Riello G5 444T50 User manual

2902381 (2)
Installation, use and maintenance instructions
Light oil - kerosene burners
One stage operation
CODE MODEL TYPE
3744451 G5 444T50
3744452 G5 444T50

2381
1
TECHNICAL DATA
■Burner with CE marking in conformity with EEC directives: EMC89/336/EEC, Low Voltage 73/23/EEC,
Machines 89/392/EEC and Efficiency 92/42/EEC
■The burner meets protection level of IP 40, EN 60529.
Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h
Fuel Light oil 35s, max. viscosity at 20 °C: 6 mm2/s
Kerosene 28s
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 0.85A – 2850 rpm – 298 rad/s
Capacitor 4 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Maximum pressure 14 bar (203 psi)
Absorbed electrical power 0.16 kW
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– Lock-out lamp and reset button
9– Flange with insulating gasket
10 – Combustion head adjustment screw
BURNER EQUIPMENT
Quantity Description
1
1
2
1
1
1
1
Flexible pipe with nipple
Flange with insulating gasket
Screws and nuts for flange
Hinge
Screw of pump by-pass
Grommet
Screw with two nuts for flange
Fig. 1
5
D5553 12
3
4
86
6
7
9
10

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FIRING RATE, (as EN 267)
OVERALL DIMENSIONS
MOUNTING THE BURNER
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
2,3
272 76 236
130
=
37
45°
ø89
233
11
180
D5554
=
180
75 72
150
45°
Flange Burner
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
S7384

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3
OIL LINES
WARNING
The pump is supplied for use with
a one pipe system. For use on a two pipe system, it
is necessary to screw the by-pass screw (A) sup-
plied as burner’s accessory. (See figure).
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.
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 possi-
bility of leakage of the valve.
WARNING:
◆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.
PRIMING THE 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.
W
arning: before starting the burner make sure that the return pipe-line is not clogged: any obstruc-
tion would cause the pump seals to break.
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
PRIMING THE PUMP
Loosen the plug of the vacuum
gauge (5, fig. 1) and wait until the
fuel flows out.
A
H
meters
Lmeters
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
H max. 4 m
H
H
max. 4 m
min. 0.1 m
D5219
D5220
D5199
H=Difference of level.
L=Max.length of the
suction line.
I.D.=Internal diameter of the
oil pipes

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ELECTRICAL WIRING
Brown
White (50V)
Blue
Motor
Capacitor
Regulating thermostat
Neutral
Switch with fuse
6A max.
NL
M
~
S7026
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-trans-
former) 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
NL
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
RUN OF THE ELECTRICAL CABLE
1- Cable gland N- Neutral
2- Cable-clamp L- Phase
3- Terminal block - Burner-earth
A321
D5228
Black

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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
combustion head and the air damper opening in accordance with the following schedule.
LIGHT OIL FUEL
KEROSENE FUEL
NOZZLES RECOMMENDED: Monarch type R - NS ; Delavan type W -A - E
Steinen type Q - H ; Danfoss type B - H
Angle: 60° - in most cases.
80° - in case of flame detachment, during ignitions at low temperatures.
PRESSURE:
8 bar: the pump leaves the factory set at this value, which is suitable only for kerosene.
10 bar: maximum pressure for kerosene.
FOR LIGHT OIL INCREASE PRESSURE
12 bar: in most cases.
14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.
1 2 34
Nozzle Pump pressure Burner output Comb. head
adjustment
Air damper
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.60 60°/80° 12 2.6 1.5 2
0.65 60°/80° 12 2.8 2 2.2
0.75 60° 12 3.2 2.5 2.5
0.85 60° 12 3.7 3 3
1.00 60° 12 4.3 4 4.5
1.10 60° 12 4.8 5 6
1.10 60° 13 5.0 6 7
1 2 34
Nozzle Pump pressure Burner output Comb. head
adjustment
Air damper
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.75 60° 8 2.2 1 2
0.85 60° 8 2.5 1.5 2
1.00 60° 8 2.9 2 2.3
1.10 60° 8 3.2 2.5 2.5
1.25 60° 8 3.7 3 3
1.35 60° 8 4.0 4 4
1.50 60° 8 4.4 5 5
1.50 60° 10 5.0 6 7
1
2

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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 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 0.85 GPH at 12 bar (for light oil) or
1.25 GPH at 8 bar (for kerosene).
The shutter is level with set-point 3, as required by the schedule at page 5.
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 advisable for ignitions at low temperatures).
TURN TO THE LEFT: (SIGN –)
In order to reduce the volume of air entering the combustion chamber and thus increasing its pres-
sure. 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.
3
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5232
2
135
1
23
6
D5551

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AIR DAMPER ADJUSTMENT: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 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 schedule (4);
– 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.
ELECTRODE SETTING
4
4
3
D5550
4
1 2
Attention:
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
2 – 2.5 mm
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230
A

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BURNER START-UP CYCLE
ONLY FOR LIGHT OIL
ADJUSTMENTS, TO AVOID FLAME - DETACHMENT,
AT BURNER - IGNITION
This inconvenience can occur, when the temperature of the light oil decreases below +8 °C.
1) CORRECT POSITIONING OF THE ELECTRODES
2) PUMP - SETTING
When the temperature of the light oil decreases below +8 °C, increase the pressure to 14 bar.
3) COMBUSTION-HEAD SETTING
Regulate the combustion-head one set-point further ahead than indicated in the instructions.
Example: the instructions require to set the combustion-head on set-point 3.
Instead, the setting is made on set-point 4.
4) FAN - AIR DAMPER ADJUSTMENT
Adjust the air damper of the fan, such as to obtain a smoke number not inferior to 1.
(i.e. a combustion with the lowest possible excess-air).
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
~12s D5229 ~12s ~5s
2 – 2.5 mm
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230
A

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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 match-
ing 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, animals and property due to installation, adjustment and maintenance errors or to
improper use.
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
identified thus making any installation or maintenance work potentially dangerous.
BASIC SAFETY RULES
®Children or inexpert persons must not use the appliance.
®Under no circumstances 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.