Riello G20S Quick start guide

2902406 (5) - 09/2014
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Light oil burner
Quemador de gasóleo
One stage operation
Funcionamiento de una llama
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3748259 G20S 482 T58
GB
ES

2406
1 GB
ENGLISH
TECHNICAL DATA
■
Burner with CE marking in conformity with EEC Directives: Machine Directive 2006/42/EC, Low Voltage
Directive 2006/95/EC, Electromagnetic Compatibility 2004/108/EC and Efficiency 92/42/EEC.
■
The burner meets protection level of IP 40, EN 60529.
TYPE 482T58
Thermal power – output 95 – 240 kW - 8 – 20 kg/h
Fuel Light oil, viscosity 4 – 6 mm
2
/s at 20 °C
Electrical supply Single phase, 220V ± 10% ~ 60Hz
Motor Run current 2.2A – 3250 rpm – 340 rad/s
Capacitor 4 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 8 – 15 bar
Absorbed electrical power 0.41 kW
1– Return line
2– Suction line
3– Gauge connection
4– Pump pressure regulator
5– Vacuum gauge connection
6– Hydraulic jack with air-damper
7– Combustion head adjustment screw
8– Reset button with lock-out lamp
9– Flange with insulating gasket
10 – Start delaying device
D8077
Fig. 1
BURNER EQUIPMENT
Quantity Description
2
1
4
1
1
1
Flexible pipes with nipples
Flange with insulating gasket
Screws and nuts for flange
Maintenance assembly
Cable grommet
Screw with two nuts for flange

2406
2 GB
WORKING FIELD
OVERALL DIMENSIONS
3.6
0
2.4
Pressure in the combustion
chamber – mbar
8 10 12 14 Fuel output - kg/h
90 120 240 Thermal power - kW
D5797
150 180 210
1.2
16 18 20
0.3
Flange Burner
350 118 295
160
=
41
45°
ø
125
298
11
230
D5283
=
213
99 99
190
45°

2406
3
GB
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

2406
4 GB
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
L meters
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
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
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.

2406
5
GB
ELECTRICAL WIRING
Brown
White (50V)
Blue
Motor
Capacitor
Limit thermostat
Neutral
Main switch
6A max.
N L
M
~
Black
NOTES:
– Wires of min. 1 mm
2
section.
(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
N L
Safety thermostat
Remote lock-out signal
(220V - 0.5A max.)
1 2 3 4 5 6 7 8 9
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.
S7333

2406
6 GB
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 CO
2
concentration 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% CO
2
at 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.
For narrow and long combustion-chambers it is advisable
to use full cone nozzles (e.g. 60° B).
COMBUSTION HEAD SETTING :
(See fig. 2 and 3)
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 on the right, the combus-
tion 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.
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:
Nozzle
Pump pressure Burner output Comb. head adjustment Air damper adjustment
Low-flame High-flame
GPH Angle bar kg/h ± 4% Set-point Set-point Set-point
2.00 60° 12 8.0 1 1.8 2.0
2.25 60° 12 9.0 1.5 2.1 2.5
2.50 60° 12 10.0 2 2.4 2.8
3.00 60° 12 12.0 2.5 2.8 3.2
3.50 60° 12 14.0 3.5 3.2 4.0
4.00 60° 12 16.1 4 3.6 5.0
4.50 60° 12 18.1 5 4.0 6.0
4.50 60° 14.5 19.9 6 4.5 7.0
1
2
3
1
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5284
2
135
Fig. 2
2

2406
7
GB
TURN TO THE RIGHT: (sign
+ )
In order to increase the volume of air entering the com-
bustion chamber and thus diminishing its pressure.
There is a reduction of CO
2
and the adhesion of the
flame to the air diffuser disc improves. (Setting advisa-
ble for ignitions at low temperatures).
TURN TO THE LEFT: (sign – )
In order to reduce the volume of air entering the com-
bustion chamber and thus increasing its pressure.
The CO
2
improves 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.
PUMP-PRESSURE AND AIR-FLOW
(See fig. 4 and 5)
The burner, in order to guarantee good smooth starts,
irrespective of the type of boiler, is fitted with a hydrau-
lic device which, independently of the control-box,
reduces the fuel- and air-flow.
At ignition, the pressure at the nozzle is 9 bar.
After 4 - 6 seconds, it automatically increases to 12 bar.
The air-flow, initially adjusted to the low setting, is, at the
change-over of pressure, automatically brought to the
air-flow required for the big flame.
SETTING FOR THE LOW IGNITION-FLAME
Air-damper adjustment
Loosen the screw (1), by approximately one full turn; in
this way, the burner remains permanently on low flame.
Loosen the nut (2), turn the screw (3), in order to set
the air-damper (4) in the position required.
Then, lock the nut (2) and tighten the screw (1).
Reducer-adjustment
The pressure-reducer is factory set, at 9 bar.
The pressure-gauge should be mounted, in place of
plug (6). Should it be necessary to re-set or alter such
pressure, this can be done, by adjusting screw (5)
(always, after having loosened screw (1) ).
HIGH-FLAME SETTING
Air-damper adjustment
Loosen the nut (7), turn the screw (8), until the air-damper
(4) is in the required position. Then, lock the nut (7).
Pump-adjustment
The pump-pressure is pre-set, during production, at
12 bar. Should it become necessary to re-set or alter
such pressure, this can be done by turning screw (9).
S7334
S7743
1
2 3
6
D8068
Fig. 3
Fig. 4
Fig. 5

2406
8 GB
AIR DAMPER ADJUSTMENT :
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 (3, page 6);
– 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
18 kg/h remove the panel fitted inside the metal
cover. (See figure).
ELECTRODES ADJUSTMENTS
BURNER START-UP CYCLE
3
PANEL
S7335
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
~ 12s
D5796
~ 5s
Thermostat
Motor
Ignition transformer
Valve
Ignition flame
Lock-out lamp
High flame
~ 6s ~ 12s