Riello Burners Gulliver RG1R Quick start guide

2902867 (0)
Montage- og driftsinstruktion
Montage- och driftinstruktion
Montasje og driftsinstruks
Installation, use and maintenance instructions
Light oil burner
Oliebrænder
Oljebrännare
Oljebrenner
CODE - KODE - KOD MODEL - MODELL TYPE -TYP
3736420 RG1R 364 T2
GB
DK
S
N
One stage operation
Et-trins funktion
Enstegsfunktion
Ett-trinns brenner

4

2867 1GB
INDEX
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . . . . No. 1 Screw and nuts for flange to be fixed to boiler . . . No. 4
Screw and nuts for flange . . . . . . . . No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . . . No. 2
7 pin plug. . . . . . . . . . . . . . . . . . . . . No.1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions. . . . . . . . . . . . . . . . . 2
2.3 Working field . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Recommended nozzles. . . . . . . . . . . . . . 6
4.3 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7
4.5 Combustion head setting. . . . . . . . . . . . . 8
4.6 Air damper adjustment . . . . . . . . . . . . . . 8
4.7 Fuel heating . . . . . . . . . . . . . . . . . . . . . . 8
4.8 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9
1– Oil pump
2– Control-box
3– Reset button with lock-out
lamp
4– Flange with insulating
gasket
5– Air damper adjustment
assembly
6– Nozzle holder assembly
7– Photoresistance
■The burner meets protection level of IP 40, EN 60529.
■Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
Fig. 1
S7636
2
4
3
1
6
7
5

2867 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD (as EN 267)
TYPE 364T2
Output - Thermal power 2.3 –5 kg/h - 27.3 –
60 kW
Fuel Light oil, viscosity 4 –
6 mm2/s at 20 °C
Electrical supply Single phase, ~50Hz 230V ±
10%
Motor Run current 0.85A – 2750 rpm – 289 rad/s
Capacitor 4
µ F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 –15 bar
Absorbed electrical power 0.29 kW
196 93 122 180
130
150
4
22
210
254
11
7272
91
45°
45°
D5699
112
ø84
2 3 Light oil output – kg/h
30 40 Thermal power – kW
0,8
0,6
0,4
0,2
0
Pressure in combustion
chamber – mbar
D4443 4
50
5
605525 35 45

2867
3
GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
➤
Put on the flange (1) the screw and two nuts, (see fig. 3).
➤
Widen, if necessary, the insulating gasket holes (5).
➤
Fix the flange (1) to the boiler door (4) using screws (2) and (if necessary) the nuts (3) interposing the
insulating gasket (5)
, (see fig. 2).
3.2 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and closing plate (2) should be reversed, (see fig. 4).
Fig. 2
Fig. 3 S7189
Fig. 4
2 1
D4074
1

2867
4
GB
3.3 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
H
= difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes.
H
max. 4 m
max. 4 m
H
H
H
D5705
Fig. 7 Fig. 8
PRIMING PUMP:
On the system in fig. 6 it is sufficient to loosen the suction gauge
connection (5, 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 seconds
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 re-
quired. Should however the return line arrive over the fuel level, a non-return
valve is required.
This solution however is less safe than previous one, due to the possibility of
leakage of the valve.
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
■
The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to
unscrew the return plug (2), remove the by-pass screw
(3) and then screw again the plug (2). (See fig. 5).
■
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:
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
SYSTEM NOT PERMITTED
IN GERMANY
1- Suction line
2- Return line
3- By-pass screw
4- Pressure adjuster
5- Suction gauge connection
6- Valve
7- Gauge connection
Fig. 6
H
max. 4 m
D5703
1
32465
Fig. 5
D4063
7

2867
5
GB
3.4 ELECTRICAL WIRING
ESEGUITO IN FABBRICA
WARNING
CONTROL BOX
To remove the control-box from the burner, loosen screw (A, fig. 9)
and pull to the arrow direction, after removing all components, the
7 pin plug and earth wire.
In case of disassembly of the control box, retighten the screw
(A) with a torque wrench setting of 1 – 1.2 Nm.
DO NOT EXCHANGE NEUTRAL WITH PHASE
S7186
Fig. 9
A
7 pin plug
7 pole socket
Black
White
Capacitor
Main switch
T6A
Motor
Safety
thermostat
Blue
Oil valve
Hour counter
(230V - 0.1A max.)
Limit
thermostat Remote lock-out signal
(230V - 0.5A max.)
Ignition
electrodes
Brown
Burner-earth
CARRIED-OUT IN THE FACTORY
Heater with start
thermostat
553SE/H
CONTROL BOX
D4070
Photoresistance
PE L N
~50Hz 230V
Blue
Brown
Blue
TESTING
Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
NOTES:
– Wires of min. 1 mm2section. (Unless requested
otherwise by local standards and legislation).
– The electrical wiring carried out by the installer
must be in compliance with the rules in force in
the Country.

2867 6GB
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, choose the proper nozzle and adjust the pump pressure, the setting
of the combustion head, 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 RECOMMENDED NOZZLES: Delavan type W - B; Danfoss type S - B
Monarch type R ; Steinen type S - Q.
MAINTENANCE POSITION
THE ACCESSIBILITY TO THE NOZZLE, THE DIF-
FUSER DISC AND THE ELECTRODES IS MADE
EASY IN 2 WAYS:
Fig. 10
➤Remove the burner out of the boiler, after loosing
the fixing nut to the flange.
➤Hook the burner to the flange (1), by removing the
blast tube (2) after loosing the fixing screws (3).
➤Remove the small cables (4) from the electrodes
and the diffuser disc-holder assembly (5) from
the nozzle-holder assembly after loosing its fixing
screw (3, fig. 12, page 7).
➤Screw the nozzle (6) correctly and tighten it
as shown in the figure.
Nozzle Pump
pressure Burner output Combustion head adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.60 60° 12 2.3 1 1.2
0.65 60° 12 2.5 1.5 1.8
0.75 60° 12 2.9 2.5 2.9
0.85 60° 12 3.3 3 3.7
1.00 60° 12 3.8 3.5 5.1
1.10 60°/45° 12 4.2 4 5.6
1.25 60°/45° 13 5.0 4 6.7
AFig. 10
2
5
4
3
6
1
S7477
A

2867 7GB
Fig. 11
➤Remove nozzle-holder assembly (1) after loos-
ing screws (2) and nut (3), remove the small ca-
bles (4) from the control box, the
photoresistance (6) and the socket (10).
➤Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc-holder assem-
bly (11) from the nozzle-holder assembly (1)
after loosing screw (3, fig. 12).
➤Screw the nozzle (12) correctly and tighten it
as shown in figure.
ATTENTION
During the reassembly of the nozzle-holder assem-
bly screw the nut (3) as shown in the figure below.
4.3 ELECTRODES ADJUSTMENT (see fig. 12)
4.4 PUMP PRESSURE
The pump leaves the factory set at 12 bar.
To change it act on pump pressure adjust screw (4, fig. 5, page 4).
S7638
BFig. 11
B
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684
Lean the diffuser disc-holder assem-
bly (1) on the nozzle-holder (2) and
lock it by screw (3).
For prospective adjustments of the
electrodes assembly (4), loosen
screw (5).
WARNING
To have access to the electrodes carry
out operation as described in chapter
“4.2 RECOMMENDED NOZZLES”
(page 6).
D5022
4.5 – 0.5 mm
0
2.5 ±0.2 mm
3 + 0.5 mm
0
WARNING MEASURES
MUST BE RESPECTED
Fig. 12
123
5
4

2867 8GB
4.5 COMBUSTION HEAD SETTING (see fig. 11, page 7)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the set-
ting screw (5) until the set-point marked on the regulating rod (9) is level with the outside plane of the noz-
zle-holder assembly (1).
➤In the sketch the combustion head is set for an output of 0.85 GPH at 12 bar.
The set-point 3of the regulating rod (9) is at the same level with the outside plane of the nozzle-holder
assembly (1) as shown in the schedule.
4.6 AIR DAMPER ADJUSTMENT (see fig. 11, page 7)
➤To vary the setting adjust the screw (7) after loosing the nut (8).
➤When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.
4.7 FUEL HEATING
In order to assure regular ignition and working also at low temperature the burner has an oil pre-heater
fitted in combustion head. The pre-heater starts when thermostats close.
When the required temperature for ignition is reached the thermostat fitted on the nozzle holder starts the
burner. The pre heater remains energised during working and cuts out when burner shuts-down.
4.8 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and conse-
quent 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:
➤Check that there are not obstructions or dents in the supply or return oil pipes.
➤Clean the filter in the oil suction line and in the pump.
➤Clean the photoresistance, (7, fig. 1, page 1).
➤Check for correct fuel consumption.
➤Replace the nozzle (fig. 10, page 6) and check the correct position of electrodes (fig. 12, page 7).
➤Clean the combustion head in the fuel exit area, on the diffuser disc.
➤Leave the burner working without interruptions for 10 min. and set rightly all the components stated in
this manual. Then carry out a combustion check verifying:
●Smoke temperature at the chimney; ●Contentof CO2(%); ●ContentofCO(ppm);
●Smoke value according to opacity smokes index according to Bacharach scale.
Lock-out lamp
D5023
0–150s 0 –150s
5s
~ 12s~ 12s
Thermostat
Heating
Motor
Ignition transformer
Valve
Flame
Lock-out due to failure to light C Normal
C