Riello G20 Quick start guide

Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
2902404 (5) - 05/2011
Light oil burner
Quemador de gasóleo
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3747459 G20 474T58
GB
E
One stage operation
Funcionamiento de una llama

2404
1GB
ENGLISH
TECHNICAL DATA
Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 2004/108/EC,
Low Voltage 2006/95/EC, Machines 2006/42/EC.
The burner meets protection level of IP 40, EN 60529.
TYPE 474T58
Thermal power – output 95 – 213 kW – 8 – 18 kg/h
Fuel Gas oil, viscosity 4 – 6 mm2/s at 20 °C
Electrical supply Single phase, 220V ±10% ~60Hz
Motor Run current 2.15A – 3250 rpm – 340 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 8 – 15 bar
Absorbed electrical power 0.4 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– Reset button with lock-out lamp
9– Flange with insulating gasket
10 – Combustion head adjustment screw
5
D8067
Fig. 1
123
4
86
7
9
10
6
HYDRAULIC JACK OPERATION 7)(Fig. 1)
It is strongly recommended a periodic check of
the pump pressure operation (annually or bet-
ter every six months, if the burner operation is
continuous).
If the value is lower than 1 bar, compared to
that one of the initial setting, please check the
cleaning of the pump and line filters.
In case the pressure setting was not restora-
ble, please replace the pump, in order to guar-
antee that the pump pressure during the pre-
purge time is at least 3.7 bar.
DANGER

2404
2GB
BURNER EQUIPMENT
WORKING FIELD
OVERALL DIMENSIONS
Quantity Description
2
1
4
1
1
1
Flexible pipes with nipples
Flange with insulating gasket
Screws and nuts for flange
Maintenance assembly
Screw with two nuts for flange
Cable grommet
1.8
0
1.2
Pressure in the combustion
chamber – mbar
8 10 12 14 Fuel output - kg/h
90 110 230 Thermal power - kW
D5282 130 150 170 190 210
0.6
16 18 20
Flange Burner
350 118 295
160
=
41
45°
ø125
298
11
230
D5283
=
213
99 99
190
45°

2404
3GB
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

2404
4GB
HYDRAULIC SYSTEMS
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.
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.
When the return line arrives over the
fuel level, a non-return valve must be
used.
This solution however is less safe than
previous one, due to the possibility of
leakage of the valve.
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.
A filter must be installed on the suction fuel line.
H
meters
Lmeters
I. D.
8 mm I.D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
WARNING
The pump is supplied for use with a two pipe system.
For use on a one pipe system, it is necessary to remove the by-pass
screw (A), (see figure).
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
suction line.
I.D.=Internal diameter of the
oil pipes.
PRIMING THE PUMP
Loosen the plug of the vacuum gauge (5, fig. 1) and
wait until the fuel flows out.

2404
5GB
ELECTRICAL WIRING
S7029
Brown
White (50V)
Blue
Motor
Capacitor
Limit thermostat
Neutral
Main switch
6A max.
NL
M
~
Black
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.
– 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 con-
trol-box (underneath the ignition-transformer) on
a plug-in support.
TESTING
Check the shut-down of the burner by opening
the thermostats.
220V ~60Hz
NL
Safety thermostat
Remote lock-out signal
(220V - 0.5A max.)
123456789
Blue
Brown
Terminal board of
control-box 530SE*
Valve
T
T
RUN OF THE ELECTRICAL CABLE
1- Cable grommet N- Neutral
2- Cable-clamp L- Phase
3- Terminal board - Burner-earth
ATTENTION
Do not connect burner’s grounding, to fail-
ure indicator terminal . This may result
the destroy of the control box.
D5228
Black
CARRIED-OUT IN THE FACTORY
WARNING
DO NOT EXCHANGE THE
NEUTRAL WITH THE PHASE.

2404
6GB
COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjust-
ment and testing must be carried out observing the instruction manual of the boiler, including verifica-
tion 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 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.
NOZZLES RECOMMENDED: Monarch type R - PLP ; Delavan type B - W
Steinen type S - SS ; Danfoss type S - B
Angle: 60° :in most cases. Particularly suited to avoid flame-detach-
ment during ignition.
45° : for narrow and long combustion-chambers.
PUMP PRESSURE: 12 bar - the pump leaves the factory set at this value
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
2.00 60° 12 8.0 1 2.2
2.25 60° 12 9.0 1.5 2.6
2.50 60° 12 10.0 2 2.8
3.00 60° 12 12.0 2.5 3.5
3.50 60° 12 14.0 3.5 4.0
4.00 60°/45° 12 16.1 5 5.5
4.50 60°/45° 12 18.0 6 6.5
1
2
3
4
1
2
3
D5284
In the sketch on the left, the combustion
head is set for an output of 3.50 GPH at
12 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
2
135

2404
7GB
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 pres-
sure. 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.
1
2 3
6
D8068
B
C
D
D
A
D5775
4

2404
8GB
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, page 6);
– 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
17 kg/h remove the panel fitted inside the metal
cover. (See figure).
ELECTRODES ADJUSTMENTS
BURNER START-UP CYCLE
PANEL
D5682
Attention:
Before assembling or removing the noz-
zle, loosen the screw (A) and move the
electrodes ahead. 4± 0.3 mm
D6313
6.5 ± 0.5 mm
A
MOVE THE ELEC-
TRODE HOLDER BACK-
WARDS TO THE END
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
~12s D5229 ~12s ~5s