Riello R40 G7 140-160 Quick start guide

Installation, use and maintenance instructions
2902374 (5) - 06/2015
Light oil and kerosene burners
One stage operation
CODE MODEL TYPE
3745959 R40 G7 140 - 160 459T55
3745961 R40 G7 160 - 200 459T55
GB

2374 1
TECHNICAL DATA
OThe burner meets protection level of IP 40, EN 60529.
OBurner with CE marking in conformity with EEC Directives: Machine Directive 2006/42/EC, Low Voltage
Directive 2006/95/EC and Electromagnetic Compatibility 2004/108/EC.
TYPE 459T55
Thermal power – output 29 – 69 kW – 2.45 – 5.8 kg/h
Fuel Kerosene, viscosity 1.5 – 6 mm2/s at 20 °C
Light oil, max. viscosity 6 mm2/s at 20 °C
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 0.85A – 2850 rpm – 298 rad/s
Capacitor 4 F
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– Lock-out lamp and reset button
6– Screws fixing air-damper
7– Flange with insulating gasket
8– Vacuum gauge connection
EQUIPMENT
Quantity Description
1
1
1
2
2
1
Flange with insulating gasket
Screw of by-pass pump
Screw with two nuts for flange
Screws
Screws with washer, nuts
Flexible pipe with nipple
8
D5534
Fig. 1
123
4
56
6
7

2374 2
WORKING RANGE (as EN 267)
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
D5236 35 40 45 50 55
0.2
0.6
1.0
1.2
1.4
6
2.45
65 70
Flange Burner
305 73 261
140
=
40
45°
ø89
262
11
204
D5235
=
189
83 83
170
45°
It is necessary that the insulating gasket
(7, 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.
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-line on either side of
the burner.
D5242
Fig. 2
D5572
S7389
BURNER FIXING

2374 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:
OCheck periodically the flexible pipes conditions. Using kerosene, they have to be replaced at
least every 2 years.
OA 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.
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.
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 (8, 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
Hmax.4m
H
H
max. 4 m
min. 0.1 m
D5219
D5220
D5199
H=Difference of level.
L=Max. length of the suc-
tion line.
I.D.=Internal diameter of the
oil pipes.

2374 4
BURNER ELECTRICAL WIRING
S7029
Brown
White (50V)
Blue
Motor
Capacitor
Regulating thermostat
Neutral
Main switch
T6A
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-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
D5228
Black

2374 5
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. The values
in the table refer to 12.5% CO2at sea level and to “zero” pressure in the combustion chamber.
FUEL LIGHT OIL
FUEL KEROSENE
NOZZLES RECOMMENDED: Monarch type R - NS; Delavan type W - A - E
Steinen type Q - H ; Danfoss type S - B - H
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 2.50 1 1.2
0.65 60°/80° 12 2.80 1.5 1.4
0.75 60° 12 3.10 2 1.8
0.85 60° 12 3.60 2.5 2.2
1.00 60° 12 4.29 3 2.6
1.10 60° 12 4.72 4 3
1.25 60° 12 5.30 5 3.5
1.35 60° 12 5.80 6 4.2
Angle: 60° in most cases.
80° in case of flame detachment, during ignitions at low temperatures.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.85 60° 8 2.51 1 1.2
1.00 60° 8 2.95 1.5 1.4
1.10 60° 8 3.25 2 1.8
1.25 60° 8 3.69 3 2.2
1.35 60° 8 3.99 3.5 2.4
1.50 60° 8 4.43 4.5 2.7
1.75 60° 8 5.20 6 3.2
2.00 60° 8 5.80 6 4.2
1
2
3
4
1
2
3
4
1

2374 6
PRESSURE:
12 bar: pressure suitable for light oil in most cases.
14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.
FOR KEROSENE DECREASE PRESSURE
8 bar: pressure suitable for kerosene in most cases.
10 bar: maximum pressure for kerosene.
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.
AIR DAMPER ADJUSTMENT
The regulation of the air-rate is made by adjusting the air
damper (1), after loosing the screws (2).
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: actu-
al 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.
2
3
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5244
2
135
In the sketch on the left, the combustion
head is set for an output of 1.00 GPH at
12 bar (for gas-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
2
1
D5514
2
4

2374 7
ELECTRODE SETTING
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 gas-oil decreases below +8 °C.
1) CORRECT POSITIONING OF THE ELECTRODES (see figure above)
2) PUMP - SETTING
When the temperature of the gas-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 damper, reducing the excess air until the Bacharach number is not near 1.
(i.e. a combustion with the lowest possible excess-air).
Attention:
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
2 – 2.3 mm
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230 A
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s