Riello G5 Quick start guide

20013752 (3) - 04/2011
Installation, use and maintenance instructions
安装 , 使用以及维护说明书
Light oil burner
轻油燃烧器
CODE - 编码 MODEL - 型号 TYPE - 类型
20013633 G5 445T1
GB
CN
One stage operation
一段火运行

20013752
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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 sepa-
rated 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 maintenance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-
UAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the system manu-
facturer, 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 techni-
cian.
To ensure a periodic check, recommends the drawing up
of a Maintenance Contract.
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1 20013752
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TECHNICAL DATA
Burner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,
Machines 2006/42/EC.
The burner meets protection level of IP 40, EN 60529.
TYPE 445T1
Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h
Fuel Light oil, max. viscosity at 20 °C: 6 mm2/s
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 0.75A – 2850 rpm – 298 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 7 – 15 bar
Absorbed electrical power 0.130 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
HYDRAULIC JACK OPERATION 7)(Fig. 1)
It is strongly recommended a periodic check of the
pump pressure operation (annually or better 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 restorable,
please replace the pump, in order to guarantee that
the pump pressure during the pre-purge time is at
least 3.7 bar.
DANGER
Fig. 1
5
D5553 12
3
4
86
6
7
9
10

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BURNER EQUIPMENT
FIRING RATE
OVERALL DIMENSIONS
Quantity Description
2
1
4
1
1
1
Flexible oil pipes with nipples
Flange with insulating gasket
Screws and nuts for flange
to be fixed to boiler
Hinge
Screw and nuts for flange
Grommet
0.8
0
0.4
Pressure in the combustion
chamber – mbar
2 3 4 5 Fuel output - kg/h
25 30 60 Thermal power - kW
D5226 35 40 45 50 55
0.2
0.6
2.3
272 107 236
130
=
37
45°
ø89
233
11
180
D5554
=
180
75 72
150
45°
Flange Burner

3 20013752
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BOILER FIXING
It is necessary that the insulating gasket
(9, fig. 1) is placed between the boiler door
and the burner flange.
This insulating gasket has six holes,
which, if necessary, can be modified as
shown on the drawing on the right.
D5242
Fig. 2
Verify that the installed
burner is lightly leaned
towards the button.
(See figure 2).
The burner is designed to
allow entry of the flexible
oil-lines on either side of
the burner.
D5572
BURNER FIXING AND
HINGE ASSEMBLY
S7384

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HYDRAULIC SYSTEMS
Warning: 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 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
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,
page 1) and wait until the fuel flows out.

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ELECTRICAL WIRING
Brown
White (50V)
Blue
Motor
Capacitor
Regulating thermostat
Neutral
Switch with fuse
6A max.
NL
M
~
S7026
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 con-
trol-box (underneath the ignition-transformer) on
a plug-in support.
TESTING
Check the shut-down of the burner by opening the
thermostats.
ATTENTION
Do not connect burner’s grounding, to failure
indicator terminal . This may result the destroy
of the control box.
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- Grommet N- Neutral
2- Cable-clamp L- Phase
3- Terminal block - Burner-earth
A321
D5228
Black
CARRIED-OUT BY THE INSTALLER
CARRIED-OUT IN THE FACTORY

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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.
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.
RECOMMENDED NOZZLES: Monarch type R - NS; Delavan type W - A - E
Steinen type H - Q ; Danfoss type H
Angle:60°:in most cases.
80° : in case of flame detachment, during ignitions at low temper-
atures.
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
carried out by rotating the regulating rod, till the terminal
plane of the blast tube is level with the set-point, as indi-
cated in the schedule.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.60 60°/80° 11 2.3 1.5 2
0.65 60°/80° 12 2.6 2 2.2
0.75 60° 12 3.0 2.5 2.5
0.85 60° 12 3.4 3 3
1.00 60° 12 4.0 4 4.5
1.10 60° 12 4.4 5 6
1.25 60° 12 5.0 6 7
1
2
3
4
1
2
3
In the sketch on the left, the combustion
head is set for an output of 0.85 GPH at
12 bar, while the shutter is level with set-
point 3, as required by the above sched-
ule.
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
D5232
2
135

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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 vol-
ume 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 increas-
ing its pressure. 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) as-
sures 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 mo-
bile 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.
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 5);
– 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.
1
23
6
D5551
D
C
D5555
D
A B
4

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ELECTRODE SETTING (See fig. 3)
BURNER START-UP CYCLE
ADJUSTMENTS, TO AVOID FLAME - DETACHMENT, AT BURNER - IGNITION
This inconvenience can occur, when the temperature of the light-oil decreases below +8 °C.
1) CORRECT POSITIONING OF THE ELECTRODES
See fig. 3.
2) PUMP - SETTING
The pump is factory set, at a pressure of 12 bar.
When the temperature of the light oil decreases below +8 °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).
2 – 2.5 mm
4± 0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230 A
Attention:
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
Fig. 3
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s D5229
~12s ~5s