Riello GULLIVER RG1 Quick start guide

20024093 (2) - 01/2015
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 - 型号
20024095 RG1 363 T1
GB
CN
One stage operation
一段火运行

20024093
1GB
INDEX
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket. . . .No. 1 Screw and nuts for flange to be fixed to boiler . No. 4
Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . No. 2
7 pin plug. . . . . . . . . . . . . . . . . . .No.1
1. BURNER DESCRIPTION. . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2
2.2 Overall dimensions . . . . . . . . . . . . . . . . 2
2.3 Firing tare . . . . . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Recommended nozzles. . . . . . . . . . . . . . 6
4.3 Setting of diffuser disc / electrodes . . . . . 7
4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7
4.5 Combustion head setting. . . . . . . . . . . . . 8
4.6 Air damper adjustment . . . . . . . . . . . . . . 8
4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
1– Oil pump
2– Control-box
3– Reset button with lock-out
lamp
4– Flange with insulating
gasket
5– Air damper adjustment assembly
6– Nozzle holder assembly
7– Photoresistance
The burner meets protection level of IP X0D (IP 40), EN 60529.
Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility - 2004/108/
EC, Low Voltage 2006/95/EC, Machines 2006/42/EC.
Fig. 1
S7194

20024093 2GB
4
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 FIRING RATE, (as EN 267)
TYPE 363T1
Output - Thermal power 2.7 –5 kg/h - 32 –60 kW
Fuel Light oil, viscosity 4 –6 mm2/s at 20 °C
Electrical supply Single phase, ~50Hz 230V ±10%
Motor Run current 0.85A – 2750 rpm – 289 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 –15 bar
Absorbed electrical power 0.17 kW
196 93 122 180
130
150
4
22
210
254
11
7272
91
45°
45°
D5699
112
ø84
Pressure in combustion
chamber – mbar
0,6
0,4
0,2
-1,0
0,1
0,3
0,5
0,7
-2,0
0
-0,5
-1,5
20095949
EN 267
33,5
30 40
4
50
5
60
2,5 4,5
35 45 55
EN 746-2
Light oil output – kg/h
Thermal power – kW

20024093
3GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
Put on the flange (1) the screw and two nuts, (see fig. 3).
Widen, if necessary, the insulating gasket holes (5).
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. 2).
3.2 FUEL SUPPLY
The burner is designed to allow entry of the oil supply pipes on either side.
Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate
(1) and closing plate (2) should be reversed, (see fig. 4).
Fig. 2
Fig. 3 S7189
D5700
221 1
Fig. 4

20024093 4GB
3.3 HYDRAULIC SYSTEMS
It is necessary to install a filter on the fuel supply line.
H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.
H
max. 4 m
max. 4 m
H
H
H
D5705
Fig. 7 Fig. 8
PRIMING PUMP:
On the system in fig. 6 it is sufficient to loosen the suction gauge
connection (5, fig. 5) and wait until oil flows out.
On the systems in fig. 7 and 8 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.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 8) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not re-
quired. Should however the return line arrive over the fuel level, a non-return
valve is required.
This solution however is less safe than previous one, due to the possibility of
leakage of the valve.
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
The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to
unscrew the return plug (2), remove the by-pass screw
(3) and then screw again the plug (2). (See fig. 5).
Before starting the burner make sure that the return
pipe-line is not clogged. An excessive back pressure
would cause the damage of the pump seal.
WARNING:
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
SYSTEM NOT PERMITTED
IN GERMANY
Fig. 6
H
max. 4 m
D5703
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve
8- Auxiliary pressure test point
1
324
8
76
Fig. 5
D5487
5

20024093
5GB
3.4 ELECTRICAL WIRING
D1913
ESEGUITO IN FABBRICA
NOTES:
– Wires of min. 1 mm2section.
(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.
WARNING
CONTROL BOX
To remove the control-box from the burner, loosen screw (A, fig. 9)
and pull to the arrow direction, after removing all components, the
7 pin plug and earth wire.
In case of disassembly of the control box, retighten the screw
(A) with a torque wrench setting of 1 – 1.2 Nm.
DO NOT EXCHANGE NEUTRAL WITH PHASE
7 pin plug
7 pole socket
Black
White
Capacitor
Main switch
T6A
Motor
Blue
Oil valve
Hour counter
(230V - 0.
1A max.)
Limit thermostat Remote lock-out signal
(230V - 0.5A max.)
Ignition
electrodes
Brown
Burner-earth
CARRIED-OUT IN THE FACTORY
552SE
CONTROL BOX
Photoresistance
PE L N
~ 50Hz 230V
Blue
TESTING
Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
S7186
Fig. 9
A
Safety thermostat

20024093 6GB
4. WORKING
4.1 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 CO2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle and 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.
4.2 RECOMMENDED NOZZLES: Delavan type W- B ; Danfoss type S - B - H
Monarch type R - NS ; Steinen type S - Q - H
For ignitions at low temperature (lower than + 8 °C) act as follows:
Use nozzles with empty or half-empty cone of
the following type:
Delavan type W; Danfoss type H;
Monarch type NS ; Steinen type H,
or (as alternative) increase the pump pressure
up to 14 bar.
If necessary, adopt both solutions.
MAINTENANCE POSITION
THE ACCESSIBILITY TO THE NOZZLE, THE
DIFFUSER DISC AND THE ELECTRODES IS
MADE EASY IN 2 WAYS:
Fig. 10
Remove the burner out of the boiler, after loos-
ing the fixing nut to the flange.
Hook the burner to the flange (1), by remov-
ing the blast tube (2) after loosing the fixing
screws (3).
Remove the small cables (4) from the elec-
trodes and the diffuser disc-holder assembly (5)
from the nozzle-holder assembly after loosing
its fixing screw (3, fig. 12, page 7).
Screw the nozzle (6) correctly and tighten it
as shown in the figure.
Nozzle Pump
pressure Burner output Combustion head adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.65 60° 12 2.7 2.5 1.5
0.75 60° 12 3.0 3 2.9
0.85 60° 12 3.4 3.5 4.2
1.00 60° 12 4.0 4 5.6
1.10 60° 12 4.4 4 6.3
1.10 60° 15 5.0 4 6.7
AFig. 10
2
5
4
3
6
1
S7477
A

20024093
7GB
Fig. 11
Remove nozzle-holder assembly (1) after loos-
ing screws (2) and nut (3), remove the small ca-
bles (4) from the control box and the
photoresistance (6).
Withdraw the small cables (4) from the elec-
trodes, remove the diffuser disc-holder assem-
bly (10) from the nozzle-holder assembly (1)
after loosing screw (3, fig. 12).
Screw the nozzle (11) correctly and tighten
it as shown in figure.
ATTENTION
During the reassembly of the nozzle-holder
assembly screw the nut (3) as shown in the figure
below.
4.3 SETTING OF DIFFUSER DISC /
ELECTRODES (see fig. 12)
4.4 PUMP PRESSURE
The pump leaves the factory set at 12 bar.
To change it act on pump pressure adjust screw (4, fig. 5, page 4).
S7206
BFig. 11
B
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684
Loosen screw (3) to set the dif-
fuser disc-holder assembly (1)
and loosen screw (4) to set the
electrodes assembly (2).
ATTENTION
To have access to the electrodes
carry out operation as described in
chapter “4.2 RECOMMENDED
NOZZLES” (page 6).
WARNING MEASURES
MUST BE RESPECTED
D5028
24
31
4.5 – 0.5 mm
0
2.5 ± 0.2 mm
3 + 0.5 mm
0
Fig. 12

20024093 8GB
4.5 COMBUSTION HEAD SETTING (see fig. 11, page 7)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting
screw (5) until the set-point marked on the regulating rod (9) is level with the outside plane of the nozzle-holder
assembly (1).
In the sketch the combustion head is set for an output of 0.75 GPH at 12 bar.
The set-point 3of the regulating rod (9) is at the same level with the outside plane of the nozzle-holder as-
sembly (1) as shown in the schedule.
4.6 AIR DAMPER ADJUSTMENT (see fig. 11, page 7)
To vary the setting adjust the screw (7) after loosing the nut (8).
When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.
4.7 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the burner
acting on the main switch of the system.
THE BASIC CHECKS ARE:
Check that there are not obstructions or dents in the supply or return oil pipes.
Clean the filter in the oil suction line and in the pump.
Clean the photoresistance, (7, fig. 1, page 1).
Check for correct fuel consumption.
Replace the nozzle (see fig. 10, page 6) and check the correct position of electrodes (fig. 12, page 7).
Clean the combustion head in the fuel exit area, on the diffuser disc.
Leave the burner working without interruptions for 10 min. and set rightly all the components stated in
this manual. Then carry out a combustion check verifying:
Smoke temperature at the chimney; Contentof CO2(%); ContentofCO(ppm);
Smoke value according to opacity smokes index according to Bacharach scale.
Lock-out due to failure to light
C
Normal
D5029
~12s
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp ~12s 5s
C