Riello GI/EMME 400 Quick start guide

2915143 (6)
Installation, use and maintenance instructions
Dual fuel Gas-Oil/Gas burner
MODEL TYPE
GI/EMME 400 496 T80

5143
1
TECHNICAL FEATURES
The burner conforms to IP 40 level of insulation as per CEI/70.1
Thermal power 116/232 ÷ 465 kW - 100.000/200.000 ÷ 400.000 kcal/h
Fuels Oil, max. viscosity at 20°C: 6mm
2
/s (1.5°E) natural gas with
Pci 8600 kcal/m
3
Lpg with Pci 22.200 kcal/m
3
Minimum gas pressure
(measured at the test-point) Maximum capacity requires 9 mbar with natural gas, 9.5 mbar with LPG. Combustion chamber at 0 mbar.
Maximum gas pressure 150 mbar
Electrical supply Three-phase 380 V +10% -15% ~60 Hz with neutral
Motor 1.5 A/380V
Pump-capacitor motor1A / 220 V - 6.3 µF
Ignition transformer Primary: 1.8A / 220 V - Secondary: 30 mA / 1x8 kV
Pump Output 55 kg/h at 12 bar - max pressure 15 bar
OperationTwo stages
Fig. 1
EQUIPMENT
Quantity Burner accessories
1 Gas-train’s gasket
8 Screws
1 Insulating screen
3 Seal
2 Oil hoses
4 Connectors
4 Gaskets
1 Lpg transf. kit
2 Oil nozzles
1 Flange
KEY TO LAY-OUT
1- Oil valve 1° stage
2- Oil valve 2° stage
3- Safety oil valve
4- Oil supply port
5- Oil return port
6- Pressure regulator at the pump
7- Air damper motor
8- Pressure gauge port (G 1/8)
9- Vacuum gauge port (G 1/8)
10 - Terminal board
11 - Reset push-button of the motor
overload relay
12 - Cable gland
13 - UV photocell
14 - Oil motor capacitor
15 - Oil-gas selector switch
16 - Control-box reset button
17 - Air pressure-switch
18 - Gas pressure socket to sleeve
2 1 389 4 5 7 18 17 15 11
10 12
16
1413
S7537
6

5143
2
DIMENSIONS
WORKING RANGE
PRESSURE IN THE COMBUSTION CHAMBER - 2
nd
STAGE OUTPUT
MINIMUM GAS PRESSURE - 2
nd
STAGE OUTPUT
Pressure : measured at the test point with combustion chamber at 0 mbar.
Boiler front-plate
drilling
* Extension that you can obtain with special extended head (to be requested separately)
.
Burner
160
160
155 M10
410 610
187
*320
397
97
292
165
Rp 1 1/2
D1785
S7564
S7565
ø 150
Kcal/h
mbar
kW
Min output at 1st stage 116kW - 10Kg/h
S7590
Kcal/h
mbar
kW
Gas pressure test point
Natural gas
LPG S7536
S7591

5143
3
FIXING TO THE BOILER
GAS SUPPLY LINE
In order to devide the combustion head from the rest of the burner, you have to:
- remove the connection (1) from the two valves;
- remove the 4 screws (2 - 3);
- slide the burner body (A) along the rails (4);
- mount the group (B) to the boiler’s plate (6) interposing gasket (5).
Mount the group (A) to the boiler front. Fit the nozzles and regulate the combustion head (as speci-
fied below).
S7539
654132
BA
{ {
1- Gas supply pipe 7- Min. gas pressure switch
2- Manual valve 8- Gas safety shut off valve
3- Isolator joint 9- 1° stage gas shut off valve
4- Filter 10 - 2° stage gas shut off valve
5- Pressure governor 11 - Burner
6- Pressure test-point 12 - Gas leak control device
S7572
6
986
7
54
6
32 1
11
10
12

5143
4
OIL SUPPLY
S7542
S7541
Please note:
all oil lines must be airtight.
We suggest copper-piping. Level as the suction
pipe, then a none return valve is not required
and the section-pipe can be disconnected with-
out causing any problems.
H= Margin; L= Inlet-pipe’s length, including the vertical line.
The copper pipes with diameter 8 and 10, shown in the schemes, can be replaced with 1/4 and 3/8
steel pipes, commercial gas without welding.
HLm
m Øi 8 Øi 10
0.5 5 10
11020
1.5 15 30
22040
HLm
m Øi 8 Øi 10
03270
0.5 28 62
12455
1.5 20 48
21640
3725
3.5 – 10
H
max. 4m
H
max. 4m
H

5143
5
BURNER ELECTRICAL WIRING
(carried out in the factory)
KEY TO LAY-OUT
C: Pump motor capacitor
CMV: Contact-maker
CO: Selector switch
MB: Burner terminal strip
MP: Pump motor
MV: Fan motor
PA: Air pressure switch
RT: Thermal relay
SM: Servo-motor
TA: Ignition transformer
TB: Burner earth
UV: Probe U.V.
V1: 1° stage valve
V2: 2° stage valve
VS: Oil safety valve
SELECTOR SWITCH
OIL O GAS
3 - 4
5 - 6
7 - 8
9 - 10
11 - 12
13 - 14
15 - 16
S7573
S7562

5143
6
ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK
(to be carried out by the installer)
KEY TO LAYOUT
MB - Burner terminal strip V1 - 1° stage gas shut off valve
MR - Gas train terminal strip V2 - 2° stage gas shut off valve
TS - Safety remote control system VS - Gas safety shut off valve
TL - Limit control system S- Remote lock signal
T2 - 2° stage remote control system PC - Check pressure switch
PG - Min. gas pressure switch TB - Burner earth
NOTICE
- The electric wiring carried out by the installer must be in compliance with the rules in force in the
country.
- Leads minimal section 1.5 mm2.
- Burners with non-stop operation: for safety reasons, this type of burner must be stopped every 24
hours of operation, by means of an hours-counter to be connected in series with the adjustment
devices.
- The flame modulation in obtainable trought the 2° stage remote control system (T2).
Connected to the terminals 9-10.
S7574

5143 7
FIXING OF THE ELECTRICAL WIRES
All the electrical wires, which are to be connected into the terminal rail 10 (fig. 1) should pass through
the cable glands hubes 12 (fig. 1), accordingly the scheme below.
1- Supply : gland Pg 21
2- Regulation thermostat : gland Pg 13.5
3- Safety thermostat : gland Pg 13.5
4 - 2° stage thermostat : gland Pg 13.5
5- GAS TRAIN : gland Pg 13.5 - for sheath ø 13
To guarantee the IP 40 protection level, in accordance to CEI 70.1, seal the glands that are not used.
NOTES
- Do not exchange “Neutral” with “Phase” (avoid a plug/socket connection).
- Make a good earth connection.
Verify that the burner will lockout by firing the burner and obscuring the UV cell.
ATTENTION
When you close the burner on the two guide rail, all the slack should be pulled out the high voltage-
cable.
This burner is in accordance to the CEE law n.76/889, D.M. 9/10/1980, for protection against radio-
noises.
S7575

5143 8
COMBUSTION HEAD ADJUSTMENT
Adjustments can be made to the burner, when it is still open for installation (see page 3, fixing to
the boiler).
SETTING OF GAS DISTRIBUTOR
The burner leaves the factory setted for burning natural
gas (see the drawing on the right):
-Each hole (F) completely opened.
To burn LPG fit the kit as detailed below:
-Fit 6 nozzles with ø 3 mm on outlets to holes (F).
Nozzle
1° 2° 1°+2°
kg/h
bar GPH kg/h GPH kg/h
12 2.50 9.7 2.50 9.7 19.4
10
12 3.00 3.00 10.8 11.7 3.00 3.00 10.8 11.7 21.6 23.4
10
12 3.50 3.50 12.6 14.0 3.50 3.50 12.6 14.0 25.2 28.0
10
12 4.00 4.00 14.3 15.8 4.00 4.00 14.3 15.8 28.6 31.6
10
12 4.50 4.50 16.4 18.0 4.50 4.50 16.4 18.0 32.8 36.0
10
12 5.00 5.00 18.2 20.4 5.00 5.00 18.2 20.4 36.4 40.8
10 5.50 19.7 5.50 19.7 39.4
Pump
pressure
NOZZLE’S CHOICE
Spray angle:
- usually, 60°
- for narrow combustion chambers: 45°
S7546
S7576
Position of the ignition electrodes
4 mm
4 mm
F
1° stage nozzle 2° stage nozzle

5143 9
ADJUSTMENT OF THE AIR DAMPER MOTOR
STOP - Blue lever
This lever leaves the factory vertically positioned and
corresponds to the complete closing of the air damper.
A partial opening of the air damper might be obtained by
moving leftwards this lever (+ on the label).
The new position the air damper is detectable when the
burner is off. Do not overcome the position of the orange
lever for the 1st stage.
1st STAGE - Orange lever
Theorangelevercontrolstheairdamperpositionforthefirst
flame, it is adjustable both for opening and closing.
2nd STAGE - Red and black levers
The red lever controls the air damper position for the second flame, it is adjustable both for closing and
opening. The black lever controls the opening of the second oil valve and it must always - for a bit - the
red lever, but never the orange one.
Loosen the two screws (1), move the elbow (2) so that the rear part (3) coincides to the desired set-
point (4). Tighten the screws (1).
S7548
21
3
4
Kcal/h kW
S7592
Opening + - Closing
Black lever
Red lever
Orange lever
Blue lever
S7570

5143 10
BURNER START-UP CYCLE
Venting the gas supply.
This is done by removing the screw from the gas pressure switch, or the pressure test point.
AIR PRESSURE SWITCH (17 Fig.1)
Adjust the air pressure switch after adjustment of all the other
parts of the burner, with air pressure switch setted at beginning
of the scale.
When the burner works (1st stage) increase the regulating
pressure, turning the handle slowly in the clockwise till the
burner is locked out.
Then turn back of 1 mbar and repeat the burners starting, in
order to verify the good work; if you have a lock out, turn back
once again of 0.5 mbar.
PUMP’S FIRING
In case of drop-plant with supply from the tank’s bottom, back off the plug at the vacuumeter-joint 9)
(fig. 1), till the leaking of fuel.
In the other two situations, start up the burner, bleed the air of manometer-joint 8) P (fig. 1); if you
have a lock-out, repeat the cycle.
ATTENTION
Before starting up the burner, check that the return pipe has no occlusions.
Any occlusions will cause the break of the pump-sealing organ.
WORK WITH OIL
At the first ignition, when there is the passage from the first to the second flame, there is a strong
decrease of fuel-pressure owing to the filling of second nozzle’s pipe. This decrease can cause the
burn-out of the burner.
COMBUSTION CHECKS
CO2
It is better to set the burner with CO2not higher than 10% (gas with Pci 8600 kcal/m3).
So you avoid that a little unsetting (for example draft variation) causes combustion with few air and
with the production of CO.
CO
It must be not higher than 0.1% (thousand parts for million) in accordance to UNI-CIG 8042 norme.
Screw
Pressure gauge fixing point
Pressure switch
S7577
1 ÷ 10
mbar
Regulating handle S7550

5143 11
CURRENT TO THE UV PHOTOCELL
Min. value for a good work: 15 µA.
If the value is lower, it can depends on:
- worked out photocell.
- low current (lower than 187V)
- bad regulation of the burner.
In order to measure the current, use a microammeter of 100 µA c.c., connected to the photocell, as in
the scheme, with a capacitor of 100 µF - 10V c.c. at the same level of the instrument.
BURNER STARTING UP PROGRAMME
If during the work the flame burns off, there is a lock out within 1 second.
+-
S7551
+
-
+-
Cell
UV
Normal Lock-out because no ignition
Thermostat
Motor
Ignition transf.
1st valve
1st flame
2nd valve
2nd flame
Lock-out S7593
37s min.
4s 10s
37s min.
4s 2s max.

5143 12
BURNER STARTING DIFFICULTIES AND THEIR CAUSES
The electrical equipment is fitted with a disk which rotates during the start-up program and can be seen
through the release inspection window. When the burner does not start or stops because of a fault, the
symbol which appears in the inspection window indicates the type of interruption fault.
THE EQUIPMENT DOES NOT START WHEN THE THERMOSTATS CLOSE
- There is no gas.
- The min. gas pressure switch does not close the contact: it is incorrectly adjusted.
- The air pressure switch is set in operating position.
- The equipment fuse has blown.
- The cam pos. 1 selector switch does not close the circuit, equipment terminals 11 and 8.
HALT AFTER START-UP
- The cam pos. 2 selector switch does not close the circuit, equipment terminals 9 and 8.
LOCK HALT
The air pressure switch does not effect a selection because of:
- a fault contact;
- insufficient air pressure.
LOCK HALT
Malfunctions of the flame detection circuit:
- photo-sensitive cell exhausted;
- fault internal amplifier.
PRE-VENTILATION HALT
- The cam pos. 3 selector switch does not close the circuit, equipment terminals 10 and 8.
LOCK HALT, no flame signal:
- ……
- photo-sensitive cell connection to the equipment is interrupted;
- insufficient electrical detection current (min. 70 µA).
LOCK HALT IN OPERATION BECAUSE OF:
- no flame signal;
- no air pressure.
N.B.:
- If the lock halt takes place between start and pre-start-up without a fault symbol appearing, the fault
is usually flame simulation.
- The burner continues repeating the start-up cycle without the lock taking place:
a) there is oscillation of the min. gas pressure switch caused by adjustment very close to the mains
pressure, so that the drop in pressure which occurs at burner start-up is sufficient to trigger action and
this cause a new start-up cycle.
P
1

RIELLO S.p.A.
Via degli Alpini 1
I - 37045 Legnago (VR)
Tel.: [phone] Fax: [phone]
Con riserva di modifiche