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
GB
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

20013752 2
GB
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

20013752 4
GB
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.

5 20013752
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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

20013752 6
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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

7 20013752
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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

20013752 8
GB
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

20013752
CN
说明书的相关信息
引言
说明书随燃烧器一起提供：
- 它是产品不可或缺的组成部分，不得将其与产品分离；因此必须小心
保存以便查阅，如果将燃烧器转给另一个用户或转移至另一个系统，
则说明书必须跟随燃烧器一起转移。如果说明书损坏或丢失，则必须
从您就近的 Technical Assistance Centre （技术支持中心）索取说
明书的复本 ；
- 说明书只能由有资格的人员使用；
- 说明书提供了有关燃烧器安装、启动、使用和维护的重要指示和安全
警告。
系统和说明书的交付
一旦交付系统：
- 系统制造商也必须将说明书交付给用户，并建议其将说明书保存在热
发生器的安装区域附近。
- 说明书上显示：
- 燃烧器的序列号；
- 最近 Assistance Centre （支持中心）的地址和电话号码；
- 系统制造商必须告知用户有关以下内容的准确信息：
- 系统的使用；
- 启动系统前需要进行的测试；
- 必需的维护和检查 （每年必须由制造商代表或别的专业技术人员至少
检查系统一次）。
要保证定期检查， 建议遵照 Maintenance Contract （维护合同）
的规定。
..............................................
..............................................
..............................................
..............................................

1 20013752
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技术参数
带CE 标志的燃烧器符合下列标准 : EMC 2004/108/EC, 低电压 2006/95/EC, 机械 2006/42/EC.
燃烧器电气保护等级为 IP 40, EN 60529.
类型 445T1
燃烧器出力 28 – 60 kW – 2.3 – 5 kg/h
燃料 轻油 , 在20 °C 时最大粘度 4 –6 mm2/s
电源 单相 ,230V±10% ~50Hz
马达 运行电流 0.75A – 2850 rpm – 298 rad/s
马达启动电容 4 F
点火变压器 次级 8 kV – 16 mA
油泵 油压 : 7 – 15 bar
电功耗 0.13 kW
1–回油管
2–供油管
3–压力表接口
4–油泵压力调节器
5–真空压力表接口
6–风门固定螺钉
7–风门挡板液压传动装置
8–带锁定指示灯的复位按钮
9–带绝热垫的法兰
10 –燃烧头调节螺钉
液压千斤顶运作方式 7)( 图 1)
强烈建议周期性地检查泵压力是否正常运作 （每年
一次，或者在燃烧器不断运行的情况下，建议检查的
时间为六个月一次）。
如果压力值比初始设定值小 1 巴， 检查泵和线路中
的过滤器是否干净。
如果压力无法复位， 请更换泵以便保证预吹扫过程
中，压力至少为 3.7 巴。
危险
图. 1
5
D5553 12
3
4
86
6
7
9
10

20013752 2
CN
燃烧器随机附件
工作范围
外观尺寸
数量 描述
2
1
4
1
1
1
带变径头的油软管
带绝热垫的法兰
将法兰安装到锅炉上的螺栓和螺母
铰链
法兰用螺栓和螺母
电缆护套
0.8
0
0.4
燃烧室压力 – mbar
2345轻油流量 - kg/h
25 30 60 燃烧器出力 - kWD5226 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°
法兰 燃烧器

3 20013752
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锅炉安装
必须将绝热垫 (9, 图. 1) 安装在炉门和燃烧器
法兰之间 .
绝热垫有6个孔, 如有必要，可参考右图所示
对绝热垫扩孔 .
D5242
图. 2
确保燃烧器如 图所示，稍微
向上倾斜 .
(参见图 2).
燃烧器允许油软管从任何一边
进入 .
D5572
燃烧器安装和
铰链装配
S7384

20013752 4
CN
油路系统
警告 :启动燃烧器之前，确保回油管无堵塞 . 任何堵塞会使泵的密封损坏 .
油泵进油真空度不能超过 0.4 bar (30 cm
Hg).
大于这一值，气体可能从油中分离出来 .
油管一定要完全密封 . 回油管应回到油箱中
与入油管相同的水平高度; 在这种情况下，不
需止回阀 .
如果回油管回到比燃料表面高的位置，必须
装一个止回阀 .
这种方法不如前一种方法，因为阀门有可能
漏油 .
首次启动油泵
启动燃烧器直到油泵充油 .
如在燃料到达油泵之前锁定 , 至少等 20 秒才
能再次启动 .
在供油管路上必须装滤网 .
H
（m）
L（m）
I. D.
8 mm I.D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
警告
燃烧器油泵是按双管油系统设计运行的 .
如要单管运行，必须 拆下旁路螺钉 (A), ( 参见图 ).
A
H
（m）
L（m）
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=高度差 .
L=供油管最大长度 .
I.D.=油管内径 .
油泵首次启动
松开真空压力表接口螺钉 (5, 图. 1) 直到有油流出为至 .

5 20013752
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电气连接
褐色
白色
(50V)
兰色
马达
电容
启动温控器
零线
主开关
T6A
NL
M
~
S7026
黑色
注意
–最小电线截面积：1 mm2.
–电气接线必须符合所在国家的强制规定 .
–松开螺钉 (A, 参见右图 )后，沿箭头方向拔出控制盒 .
–光电管通过接线插头直接安装在控制器上 (
在点
火变压器底部
).
测试
检查当温控器断开后，燃烧器是否停止运行 .
注意
如燃烧器不接地 , 端子 就失去作用 . 这也有可能
损坏控制盒 .
警告
不要将火线与零线接反 .
230V ~50Hz
NL
安全温控器
远程锁定信号
(230V - 0.5A max.), 如需要
123456789
兰色
褐色
控制盒 530SE*
的接线端子
阀门
T
T
电气连接电线
1- 电缆护套 N- 零线
2- 线卡 L- 火线
3- 接线端子 - 燃烧器接地
A321
D5228
黑色
安装者负责
厂家设置

20013752 6
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燃烧调整
根据燃烧器运用在锅炉上的效率标准 92/42/EEC，调试燃烧器必须参考锅炉的使用说明书 , 这一工作包括调整烟气
中的 CO 和CO2含量，烟温及锅炉的平均水温。
要达到所需要的出力，应按照下表选择合适的喷嘴，检测油泵压力，设定燃烧头和风门 .
表中的数值由 CEN 锅炉测得 ( 按照 EN 267).
参考条件：12.5% CO2，在零海拔，油温和室温为 20 °C.
推荐的喷嘴 :Monarch 类型 R - NS; Delavan 类型 W - A - E
Steinen 类型 H - Q ; Danfoss 类型 H
角度 :60°:广泛应用 .
80° : 适合在低温点火时火焰易分离的情况下应用 .
油泵压力 12 bar : 出厂时泵压设定为 12 bar.
14 bar : 适合在低温时应用 ;提高火焰稳定性 .
燃烧头设定 :在安装喷嘴时进行 , 同时燃烧筒已移开 . 根据燃烧出力 , 转动
调节杆直到燃烧筒端面达到设定值 , 如图所示 .
喷嘴 泵压 燃烧器出力 燃烧头设置 风门调节
GPH 角度 bar kg/h ± 4% 设定点 设定点
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
在左图所示中 , 泵压为 12 bar, 喷嘴出力
为0.85 GPH , 燃烧头刻度设置为 3.
燃烧筒
调节杆
标尺
燃烧筒端面
D5232
2
135

7 20013752
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以上所示的燃烧头设定适用于大多数情况 .
风量的设置可通过调节风门挡板来进行. 如果在燃烧头安装好后 , 并且运行时仍要调节燃烧头, 可用 6 mm
扳手 (2) 转动调节杆 (1),如下所示 :
右旋:(
+的方向), 可增大进入燃烧室的风量相应降低其风
压.
烟气中 CO2含量减少但火焰燃烧状况得到改善 .
(
温度较低点火时可采取此设置 ).
左旋 : (
–的方向 ), 可减少进入燃烧室的风量同时增加其
压力 .
烟气中 CO2含量增加但火焰贴盘现象减少 .(
温度较低点
火时不宜采取此设置
).
任何情况下燃烧头的设定值不要偏离上图所示的参考值太
多 （不能大于 1 个刻度） . 调节杆转 3 圈相当于一个刻度
; 可通过端面上的孔 (3) 来方便的记录所转的圈数 .
风门挡板调整 :
可调风门挡板 (A) 通过液压装置 (B) 驱动 , 确保风门入口
完全打开 .
拧松螺钉 (D) 后调整固定风门挡板 (C) 来调节风量 .
当达到合适的风门位置后 , 拧紧螺钉 (D) 以确保可调风门
挡板 (A) 的运行 .
上表所示的设置值是在燃烧器安装金属外壳和燃烧室背
压为零的情况下测得 .
每一次安装 , 都可能有不同状况 : 实际喷嘴出力 ; 燃烧室
的正负压力 , 空气过剩量 ,等等 .
所有这些条件都需要不同的风门挡板设置 .
应考虑燃烧器是否装上金属外壳对进风量大小的影响 .
因此建议按以下步骤进行 :
– 按表中所示 (4, p 5)调节风门挡板 ;
– 安装外壳 , 仅固定上部螺钉 ;
– 检查烟气等级 ;
– 如必须调整风门挡板 , 拧下上部螺钉后移开外壳 , 调节
风门挡板 , 然后安装外壳并再次检查烟气等级 .
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23
6
D5551
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C
D5555
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A B
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点火电极的设定 (参见图 . 3)
燃烧器启动程序
在燃烧器点火时 , 为避免火焰不稳 , 可调整电极位置
当轻油油温低于 +8°C,有可能引起点火困难 .
1) 正确的点火电极位置
参见图 . 3.
2) 油泵压力 - 设定
油泵压力出厂时设定为 12 bar.
当轻油油温低于 +8°C,将油压增加到 14 bar.
3) 燃烧头的设定
可将燃烧头的设定点调整得比上表中所给设置值大一个设定点
例如 :
说明书中所给设定值为 3, 此时可将设定点调整到 4.
4) 风门挡板调整
调整减震器，减少过量空气直至黑度指数不接近 1。
(即在最小过量空气的条件下燃烧 ).
2 – 2.5 mm
4± 0.3 mm
重要提示 :
电极安装距离须按下图所
示
D5230 A
注意 :
在更换或安装喷嘴前 , 拧松 螺钉 (A)
并将电极向前移动 .
图. 3
正常点火 由于点火失败而锁定
启动温控器
马达
点火变压器
阀门
火焰
锁定信号 ~12s D5229
~12s ~5s