use on a two pipes system, it is necessary to screw the
BY-PASS SCREW (A) supplied with kit code 3000970.
WARNING
H=Difference of level.
L= Max.length of the suction line.
I.D.=Internal diameter of the oil pipes.

2136
5
BURNER ELECTRICAL WIRING
Brown
White (50V)
Blue
Motor
Capacitor
Regulating thermostat
Neutral
Switch with fuse
6A max.
NL
M
~
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-
transformer) 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
N L
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
T
T
D5228
Black
RUN OF THE ELECTRICAL CABLE
1- Terminal block N- Neutral
L- Phase
- Burner-earth
A
1S7130

2136 6
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 com-
bustion head for type 489 T53) and the air damper opening in accordance with the following schedule.
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.
NOZZLES RECOMMENDED: Monarch type R - NS ; Delavan type W - A - E - B
Steinen type Q - H ; Danfoss type B - H - S
Angle: 60°- in most cases.
80°- in case of flame detachment, during ignitions at low temperatures.
PRESSURE: 8bar : the pump leaves the factory set at this value.
10bar : maximum pressure for kerosene.
TYPE
Nozzle Pump pressure Burner
output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ±4% Set-point Set-point
490T53
0.50 60°8 1.5 2.5
0.60 60°8 1.7 3.0
0.65 60°8 1.9 3.3
0.75 60°8 2.2 3.9
0.85 60°8 2.5 4.2
1.00 60°8 2.9 6.0
1.00 60°9 3.0 8.0
For 1.00 GPH nozzles it is advisable to use , if possible, full cones.
492T57
0.50 60°8 1.5 2.2
0.60 60°8 1.7 2.4
0.65 60°8 1.9 2.6
0.75 60°8 2.2 3.0
0.85 60°8 2.5 3.2
1.00 60°8 2.9 3.9
1.10 60°8 3.4 5.2
For 1.00 - 1.10 GPH nozzles it is advisable to use , if possible, full cones.
489T53
0.75 60°8 2.2 0 2.8
0.85 60°8 2.5 0.5 3.0
1.00 60°8 2.9 1.5 3.2
1.10 60°8 3.2 2.0 3.5
1.25 60°8 3.7 3.0 4.0
1.35 60°8 4.0 4.0 4.2
1.50 60°8 4.4 5.0 4.9
1.50 60°10 5.0 6.0 6.5
1 2 3
4
1
2

2136 7
THE BURNERS LEAVE THE FACTORY SET AT THESE VALUES
COMBUSTION HEAD SETTING (Only type 489T53)
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.
In the sketch below, the combustion head is set for an output of 1.25 GPH at 8 bar
.
The shutter is level with set-point 3, as required by the schedule at page 6.
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:
TURNTOTHE RIGHT : (sign +)
In order to increase the volume of air entering the combustion chamber and thus diminishing its pres-
sure.
There is a reduction of CO2and the adhesion of the flame to the air diffuser disc improves. (Setting
advisable for ignitions at low temperatures).
TURNTOTHE LEFT : (sign –)
In order to reduce the volume 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 temperatures).
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.
TYPE Nozzle Pump
Pressure Comb. head adjustment Air damper adjustment
bar Set-point Set-point
490T53 Danfoss 0.60 GPH - 80°H 8 – 3.8
492T57 Danfoss 0.75 GPH - 80°H 8 – 4.0
489T53 Danfoss 1.00 GPH - 80°H 8 2.5 3.9
3
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
1
2 3
6
D5232 D5233
2
135

2136 8
AIR DAMPER ADJUSTMENT
The air-output setting can be carried out acting with the rod
(2) on the screw (1) that makes the air-damper (3) turn.
Further retouchs can be carried out without removing the
cover but unscrewing the plug (A) as shown in the figure on
the below.
ELECTRODE SETTING
BURNER START-UP CYCLE
31
2
3
D5141
Turn to the right (sign +) to increase the
air quantity in the combustion chamber,
turn to the left (sign –) to decrease it.
S7021
Attention:
Before assembling or removing the
nozzle, loosen the screw (A) and
move the electrodes ahead.
2 – 2.5 mm
4±0.3 mm
D5230 A
MEASURES
MUST BE RESPECTED
WARNING
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s