Riello G10 Quick start guide

2903442 (0) - 05/2008
Installation, use and maintenance instructions
Oil - kerosene burners
One stage operation
CODE MODEL TYPE
3746467 G10 464T52
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3442 1
TECHNICAL FEATURES
Burner with CE marking in conformity with EEC directives: EMC89/336/EEC - 2004/108/EC,
Low Voltage 73/23/EEC - 2006/95/EC, Machines 98/37/EEC and Efficiency 92/42/EEC
The burner meets protection level of IP 40, EN 60529.
Thermal power – output 54 – 120 kW – 4.5 – 10 kg/h
Fuel Light oil, max. viscosity at 20 °C: 4 ÷ 6 mm2/s (Hi= 11.86 kWh/kg)
Kerosene, max. viscosity at 20 °C: 1.6 ÷ 6 mm2/s (Hi= 11.97 kWh/kg)
Electrical supply Single phase, 230V ± 10% ~ 50Hz
Motor Run current 0.85A – 2800 rpm – 293 rad/s
Capacitor 4 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Maximum pressure 14 bar (203 psi)
Absorbed electrical power 0.18 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
EQUIPMENT
Quantity Description
1
1
2
1
1
1
1
Flexible pipe with nipple
Flange with insulating gasket
Screws and nuts for flange
Maintenance assembly
Screw of pump by-pass
Cable gland
Screw with two nuts for flange
5
D8067
Fig. 1
12
3
4
86
7
9
10
6
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3442 2
WORKING RANGE
DIMENSIONS
0.8
0
0.4
4 5 6 Fuel output - kg/h
50 60 120 Thermal power - kW
D5669 70 80 90 100 110
0.2
0.6
Pressure in the combustion
chamber – mbar
78910
Flange Burner
305 108 261
140
=
40
45°
262
11
204
D5670
=
189
83 83
170
45°
ø105
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3442 3
INSTALLATION
BOILER FIXING
Put on the flange (1) the screw and two nuts, (see fig. 2).
Widen, if necessary, the insulating gasket holes (5), (see fig. 3).
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. 4).
MAINTENANCE POSITION
Access to the combustion head, diffuser disc / electrodes unit and nozzle, (see fig. 5).
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 combustion head (6) after loosing the fixing screws (7).
Remove the diffuser disc-holder assembly (9) from the nozzle-holder (8) after loosing its fixing screw.
Screw the nozzle (10).
D5012
Fig. 2
1
Fig. 3
5
E9022
D8058
1
Fig. 4
43
2
2
5
1
10
9
8
7
6
Fig. 5
Fig. 6
Verify that the installed burner is lightly leaned towards the
button.
(See figure 6).
The burner is designed to allow entry of the flexible oil-lines
on either side of the burner.
D5572
D8056 D8057
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3442 4
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.
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 (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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3442 5
BURNER ELECTRICAL WIRING
S7029
Brown
White (50V)
Blue
Motor
Capacitor
Regulating thermostat
Neutral
Switch with fuse
6A max.
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
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3442 6
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.
NOZZLES RECOMMENDED: Monarch type R
Delavan type W - B
Steinen type S - Q
Danfoss type S - B
PRESSURE: 8 bar : the pump leaves the factory set at this value, which is suit-
able only for kerosene.
FOR LIGHT OIL INCREASE 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.
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 car-
ried 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.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
1.10 60° 12 4.72 2 3
1.25 60° 12 5.37 2.5 3.4
1.50 60° 12 6.44 3 3.8
1.75 60° 12 7.51 4 4
2.00 60° 12 8.59 5 5
2.25 60° 12 9.66 6 6
FUEL LIGHT OIL
1 2 3 4
1
2
3
In the sketch on the left, the combustion
head is set for an output of 1.50 GPH
at 12 bar, while the shutter is level with
set-point 3, as required by the above
schedule.
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5398
2
135
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3442 7
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.
NOZZLES RECOMMENDED: Monarch type R
Delavan type B - W
Steinen type S - Q
Danfoss type S - B
PRESSURE: 8 bar : the pump leaves the factory set at this value.
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 car-
ried 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.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
1.50 60° 8 4.43 1.5 2.6
1.75 60° 8 5.17 2 2.9
2.00 60° 8 5.91 2.5 3.3
2.25 60° 8 6.64 3.5 3.5
2.50 60° 8 7.38 4 3.8
3.00 60° 8 8.86 5 5
3.00 60° 10 9.99 6 6
FUEL KEROSENE
1 2 3 4
1For 2.50 - 3.00 GPH nozzles it is
advisable to use, if possible,
full cones.
2
3
In the sketch on the left, the combustion
head is set for an output of 2.25 GPH
at 8 bar, while the shutter is level with
set-point 3.5, as required by the above
schedule.
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5676
2
135
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3442 8
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.
AIR DAMPER ADJUSTMENT:
The mobile air damper (A) operated by the jack (B) assures the complete opening of the air intake.
The regulation of the air-rate is made by adjusting the fixed air damper (C), after loosing the screws
(D). When the optimal regulation is reached, screw tight the screws (D) to assure a free movement
of the mobile air damper (A).
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.
D
C
D5782
D
A B
1
2 3
6
D8068
4
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3442 9
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 out-
put, remove the cover by loosening the screw,
adjust the air damper, remount the cover and finally
recheck the smoke number.
NOTE: When the burner works at a firing rate
higher than 9 kg/h remove the panel fitted
inside the metal cover. (See figure).
ELECTRODE SETTING
BURNER START-UP CYCLE
PANEL
D5287
Attention:
Before assembling or removing the nozzle, loosen
the screw (A) and move the electrodes ahead.
4± 0.3 mm
D5288 A4.5 ± 0.5 mm
MOVE THE ELECTRODE
HOLDER BACKWARDS TO
THE END
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s
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3442 10
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 + 5 °C.
1) CORRECT POSITIONING OF THE ELECTRODES
2) PUMP - SETTING
When the temperature of the light-oil decreases below + 5 °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).
4± 0.3 mm
D5288 A4.5 ± 0.5 mm
MOVE THE ELECTRODE
HOLDER BACKWARDS TO
THE END
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RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com
Subject to modifications
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