Riello G20KI User manual

Installation, use and maintenance instructions
2902403 (6) - 05/2011
Light oil - kerosene burner
One stage operation
CODE MODEL TYPE
3747455 G20KI 474T52

INFORMATION ABOUT THE INSTRUCTION MANUAL
INTRODUCTION
The instruction manual supplied with the burner:
- is an integral and essential part of the product and
must not be separated from it; it must therefore be
kept carefully for any necessary consultation and
must accompany the burner even if it is transferred
to another owner or user, or to another system. If the
manual is lost or damaged, another copy must be
requested from the Technical Assistance Service
of the area;
- is designed for use by qualified personnel;
- offers important indications and instructions relating
to the installation safety, start-up, use and mainte-
nance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUC-
TION MANUAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the
system manufacturer, with the recommendation to
keep it in the room where the heat generator is to be
installed.
- The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest
Assistance Centre;
- The system supplier carefully informs the user
about:
- the use of the system,
- any further tests that may be necessary before the
system is started up,
- maintenance and the need to have the system
checked at least once a year by the manufacturer
or another specialised technician.
To ensure a periodic check, recommends
the drawing up of a Maintenance Contract.
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1
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.
Thermal power – output 95 – 213 kW – 8 – 18 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 1.4A – 2750 rpm – 288 rad/s
Capacitor 5 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Maximum pressure 14 bar (203 psi)
Absorbed electrical power 0.320 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
7– Flange with insulating gasket
10 – Combustion head adjustment screw
5
D8067
Fig. 1
1
2
3
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

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BURNER EQUIPMENT
FIRING RATE
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
Cable gland
Screw with two nuts for flange
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
D5683
0
0.4
8101214
90 110 230130 150 170 190 210
16
0.6
0.2
0.8
18
1.0
Flange Burner
350 118 295
160
=
41
45°
ø125
298
11
230
D5283
=
213
99 99
190
45°

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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. 3
5
D8058
1
Fig. 4
43
2
2
5
1
6
5
4
3
2
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
Fig. 2
1
E9022

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HYDRAULIC SYSTEM
WARNING ONLY FOR TWO PIPE SYSTEM: before starting the burner make sure that the return
pipe-line is not clogged: any obstruction 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 metal bowl filter with replaceable micronic filter must be fitted in the oil supply pipe.
Check periodically the flexible pipes conditions. Using kerosene, they have to be replaced at
least every 2 years.
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 one pipe system.
For use on a two pipe system, it is necessary to screw the by-pass
screw (A), hang up to the pump.
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.
PRIMING THE PUMP
Loosen the plug of the vacuum gauge (5, fig. 1) and
wait until the fuel flows out.

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BURNER ELECTRICAL WIRING
Brown
White (50V)
Blue
Motor
Capacitor
Limit thermostat
Neutral
Main switch
T6A
NL
M
~
S7029
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.
240V ~50Hz
NL
Safety thermostat
Remote lock-out signal
(240V - 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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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.
FUEL LIGHT OIL
FUEL KEROSENE
NOZZLES RECOMMENDED: Monarch type R - PLP; Delavan type B - W
Steinen type S - SS ; Danfoss type S - B
Angle 60°: in most cases.
Particularly suitable to avoid flame-detachment during ignition.
45°: for narrow and long combustion-chamber.
PRESSURE:
8 bar: the pump leaves the factory set at this value, which is suitable only for kerosene.
10 bar: maximum pressure for kerosene.
FOR LIGHT OIL INCREASE PRESSURE
12 bar: in most cases.
14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.
1 2 34
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 8.6 1 3
2.25 60° 12 9.7 1.5 3.2
2.50 60° 12 10.7 2 3.5
3.00 60° 12 12.9 2.5 4.3
3.50 60° 12 15.0 3.5 5.5
4.00 60°/45° 12 17.2 5 6.5
4.00 60°/45° 13 17.9 6 7
1 2 34
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
2.75 60° 8 8.1 0.5 2.2
3.00 60° 8 8.9 1 2.4
3.50 60° 8 10.3 1.5 3.0
4.00 60° 8 11.8 2.5 3.2
4.50 60° 8 13.3 3 4.0
5.00 60° 8 14.8 3.5 6.0
5.50 60°/45° 8 16.2 5 6.5
6.00 60°/45° 8 17.7 6 7.0
1
2

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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.
In the sketch below, the combustion head is set for an output of 3.50 GPH at 12 bar (for light oil)
or 5.00 GPH at 8 bar (for kerosene).
The shutter is level with set-point 3.5, as required by the schedule at page 6.
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.
3
1
2 3
6
D8068
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5676
2
135

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AIR DAMPER ADJUSTMENT:
The mobile air damper (1) operated by the jack (2)
assures the complete opening of the air intake.
The regulation of the air-rate is made by adjusting the
fixed air damper (3), after loosing the screws (4). When
the optimal regulation is reached, screw tight the
screws (4) to assure a free movement of the mobile air
damper (1).
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.
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.
NOTE: When the burner works at a firing rate
higher than 17 kg/h remove the panel
fitted inside the metal cover (see figure).
ELECTRODE SETTING
4
PANEL
D5682
4
3
D5550
4
1 2
Attention:
Before assembling or removing the nozzle, loosen the
screw (A) and move the electrodes ahead.
4± 0.3 mm
D5288 A6.5 ± 0.5 mm
MOVE THE ELECTRODE HOLDER
BACKWARDS TO THE END