Riello Burners Gulliver RG1RKD Quick start guide

Manuel d’entretien
Installation, use and maintenance instructions
Installatie-, gebruiks- en onderhoudsvoorschriften
Montage und Bedienungsanleitung
2902305 (5)
Öl-Gebläsebrenner
Brûleur fioul
Oil burner
Stookoliebrander
CODE MODELL - MODELE - MODEL TYP -TYPE
3736650 RG1RKD 366 T1
D
F
GB
NL
Zweistufiger Betrieb
Fonctionnement à 2 allures
Two stage operation
Tweetrapsbranders

2305
1
GB
INDEX
1. BURNER DESCRIPTION
Two stages 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 4 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 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.3 Pump pressure and air output . . . . . . . . . 8
4.4 Fuel heating . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Burner start-up cycle. . . . . . . . . . . . . . . . 9
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 9
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 10
1– Pump with pressure reducer
2– Electronic start delaying
device
3– Control-box
4– Reset button with lock-out
lamp
5– Flange with insulating
gasket
6– 2nd stage air damper
adjustment assembly
7– Nozzle holder assembly
8– Photoresistance
9– Hydraulic jack
10 – 4 pole socket
11 – 2nd stage valve
12 – 1st stage valve
➤CE Certification No.: 0036 0347/04 as 92/42/EEC.
➤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 S7199

2305
2
GB
4
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD
(as EN 267)
TYPE 366T1
Output - Thermal power 1.2/1.45
–
5 kg/h - 14/17
–
60 kW
Fuel Light oil, viscosity 4 –
6 mm
2
/s at 20 °C
Electrical supply Single phase, 230V
±
10%
~
50Hz
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
196 111 122 180
130
150
4
22
210
254
11
7272
91
45°
45°
D5699
112
ø84
1 2 3 Light oil output – kg/h
15 20 30 40 Thermal power – kW
0.8
0.6
0.4
0.2
0
Pressure in combustion
chamber – mbar
D5354 4
50
1.0
5
60

2305
3
GB
3. INSTALLATION
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), (see fig. 4).
■
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 cable clamp (2) should be reversed, (see fig. 5).
D5012
Fig. 4Fig. 2
Fig. 3 S7189
D5701
2
1 1
Fig. 5

2305
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.
PRIMING PUMP:
On the system in fig. 6 it is
sufficient to loosen the suction gauge
connection (6, fig. 7) and wait until oil flows out.
On the systems in fig. 8 and 9 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 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 required.
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.
8
H
meters
L meters
øi
8 mm øi 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
■
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.
■
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. 7).
WARNING:
1 - Suction line
2 - Return line
3 - By-pass screw
4 - Gauge connection
5 -2
nd stage pressure adjuster
6 - Suction gauge connection
7 -1
st stage pressure adjuster
8 - Pressure reducer piston
9 -2
nd stage valve
10 -1
st stage valve
11 - Auxiliary pressure gauge
H
meters
L meters
øi
8 mm øi 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
S7067
Fig. 7
H
max. 4 m
max. 4 m
H
H
H
D5705
Fig. 8 Fig. 9
Fig. 6
H
max. 4 m
D5703

2305
5
GB
3.4 ELECTRICAL WIRING
DO NOT EXCHANGE
NEUTRAL WITH PHASE
WARNING NOTES:
– Wires of 1 mm2 section.
– The electrical wiring carried out by the installer must be in
compliance with the rules in force in the Country.
■Connect 2nd stage thermostat between clamps T6 - T8
by removing the bridge.
TESTING: Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
To remove the control-box from the burner, loosen screw (A, fig. 10) 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.
S7186
Fig. 10
A
7 pin plug
7 pole socket
h
L1 B4S3 T2
T1
N
Black
White
Blue
Capacitor
Burner-earth
Switch with fuse
6Amax.
Neutral
CONTROL BOX
553SE
230V ~50Hz
N
123
Photoresistance
T
Blue
Ignition
electrodes
Brown
L
T
h
T
2nd stage oil valve
T8
T7
T6
B5 4 pin plug
4 pole socket
Blue
Black
White
Blue
Brown
21 321
M
~
ELECTRONIC
DELAYING DEVICE
■2nd stage
Motor
thermostat
M
12123
M
CARRIED-OUT IN THE FACTORY
1st stage oil valve
D5350
Regulating thermostat Remote lock-out lamp
(230V - 0.5A max.)
Limit thermostat
with manual
resetting
1st stage
hour counter
(230V - 0.1A max.)
2nd stage hour counter
(230V - 0.1A max.)
1234
Brown
Blue
Heater with
start thermostat

2305 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 CO2
concentration 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.
Values in the table refer to 12% CO2and to sea level.
RECOMMENDED NOZZLES
Monarch type R, Delavan type W - E, Steinen type Q, Danfoss type S, Satronic type S.
MAINTENANCE POSITION
Nozzle
Pump pressure Burner output Comb. head adjustment Air damper adjustment
bar kg/h ± 4% 1st stage 2nd stage
GPH Angle 1st stage 2nd stage 1st stage 2nd stage Set-point Set-point Set-point
0.40 80° 9 14 1.3 1.7 0.3 0 0.6
0.50 60°/80° 9 14 1.7 2.1 1 0 0.9
0.60 60° 9 14 2.0 2.5 1.3 0.1 1.3
0.65 60°/45° 9 14 2.2 2.7 1.5 0.2 1.7
0.75 60°/45° 9 14 2.5 3.1 2 0.4 2.2
0.85 45° 9 14 2.8 3.5 3 0.5 2.7
1.00 45° 9 14 3.3 4.2 4 0.7 3.8
1.10 45° 9 14 3.7 4.6 5 0.8 4
1.25 45° 9 13 4.2 5.0 6 1 6
1 2
1
Fig. 11
S7197S7184
THE ACCESSIBILITY TO THE NOZZLE,THE DIFFUSER DISC ANDTHE ELECTRODES IS MADE EASY
IN 2 WAYS:
Fig. 11 – 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 noz-
zle-holder assembly after loosing its fixing screw (3, fig. 13, page 7).
– Screw the nozzle (6) correctly and tighten
it as shown in the figure.
A

2305 7GB
Fig. 12 – Remove nozzle-holder assem-
bly (1) after loosing screws (2) and nut (3), re-
move the small cables (4) from the control box,
the photoresistance (5) and the socket (6).
– Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc-holder assem-
bly (9) from the nozzle-holder assembly (1)
after loosing screw (3, fig. 13).
–Screw the nozzle (10) correctly and tighten it
as shown in figure.
ATTENTION
During the reassembly of the nozzle-holder as-
sembly screw the nut (3) as shown in the figure
below.
COMBUSTION HEAD SETTING
(see fig. 12)
It depends on the output of the burner and is car-
ried out by rotating clockwise or counterclockwise
the setting screw (7) until the set-point marked on
the regulating rod (8) is level with the outside
plane of the nozzle-holder assembly (1).
– In the sketch the combustion head is set for an output of 0.85 GPH at 15 bar.The set-point 3of the regulating
rod (8) is at the same level with the outside plane of the nozzle-holder assembly (1) as shown in the schedule;
4.2 ELECTRODES ADJUSTMENT (see fig. 13)
B
S7198
Fig. 12
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684
2
Lean the diffuser disc-holder as-
sembly (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 4.1 (page 6) “RECOM-
MENDED NOZZLES”.
WARNING
MEASURES
MUST BE RESPECTED
D5343 5.5 ± 0.3 mm
4.5 – 0.5 mm
0
4
513
2 – 2.5 mm
Fig. 13 2

2305 8GB
4.3 PUMP PRESSURE AND AIR OUTPUT
■1st STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER:
Unloosen the nut (1), turn the screw (2) until the indicator (3) reaches the position desired. Then lock the nut
(1), (see fig. 14).
PRESSURE REGULATION:
This is set at 9 bar at the factory.
Should it be necessary to re-set or alter such pressure, this can be done, by adjusting screw (7).
The pressure gauge must be mounted in place of cap (8), (see fig. 15).
■2nd STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER:
Unloosen the nut (4), turn the screw (5) until the indicator (6) reaches the position desired.
Then lock the nut (4), (see fig. 14).
PRESSURE REGULATION:
This is set at 15 bar at the factory.
Should it be necessary to re-set or alter such pressure, this can be done, by adjusting screw (9).
The pressure gauge must be mounted in place of cap (8), (see fig. 15).
When burner shuts down the air damper automatically closes till a
max. chimney depressure of 0,5 mbar.
Fig. 15
Fig. 14
S7078

2305 9GB
4.4 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.
4.5 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (4, fig. 1, page 1).
5. MAINTENANCE
Burner requires a periodic maintenance carried out by a qualified and authorized technicians.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the bur-
ner 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.
■Check for correct fuel consumption.
■Replace the nozzle.
■Clean the combustion head in the fuel exit area, on the diffuser disc.
■Leave the burner working without interruptions for 10 min. and check the right settings at 1st and 2nd
stage of all components stated in this manual. Then carry out a combustion check verifying:
●Smoke temperature at the chimney.
●Content of CO2(%).
●Content of CO (ppm).
●Smoke value according to opacity smokes index according to Bacharach scale.
D5348
0 –150s ~12s
Lock-out due to failure to light
A
Normal
3 –28s 0 –150s ~12s 5s
1st stage thermostat
2nd stage thermostat
Heating
Motor
Ignition transformer
1st stage valve
1st stage flame
2nd stage valve
2nd stage flame
Lock-out lamp
A

2305 10 GB
6. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for problems that could cause a failure to
start or a bad working of the burner.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box
(4, fig. 1, page 1).
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the
burner functions correctly, the lock-out can be attributed to a temporary fault.
If however the lock out continues the cause must be determined and the solution found.
WARNING:
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error
in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the
technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
The burner will not
start when the ad-
justment thermo-
stat closes.
Lack of electrical supply.
Check presence of voltage in the
L1 - N clamps of the 7 pin plug.
Check the conditions of the fuses.
Check that thermostat limit is not
lock out.
The photoresistance sees false light. Eliminate the light.
Heater and start thermostats are
faulty. Replace them.
The connections in the control box
are wrongly inserted. Check and connect completely all the plugs.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective. Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve
1st stage.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned. Adjust them according to the instructions of this manual.
Air output is too high. Set the air output according to the
instructions of this manual.
Nozzle dirty or worn. Replace it.