Riello Gulliver RG4D Quick start guide

20024120 (1) - 05/2010
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
20024122 RG4D 397 T1
GB
CN
Two stage operation
两段火运行

20024120
1GB
INDEX
1. BURNER DESCRIPTION
Two 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 4 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 Working field . . . . . . . . . . . . . . . . . . . . . 2
2.4
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 Combustion head setting. . . . . . . . . . . . . 7
4.4 Electrodes adjustment. . . . . . . . . . . . . . . 7
4.5 Pump pressure and air output. . . . . . . . . 7
4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9
1– Pump with pressure reducer
2– Electronic start delaying
device
3– Control-box
4– Reset button with lock-out
lamp
5– Flange with insulating
gasket
6– 2nd stage air damper
adjustment assembly
7– Nozzle holder assembly
8– Photoresistance
9– Hydraulic jack
10 – 4 pole socket
11 – 2nd stage valve
12 – 1st stage valve
The burner meets protection level of IP X0D (IP 40), EN 60529.
Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 89/336/EEC -
2004/108/EC, Low Voltage 73/23/EEC - 2006/95/EC, Machines 2006/42/EC and Efficiency 92/42/EEC.
Fig. 1
S7242

20024120 2GB
4
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD (as EN 267)
TYPE 397T1
Output - Thermal power 9/ 11 – 20 kg/h - 106/ 130 – 237 kW
Fuel Light oil, max. viscosity at 20°C: 6 mm2/s
Electrical supply Single phase, ~50Hz 230V ±10%
Motor Run current 2 A - 2730 rpm - 286 rad/s
Capacitor 6.3 F
Ignition transformer Secondary 8 kV - 16 mA
Pump Pressure: 8 –15 bar
Absorbed electrical power 0.39 kW
228 142 300 213
160
190
12
36
285
345
11
9999
127
45°
45°
D5353
ø123
Light oil output – kg/h
Thermal power – kW
Pressure in combustion
chamber – mbar
8101214
100
2.4
1.8
1.2
0.6
0
D5355
16 18
120
3.0
20
140 160 180 220 240200

20024120
3GB
3. INSTALLATION
3.1 BOILER FIXING
OPut on the flange (1) the screw and two nuts, (see fig. 3).
OWiden, if necessary, the insulating gasket holes (4), (see fig. 4).
OFix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the
insulating gasket (4), (see fig. 2).
OAfter installation ensure that burner is lightly inclined as in fig. 5.
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 cable clamp (2) should be reversed, (see fig. 6).
Fig. 5
D5012
Fig. 4
D5025
Fig. 2
Fig. 3 S7071
D5345
22
11
Fig. 6

20024120 4GB
3.3 HYDRAULIC SYSTEMS Fig. 8
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.
PRIMING PUMP:
On the system in fig. 7 it is
sufficient to loosen the suction gauge
connection (6, fig. 8) and wait until oil flows out.
On the systems in fig. 9 and 10 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. 10) 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.
8
H
meters
L meters
øi
8 mm øi 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
OBefore 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.
OThe 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. 8).
WARNING:
1- Suction line
2 - Return line
3 - By-pass screw
4 - Gauge connection
5 -2
nd stage pressure adjuster
6- Suction gauge connection
7 -1
st stage pressure adjuster
8 - Pressure reducer piston
9 -2
nd stage valve
10 - 1st stage valve
11 -Auxiliary pressure test point
H
meters
L meters
øi
8 mm øi 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
S7067
H
max. 4 m
max. 4 m
H
H
H
D5744
Fig. 9 Fig. 10
Fig. 7
D5745
H
max. 4 m

20024120
5GB
3.4 ELECTRICAL WIRING
DO NOT EXCHANGE
NEUTRAL WITH PHASE
WARNING
To remove the control-box from the burner, loosen screw (A, fig. 11) 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.
NOTES:
– Wires of 1 mm2 section.
– The electrical wiring carried out by the installer must be in
compliance with the rules in force in the Country.
OConnect 2nd stage thermostat between clamps T6 - T8
by removing the bridge.
TESTING: Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
Fig. 11
S7072 A
7 pin plug
7 pole socket
h
L1 B4S3 T2
T1
N
Black
White
Blue
Capacitor
Burner-earth
Switch with fuse
6A max.
Neutral
CONTROL BOX
552SE
~ 50Hz 230V
N
123
Photoresistance
T
Blue
Ignition
electrodes
Brown
L
T
h
T
2nd stage oil valve
T8
T7
T6
B5 4 pin plug
4 pole socket
Blue
Black White Blue
Brown
21 321
M
~
ELECTRONIC
DELAYING DEVICE
O2nd stage
Motor
thermostat
M
12123
M
CARRIED-OUT IN THE FACTORY
1st stage oil valve
D5336
Regulating thermostat Remote lock-out lamp
(230V - 0.5A max.)
Limit thermostat
with manual
resetting
1st stage
hour counter
(230V - 0.1A max.)
2nd stage hour counter
(230V - 0.1A max.)
Brown
Blue

20024120 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
Monarch type R ; Delavan type W - E
Steinen type Q ; Danfoss type S
Satronic type S
TO FIT NOZZLE CARRY OUT THE FOLLOWING
ACTIONS:
Remove nozzle-holder assembly (1) after loosing
screws (2) and nut (3), remove the small cables
(4) from the control box and the photoresistance
(5), (see fig. 12).
Withdraw the small cables (4) from the electrodes,
remove the diffuser disc-holder assembly (8) from
the nozzle-holder assembly (1) after loosing screw
(3, fig. 13, page 7).
Screw the nozzle (9) correctly and tighten it as
shown in figure 12.
ATTENTION
During the reassembly of the nozzle-holder assem-
bly screw the nut (3) as shown in the figure below.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
bar kg/h ± 4% 1st stage 2nd stage
GPH Angle 1st stage 2nd stage 1st stage 2nd stage Set-point Set-point Set-point
2.50 60° 9 14 8.7 10.8 0 0.2 1.8
3.00 60° 9 14 10.4 13.0 1 0.5 2.7
3.50 60° 9 14 12.2 15.2 2.5 0.8 3.7
4.00 60° 9 14 13.9 17.3 4 1.0 4.5
4.50 60° 9 14 15.6 19.5 6 1.3 6.0
Fig. 12
S7238
3
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END
D5684

20024120
7GB
4.3 COMBUSTION HEAD SETTING (see fig. 12, page 6)
It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the set-
ting screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the
nozzle-holder assembly (1).
In the sketch the combustion head is set for an output of 3.50 GPH at 15 bar.
The set-point 2.5 of the regulating rod is at the same level with the outside plane of the nozzle-holder as-
sembly as shown in the schedule.
4.4 ELECTRODES ADJUSTMENT (see fig. 13)
Fig. 15
Fig. 14
S7064
Lean the diffuser disc-holder as-
sembly (1) on the nozzle-holder
(2) and lock it by screw (3). For
prospective adjustments loosen
screw (4) and move the elec-
trodes assembly (5).
ATTENTION
To have access to the electrodes
carry out operation as described in
chapter 4.2 (page 6) “RECOM-
MENDED NOZZLES”.
D5341
6 – 7 mm
4.5 – 0.5 mm
0
Fig. 13
4
5
123
MEASURES MUST BE
RESPECTED
WARNING
4.5 PUMP PRESSURE AND AIR OUTPUT
O1st STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER:
Unloosen the nut (1), turn the screw (2) until the indicator (3) reaches the
position desired. Then lock the nut (1), (see fig. 14).
PRESSURE REGULATION:
This is set at 9 bar at the factory.
Should it be necessary to re-set or alter such pressure, this can be done, by
adjusting screw (7).
The pressure gauge must be mounted in place of cap (8), (see fig. 15).
O2nd STAGE ADJUSTMENT
ADJUSTMENT OF AIR SHUTTER:
Unloosen the nut (4), turn the screw (5) until the
indicator (3) reaches the position desired.
Then lock the nut (4), (see fig. 14).
PRESSURE REGULATION:
This is set at 14 bar at the factory.
Should it be necessary to re-set or alter such pres-
sure, this can be done, by adjusting screw (9).
The pressure gauge must be mounted in place of
cap (8), (see fig. 15).
When burner shuts down the air damper automati-
cally closes till a max. chimney depressure of
0,5 mbar.

20024120 8GB
4.6 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (4, fig. 1, page 1).
5. MAINTENANCE
Burner requires a periodic maintenance carried out by a qualified and authorized technicians.
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:
OCheck that there are not obstructions or dents in the supply or return oil pipes.
OClean the filter in the oil suction line and in the pump.
OClean the photoresistance, (8, fig. 1, page 1).
OCheck for correct fuel consumption.
OReplace the nozzle (see fig. 12, page 6) and check the correct position of electrodes (fig. 13, page 7).
OClean the combustion head in the fuel exit area, on the diffuser disc.
OLeave the burner working without interruptions for 10 min. and check the right settings at 1st and 2nd
stage of all 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
D6040
Lock-out due to failure to light
B
Normal
3 –28s ~12s 5s
1st stage thermostat
2nd stage thermostat
Motor
Ignition transformer
1st stage valve
1st stage flame
2nd stage valve
2nd stage flame
Lock-out lamp ~12s
B