Riello P 140 T/G Quick start guide

Istruzioni per installazione, uso e manutenzione
Montage und Bedienungsanleitung
Instructions pour installation, utilisation et entretien
Installation, use and maintenance instructions
2915890 (8) - 06/2012
Bruciatori di gasolio
Öl-Gebläsebrenner
Brûleurs fioul
Light oil burners
Funzionamento tristadio
Dreistufig
Three-stage operation
Fonctionnement à 3 allures
CODE MODELLO - MODELL
MODELE - MODEL
TIPO - TYP
TYPE
3476821 - 3476823 P 140 T/G 476 M1
3476822 - 3476824 P 140 T/G 476 M1
3477721 - 3477723 P 200 T/G 477 M1
3477722 - 3477724 P 200 T/G 477 M1
3478831 - 3478837 P 300 T/G 478 M1
3478832 - 3478838 P 300 T/G 478 M1
3478833 - 3478839 P 300 T/G 478 M1
3478834 - 3478840 P 300 T/G 478 M1
3478835 - 3478841 P 300 T/G 478 M1
3478836 - 3478842 P 300 T/G 478 M1
3479331 - 3479336 P 450 T/G 479 M1
3479332 - 3479337 P 450 T/G 479 M1
3479333 - 3479338 P 450 T/G 479 M1
3479334 - 3479339 P 450 T/G 479 M1
I
D
F
GB

46
1. BURNER DESCRIPTION
1.1 STANDARD EQUIPMENT
* For versions with star-delta starting
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . N° 2
Nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 2
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 4
Gasket for flange . . . . . . . . . . . . . . . . . . . . . . . N° 1
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 3
Fairleads * . . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 1
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 4
Extensions ( P 300 T/G, P 450 T/G: for
long head only) . . . . . . . . . . . . . . . . . . . . . . . . . . N° 2
Diffuser disc (P 450 T/G) . . . . . . . . . . . . . . . . . . N° 1
1 - Suction line
2 - Return line
3 - Pump pressure adjustment screw
4 - Manometer plug
(G 1/8 for P 140 T/G and P 200 T/G;
G 1/4 for P 300 T/G and P 450 T/G)
5 - Vacuometer plug
(G 1/2 for P 140 T/G and P 200 T/G;
G 1/4 for P 300 T/G and P 450 T/G)
6 - Reset-push-button of the motor
(P 140 T/G, P 200 T/G, P 300 T/G)
7- Terminalstrip
8 - Control box reset push-button and lock-out lamp
9 - Fairleads
10 - Ignition transformer
11 - Rugulating bush for combustion head
12 - Valves group with hydraulic jacks
13 - Electric board
13
2
3
1
5 4
12
7
9
8
11
106
12
1
3
4
5
2
6
7
8
9
10 11
P 140 T/G - P 200 T/G
S8360
S8359
P 300 T/G - P 450 T/G
Fig. 1

47
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 ELECTRICAL DATA
MOTOR IE1
* Only with star-delta starter for P 450 T/G burner model
MODEL P 140 T/G P 200 T/G P 300 T/G P 450 T/G
TYPE 476 M1 477 M1 478 M1 479 M1
THERMAL POWER 380÷1660 kW 557÷2370 kW 710÷3560 kW 890÷5340 kW
OUTPUT 32÷140 kg/h 47÷200 kg/h 60÷300 kg/h 75÷450 kg/h
OPERATION 1 stage - 2 stage - 3 stage
FUEL Light oil, max. viscosity at 20 °C: 6 mm2/s (1,5 °E)
IN CONFORMITY WITH EC DIREC-
TIVES
2004/108 - 2006/95 - 2006/42
APPROVAL 0441/B (according to Machine Directive 2006/42/EC)
MODEL P 140 T/G P 200 T/G P 300 T/G P 300 T/G
CODE 3476821-3476823
3476822-3476824
3477721-3477723
3477722-3477724
3478831-3478837
3478832-3478838
3478833-3478839
3478834-3478840
3478835-3478841
3478836-3478842
ELECTRICAL SUPPLY 3N ~ 50 Hz 400 V
3 ~ 50 Hz 230 V
MOTOR * 13.5 A / 230 V
8 A / 400 V
14 A / 230 V
8.1 A / 400 V
30 A / 230 V
17.5 A / 400 V
17.5 A / 400 V
10.1 A / 690 V
IGNITION TRANSFORMER Prim.: 2 A - Sec.: 2 x 6.5 kV - 35 mA
ABSORBED ELECTRICAL POWER 5.3 kW 5.4 kW 11.2 kW 11.2 kW
ELECTRICAL PROTECTION IP 40 in accordance with EN 60529 (IEC 529 - 1989)
MODEL P 450 T/G P 450 T/G
CODE 3479331-3479336
3479332-3479337
3479333-3479338
3479334-3479339
ELECTRICAL SUPPLY 3N ~ 50 Hz 400 V
3 ~ 50 Hz 230 V
MOTOR * 50.2 A / 230 V
29 A / 400 V
29 A / 400 V
16.7 A / 690 V
IGNITION TRANSFORMER Prim.: 2 A - Sec.: 2 x 6.5 kV - 35 mA
ABSORBED ELECTRICAL POWER 18.7 kW 18.7 kW
ELECTRICAL PROTECTION IP 40 in accordance with EN 60529 (IEC 529 - 1989)

48
MOTOR IE2
* Only with star-delta starter for P 450 T/G burner model
MODEL P 140 T/G P 200 T/G P 300 T/G P 300 T/G
CODE 3476821-3476823
3476822-3476824
3477721-3477723
3477722-3477724
3478831-3478837
3478832-3478838
3478833-3478839
3478834-3478840
3478835-3478841
3478836-3478842
ELECTRICAL SUPPLY 3N ~ 50 Hz 400 V
3 ~ 50 Hz 230 V
MOTOR * 13.5 A / 230 V
7.8 A / 400 V
13.5 A / 230 V
7.8 A / 400 V
29.3 A / 230 V
16.9 A / 400 V
16.9 A / 400 V
9.7 A / 690 V
IGNITION TRANSFORMER Prim.: 2 A - Sec.: 2 x 6.5 kV - 35 mA
ABSORBED ELECTRICAL POWER 5.2 kW 5.3 kW 10.9 kW 10.9 kW
ELECTRICAL PROTECTION IP 40 in accordance with EN 60529 (IEC 529 - 1989)
MODEL P 450 T/G P 450 T/G
CODE 3479331-3479336
3479332-3479337
3479333-3479338
3479334-3479339
ELECTRICAL SUPPLY 3N ~ 50 Hz 400 V
3 ~ 50 Hz 230 V
MOTOR * 46.8 A / 230 V
27 A / 400 V
26.6 A / 400 V
15.4 A / 690 V
IGNITION TRANSFORMER Prim.: 2 A - Sec.: 2 x 6.5 kV - 35 mA
ABSORBED ELECTRICAL POWER 17.3 kW 17.3 kW
ELECTRICAL PROTECTION IP 40 in accordance with EN 60529 (IEC 529 - 1989)

49
2.3 DIMENSIONS
* It is possible with a spacer upon request
mm A B C D E F G H I L
P 140 T/G 765 365 890 253*-363-473 222 467 230 260 225 M14
P 200 T/G 795 396 890 281*-391-501 250 467 - 260 255 M16
P 300 T/G 858 447 1000 314*-444-574 295 496 - 260 300 M18
P 450 T/G 950 508 1070 346*-476-606 336 525 - 310 350 M20
Burner
Boiler front-plate
drilling

50
2.4 OPERATION AND EFFICIENCY OF THE BURNER
ACCESSOIRES
RADIO DISTURBANCE PROTECTION KIT: Code 3010386
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m) ow-
ing to the presence of an INVERTER, or in applications where the length of the thermostat connections exceeds 20
metres, a protection kit is available as an interface between the control box and the burner.
POWER AND OUTPUT
P 140 T/G
3rd STAGE MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle : 1st stage of operation 380 32 545 46
1st + 2nd nozzle : 2nd stage of operation 664 56 1103 93
1st + 2nd + 3rd nozzle : 3rd stage of operation 830 70 1660 140
POWER AND OUTPUT
P 200 T/G
3rd STAGE MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle : 1st stage of operation 557 47 794 67
1st + 2nd nozzle : 2nd stage of operation 1067 90 1576 133
1st + 2nd + 3rd nozzle : 3rd stage of operation 1186 100 2372 200
POWER AND OUTPUT
P 300 T/G
3rd STAGE MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle : 1st stage of operation 712 60 1186 100
1st + 2nd nozzle : 2nd stage of operation 1245 105 2372 200
1st + 2nd + 3rd nozzle : 3rd stage of operation 1779 150 3558 300
POWER AND OUTPUT
P 450 T/G
3rd STAGE MINIMUM MAXIMUM
kW kg/h kW kg/h
1st nozzle : 1st stage of operation 890 75 1780 150
1st + 2nd nozzle : 2nd stage of operation 1780 150 3560 300
1st + 2nd + 3rd nozzle : 3rd stage of operation 2670 225 5340 450

51
2.5 FIRING RATES (in accordance with DIN 4787)
Combustion chambre pressure - Maximum output
(three nozzles in operation)
When the burner operates with only one, or two nozzles, the pressurizzation conditions are improved and no
problems arise.
DIMENSIONS OF THE TESTING COMBUSTION CHAMBRE (ISO 5063 - 1978)
D- Boiler diameter (cm)
P- Position of the boiler movable wall (m)
For the combustion head projection carefully
follow the boiler manufacturer indications.
A proper protection with refractory material
on the combustion chamber shall be made,
when boilers with frontal smoke box are
used.
mbar
kg/h
kW
D
P

52
3. HYDRAULIC SYSTEMS
Pay attention to do not overcome the max. depression of
0.45 bar (35 cm Hg), over this value the fuel may turn into gas.
Check the pipes are perfectly sealed.
When the fuel tank is under the burner level we suggest to
let the return line arrive where the suction line starts. In this
case the foot valve is not necessary.
Should the return line arrive over the fuel level, the foot
valve is indispensable. Notice that this solution is less safe
than the previous one, because it is possible the valve has
not a good sealing.
H= Difference in the pipes heights;
L= Total lenght of the suction tube;
øi= Internal diameter of the tube. Copper tubes øi14 mm
could be replaced by steel tubes G 1/2” ; copper tubes
øi16 and 18 mm could be replaced by steel tubes
G 3/4 ”.
H
meters
P 140-200-300 T/G P 450 T/G
L meters L meters
øi øi øi øi
14 mm 16 mm 16 mm 18 mm
020402040
0,525452545
130503050
1,535553555
240604060
H
meters
P 140-200-300 T/G P 450 T/G
L meters L meters
øi
14 mm
øi
16 mm
øi
16 mm
øi
18 mm
050602040
0,540501835
130401530
1,520301325
210201020
35 10 5 10
PUMP PRIMING:
Loose the tap from the vacuometer plug (5, fig.1)
and wait for the flow of the fuel.
H
max. 10 m
Before placing the burner in operation,
ensure that the return line is open. Any
obstruction may demage the pump seal.
ATTENTION:
H
max 10 m
H
PUMP PRIMING:
Fill the pump with the light oil
from the vacuometer plug
(5, fig.1), put the burner in
operation, purge the air from the
manometer plug (4, fig.1) and.
wait for the pump priming.
If lock-out occurs repeat the
procedure

53
4. ELECTRICAL SYSTEM
4.1 ELECTRICAL SYSTEM FACTORY-SET
KEY TO LAYOUTS (A) - (B)
CMV - Motor contactor
CO - Commutator
FR - Photocell
h1,2,3 - 1., 2., 3. stage hourconters
L1,2,3 - 1., 2., 3. stage lamps
L4 - Lock-out motor lamp
MB - Burner terminal strip
MV - Fan motor
RT - Thermal relay
TA - Ignition transformer
TB - Burner ground (earth)
connection
VS - Safety solenoid valve
V1,2,3 - 1., 2., 3. stage solenoid valves
KEY TO LAYOUT (C)
F1 - Power line fuses
F2 - Control devices fuse
F3 - Thermal relay - Factory calibra-
tion at:
P 300 T/G: 10.2 A for 400 V
17.6 A for 230 V
P 450 T/G: 16.7 A for 400 V
29 A for 230 V
KL1 - Line Contact-maker
KS1 - Star Contact-maker
KST1- Timer relay for switching from
star to delta (factory calibration
at 10 s.)
KT1 - Delta Contact-maker
MA - Starter terminal strip
Q1 - Disconnecting switch with
interlock
20049884
P 300 - 450 T/G STAR-DELTA MOTOR STARTING
P 140 - 200 - 300 T/G DIRECT MOTOR STARTING
STAR-DELTA STARTER
(A)
(B)
(C)
D2567
D2569

54
4.2 ELECTRICAL CONNECTION TO THE TERMINAL STRIP
(installer-set)
LAYOUT (A) - Electrical connection P 140-200-300 T/G
burners with direct motor starting
Cables cross-section
LAYOUT (B) - Electrical connection P 300-450 T/G burners
with star-delta motor starting
Cables cross-section
KEY TO LAYOUTS (A) - (B)
I1 - Burner manual stop switch
MA - Star-delta starter terminal strip
MB - Burner terminal strip
PS - Reset push-button
S - Remote lock-out signal
TL - Load limit remote control system:
shut down the burner when the boiler
temperature or pressure reaches the
maximum preset value
TS - Safety load control system:
operateds when TL is faulty
T2 - 2nd stage load control system
T3 - 3rd stage load control system
SCHEMA (C) - Calibration of thermal relay
This is required to avoid motor burn-out in the
event of a significant increase in power
absorption caused by a missing phase.
• If the motor is star-powered, 400 V, the cursor
should be positioned to “MIN”.
• If it is delta-powered, 230 V, the cursor should
be positioned to “MAX”.
If the scale of the thermal relay does not include
rated motor absorption at 400 V, protection is
still ensured.
NOTE
In systems where the run of wiring connecting
the thermostat exceeds 20 metres in length, or
in places where the burner is subject to particu-
larly disturbing electromagnetic interference
(over 10 v/m), you must insert the relay-inter-
face kit item number 3010386.
P 140 T/G P 200 T/G P 300 T/G
230 V 400 V 230 V 400 V 230 V 400 V
FAgG/gL252540256350
Lmm22,5 2,5 4 2,5 6 4
P 300 T/G P 450 T/G
230 V 400 V 230 V 400 V
FAgG/gL50406350
Lmm264106
Emm242,56 4
P 140 - 200 - 300 T/G
DIRECT MOTOR STARTING
D2568
(C)
THERMAL RELAY
(B)
P 300 - 450 T/G
STAR-DELTA MOTOR STARTING
(A)
Check the lock-out by darkening the
photo-cell after removal of the cover.
ATTENTION: HIGH VOLTAGE
Important:
D2570

55
5. CHOICE OF NOZZLES, PUMP PRESSURE,
COMBUSTION HEAD ADJUSTMENT
•State, first of all, the maximum output required with all three nozzles in
operation.
•On the base of the maximum required output, choose, from table A, three
related nozzles.
Use nozzles with a 60° spray angle at the recommended pressure of 12 bar.
For three-stage operation, up to:
- 116 kg/h (P 140 T/G)
- 170 kg/h (P 200 T/G)
- 193 kg/h (P 300 T/G)
1st and 2nd nozzle are not equal to the 3rd one. Follow this procedure in order to obtain higher values of CO2
(during 1st and 2nd stage of operation), complying with German Standard DIN.
THREE-STAGE OPERATION SUGGESTED NOZZLES:
*The pump pressure is referred to all three nozzles operating, the pressure increases automatically with two
nozzles in operation and more with only one.
NOZZLES 60° TOTAL NOZZLES 60° TOTAL
PUMP 12 BAR *DELIVERY PUMP 12 BAR *DELIVERY
GPH kg/h GPH kg/h
1° 2° 3° 1°+2°+3° 1° 2° 3° 1°+2°+3°
6,5 6,5 3,5 71,1 10 10 5 107,3
7 7 4 77,2 10,5 10,5 5 111,7
7,5 7,5 4 81,6 10,5 10,5 6 115,9
8 8 4 85,8 11 11 6,5 122,3
8,3 8,3 4 88,4 12 12 6,5 130,9
8,5 8,5 4,5 92,3 12 12 7,5 135,2
9 9 5 98,7 13 13 7,5 143,8
9,5 9,5 6 107,4 13,8 13,8 7,5 150,7
9,5 9,5 8 115,9 13,8 13,8 10 161,3
9,5 9,5 9,5 122,4 13,8 13,8 12 169,9
10 10 10 128,7 13,8 13,8 13,8 177,6
10,5 10,5 10,5 135,3 14 14 14 180,3
11 11 11 141,6 15 15 15 193,2
15,3 15,3 15,3 197,1
1°
2° 3°
A
P 140 T/G P 200 T/G

56
Rated nozzles delivery are shown in the table. The real
nozzle delivery may vary from the rated one up to ± 5%,
its detection is made by weighing the oil sprayed out
from the nozzle inserted in a tube. The pump leaves the
factory rated at 12 bar. Pay attention to not overcome
the pump pressure values of 10 and 14 bar.
At the end, on the base of the maximum output, you
obtain the combustion head adjustment from the dia-
gramm D.
The adjustment should be made by turning the screw A till the
set-point (see diagram) is on the line with the washer B (Fig. C).
NOTE (for P 450 T/G only):
depending on the desired output, you can use the
ready-fitted standard-issue diffuser disc or the disc
supplied (see diagram B). To replace the diffuser disc,
proceed as follows (Fig. D):
-unscrew screws 1);
-slide the ventilating part back on pins 2);
-first unscrew screws 3), then replace diffuser disc;
-refit all parts following the above procedure in reverse
order.
NOZZLES 60° TOTAL NOZZLES 60° TOTAL
PUMP 12 BAR * DELIVERY PUMP 12 BAR *DELIVERY
GPH kg/h GPH kg/h
1° 2° 3° 1°+2°+3° 1° 2° 3° 1°+2°+3°
13,8 10,5 10,5 149,4 17,5 17,5 17,5 225,3
13,8 11,0 11,0 153,6 18 18 18 231,9
13,8 12,0 12,0 162,2 19 19 19 244,8
14,0 13,0 13,0 171,7 19,5 19,5 19,5 251,1
15,3 13,8 13,8 184,1 20,0 20,0 20,0 257,7
15,0 14,0 14,0 184,6 21,5 21,5 21,5 276,9
15,0 15,0 15,0 193,2 22,0 22,0 22,0 283,2
15,3 15,3 15,3 197,1 24,0 24,0 24,0 309,0
16,0 16,0 16,0 206,1 26,0 26,0 26,0 334,7
17,0 17,0 17,0 219,0 28,0 28,0 28,0 360,5
17,5 17,5 17,5 225,3 30,0 30,0 30,0 386,3
18,0 18,0 18,0 231,9 32,0 32,0 32,0 412,0
19,0 19,0 19,0 244,8 35,0 35,0 35,0 450,6
19,5 19,5 19,5 251,1
*The pump pressure is referred to all three
nozzles operating, the pressure increases auto-
matically with two nozzles in operation and more
with only one.
20,0 20,0 20,0 257,7
21,5 21,5 21,5 276,9
22,0 22,0 22,0 283,2
24,0 24,0 24,0 309,0
P 300 T/G P 450 T/G
Combustion head adjustment (set-point N°)
Maximum output kg/h
P 450: 1) With diffuser disc ø 192 (standard issue ready fitted
)
P 450: 2) With diffuser disc ø 215 (supplied)
Set-point 6
C
D3419
B
D3422

57
6. AIR DAMPER ADJUSTMENT
The air dampers adjustment shall be set each time in relation with the nozzles delivery and the combustion chamber
pressurization.
Fig. 2 shows the placement of the air dampers as fig. 3 their correspondent hydraulic jacks.
To open or close the air dampers proceed as follows:
loose the ring nut 1), turn clockwise the exagonal body 2) in order to decrease the air flow,
and counterclockwise to increase it.
The right adjustment of the air dampers may be detect by checking the combustion results
in the three stages of burner operation.
To check the combustion during the different stages, the commutator should be set to the
position corresponding to the burner stage to be controlled.
7. ELECTRIC PANEL
HOURCOUNTER
Deducting the number of hours of 2nd nozzle hourcounter from those indicated in the 1st nozzle hourcounter you
could know how many hours the burner has been performing only at 1st stage; the same procedure to detect the per-
formance hours of the 2nd stage alone, deduct from the 2nd stage hourcounter the hours indicated in the 3rd nozzle
hourcounter.
The hours of 3rd stage operation are shown rightly on the 3rd nozzle hourcounter.
COMMUTATOR
Pos. 0: Burner stop
Pos. 1: Burner operation only at 1st stage
Pos. 2: Burner operation at 1st and 2nd stage
Pos. 3: Burner operation at 1st, 2nd, 3rd stage
MOTOR LOCK-OUT
It is caused by the overload relay in case of overload or no electic supply.
Release by pressing the pushbutton on thermal relay.
1st stage air damper
2nd stage air damper
3rd stage air damper
3rd stage hyd. jack
2nd stage hyd. jack
1st stage hyd. jack
Fig. 2 Fig. 3
2nd nozzle hourcounter with operation signal
1st nozzle hourcounter with operation signal
3rd nozzle hourcounter with operation signal
Motor lock-out signal
4 positions commutator
Control box lock-out signal with re-set
push-button

58
8. ELECTRODES ADJUSTMENT
9. BURNER OPERATION
9.1 BURNER START UP CYCLE
ALTERNATIVE START-UP CYCLES
1) If you desire the pre-ignition being present during the complete pre-purge phase (37 s): remove the bridge from
the terminals 11 - 3 and put it on the terminals 11 - 7 of the control box.
2) If you desire to reduce the pre-purge period from 37 to 20 s (with contemporaneus presence of the pre-ignition)
remove the wire from the terminal no. 7 to the no. 3 of the control box (maintaining the bridge to the terminals
11 - 3).
THREE STAGE OPERATION
15 mm
4 mm
D11353
The measures must be respected.
WARNING
Normal Lock-out because of no ignition
Thermostat
Motor
Ignition transformer
Safety valve
1st flame valve
2nd flame valve
3rd flame valve
Lock-out signal
D2896
max
0
3
rd
stage
2
nd
stage
1
st
stage

59
10.BURNER START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the followin table:
11.OPERATING FAULT DIAGNOSTICS
The control box has a self-diagnostic system, which easily allows identifying the
operating faults (RED LED signal).
ITo use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a minimum of 3 sec-
onds.
After releasing the button, the RED LED starts flashing as shown in the diagram below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will provide the information on the possible faults, according to the table below:
COLOUR CODE TABLE
Sequences Colour code
Pre-purging OOOOOOOOOOO
Ignition phase OPOPOPOPOPO
Operation, flame ok TTTTTTTTTTTT
Operating with weak flame signal TPTPTPTPTP
Electrical supply lower than ~170V OVOVOVOVOVO
Lock-out VVVVVVVVVV
Extraneous light VTVTVTVTVTV
Key: POff OYellow vGreen VRed
SIGNAL PROBABLE CAUSE
2 flashes The flame does not stabilise at the end of the safety time:
– faulty photocell;
– faulty or soiled light-oil valves;
– neutral/phase exchange;
– faulty ignition transformer
– poor burner regulation (insufficient light oil).
3 flashes – Not used.
4 flashes – Not used.
7 flashes Loss of flame during operations:
– poor burner regulation (insufficient light oil);
– faulty or soiled light oil valves;
– short circuit between photocell and earth.
8 flashes – Oil enabling thermostat fault;
– Break in heating elements.
10 flashes – Wiring error or internal fault;
– Presence of electromagnetic disturbance: use the radio disturbance protection kit
RED LED on
wait at least 10 s
Press button
for > 3 s Signal Signal
Interval
3 s