Riello Gulliver RG5DF Quick start guide

Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
2902902 (3) - 10/2014
Light oil burner
Quemador de gasóleo
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3739870 RG5DF 398T1
GB
E
Two stage operation
Funcionamiento de dos llamas

2902
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burner
Model: Gulliver RG5DF
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 03.09.2014 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. R. Cattaneo
Declaración de conformidad según ISO / IEC 17050-1
Fabricante: RIELLO S.p.A.
Dirección: Via Pilade Riello, 7
37045 Legnago (VR)
Producto: Quemador de gasóleo
Modelo: Gulliver RG5DF
Estos productos están conformes con las siguientes Normas Técnicas:
EN 267
EN 12100
y según lo dispuesto por las Directivas Europeas:
MD 2006/42/CE Directiva Máquinas
LVD 2006/95/CE Directiva Baja Tensión
EMC 2004/108/CE Compatibilidad Electromagnética
Estos productos están marcados como se indica a continuación:
La calidad está garantizada mediante un sistema de calidad y management certificado según UNE EN ISO 9001.
Legnago, 03.09.2014 Director general
RIELLO S.p.A. - Dirección Quemadores Director Investigación y Desarrollo RIELLO S.p.A. - Dirección Quemadores
Ing. U. Ferretti Ing. R. Cattaneo
CE - 0036 0325/01
CE - 0036 0325/01

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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 the heat generator. . 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 Accessories . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Overall dimensions . . . . . . . . . . . . . . . . 3
2.4 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION. . . . . . . . . . . . . . . . . . . 4
3.1 Heat generator fixing . . . . . . . . . . . . . . . 4
3.2 Working position . . . . . . . . . . . . . . . . . . 4
3.3 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Hydraulic systems . . . . . . . . . . . . . . . . . 5
3.5 Electrical wiring . . . . . . . . . . . . . . . . . . . 7
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Combustion adjustment. . . . . . . . . . . . . . 8
4.2 Recommended nozzles. . . . . . . . . . . . . . 8
4.3 Combustion head setting. . . . . . . . . . . . . 9
4.4 Electrodes adjustment. . . . . . . . . . . . . . . 9
4.5 Pump pressure and air output . . . . . . . . . 10
4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 10
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 11
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 12
1– Pump
2– Electronic start delaying device
3– Control-box
4– Reset button with lock-out lamp
5– Flange with insulating gasket
6– 2
nd
stage air damper adjustment
assembly
7– Nozzles holder assembly
8– Photoresistance
9– Hydraulic jack
10 – 4 pole socket
11 – 2
nd
stage valve
12 – 1
st
stage valve
13 – Valve casing assembly
S7111
10
1
9
2
7
6
12
3
4
5
13
8
11
Fig. 1
If the burner is to be combined with a hot air generator in Germany (WLE according to DIN 4794), the con-
trol box must be replaced with a Riello 550 SMD control box (remove the bridge), and the flame sensor
must be replaced with the amplified type (both fully interchangeable). This control box, combined with the
“remote reset kit” (which can be ordered separately), means that the burner can be reset by remote control.
ATTENTION

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2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 ACCESSORIES (optional):
EXTENDED HEAD KIT
The burner’s combustion head can be replaced by the long-headed version using a special kit, to be ordered
separately.
Refer to the instructions supplied with it for installation.
The kit must be installed in conformity with laws and local regulations.
SPACER KIT
There is a special kit available that, when mounted on the burner, lets you reduce head penetration in the
combustion chamber.
Refer to the instructions supplied with the “spacer kit” for installation.
The kit must be installed in conformity with laws and local regulations.
550 SMD CONTROL BOX AND INFRARED FLAME SENSOR
A more efficient control box is available on request, for teaming with hot air generators, with the following
features:
- spark reset function;
- switch for post-firing and recycle;
- indicator LED reporting various operating stages:
(green LED = motor operating; yellow LED = pre-heating stage; red LED = post-combustion);
- socket for remote reset and reset function in case of failed shutdown.
Refer to the instructions supplied with the control box for installation.
The kit must be installed in conformity with laws and local regulations.
REMOTE RESET KIT
There is a special kit available that, when mounted on the 550 SMD control box, lets you reset the burner
by remote control.
The kit must be installed in conformity with laws and local regulations.
TYPE 398T1
Output - Thermal power 8/12 −25 kg/h – 95/142 −296 kW
Fuel Light oil, viscosity 4 – 6 mm
2
/s at 20 °C
Electrical supply Single phase
~ 50Hz 220/230V ±10% Single phase ~ 60Hz 220/230V ±10%
Motor Run current 1.8A – 2750 rpm
289 rad/s Run current 2.6A – 2940 rpm 309 rad/s
Capacitor 8 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 −15 bar
Absorbed electrical power 0.4 kW 0.575 kW

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2.3 OVERALL DIMENSIONS
2.4 FIRING RATE
Firing rate has been determined in conformity with the provision of standard EN 267 (from 3.1 to - 0.3 mbar).
In addition, burner can be applied for operation with the combustion chamber featuring negative pressure
(up to - 2 mbar) according to the approval terms provided for in standard EN 746-2 for the whole unit com-
plete with equipment.
247 159 300 213
160
190
12.5
36
285
345
11
99
99
127
45°
45°
D5390
ø
125
Fuel output – kg/h
Thermal power – kW
Pressure in combustion
chamber – mbar
0
3.0
2.0
1.0
-1.0
-2.0
8 10 12 14
100
D4444
16 18
120
20
140 160 180 220 240200
22 24 26
260 280 300
EN 267
EN 746-2

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3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 HEAT GENERATOR FIXING
➤ Put on the flange (1) the screw and two nuts, (see fig. 3).
➤ Widen, if necessary, the insulating gasket holes (4), (see fig. 4).
➤ Fix the flange (1) to the heat generator door (3) using screws (5) and (if necessary) the nuts (2) inter-
posing the insulating gasket (4), (see fig. 2).
➤ After installation ensure that burner is lightly inclined as in fig. 5.
3.2 WORKING POSITION
Fig. 5
D5012
Fig. 4
D5025
Fig. 2
Fig. 3
S7112
4
3
2
1
5
The burner is designed to work only in the po-
sitions 1, 2, 4 and 6.
Any other position could compromise the cor-
rect working of the appliance.
Installations 3and 5are forbidden for safety
reasons.
D4420
1 2 3
4 5 6

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3.3 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).
3.4 HYDRAULIC SYSTEMS
➤ It is necessary to install a filter on the fu-
el supply line.
■
The pump is designed to allow working with
two pipes.
■ In order to obtain one pipe working it is nec-
essary to unscrew the return plug (2),
remove the by-pass screw (3) and then
screw again the plug (2) with a torque of
0.5 Nm.
■
Before starting the burner make sure that
the return pipe-line is not clogged. An
excessive back pressure (Š1 bar) would
cause the damage of the pump seal, with
subsequent fuel leaks inside the burner.
The pump has a delivery pressure regulation
device (5). Pressure increases if turned in a
clockwise direction, and decreases if turned in
the other direction.
An indication of sensitivity is 1 bar per turn.
The pressure can be regulated in a range of
8 - 15 bar.
Do not loosen the knob (11) and periodically
check that it is firmly fixed, for safety reasons.
D5392
11
Fig. 6
2
D5405
Fig. 7 5
4
2
3
6
97
10
8
1
1 - Suction line
2 - Return line
3 - By-pass screw
4 - Gauge connection
5 - 2nd stage pressure adjuster
6 - Suction gauge connection
7 - 1st stage valve
8 - Valve casing assembly
9 - 2nd stage valve
10 - Auxiliary pressure test point
11 - Knob
11
PUMP (see fig. 7)

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Pressurised systems have a positive fuel pressure on in-
take to the burner. Usually the tank is higher than the
burner, or the fuel pumping systems are on the outside of
the heat generator.
In the system in fig. 8, the table shows the maximum indi-
cated lengths for the supply line, depending on the differ-
ence in level, length and the diameter of the oil pipes.
PRIMING PUMP
It is sufficient to loosen the suction gauge connection
(6, fig. 7) and wait until oil flows out.
Depressurised systems have a negative fuel pressure
(depression) on intake to the burner. Usually the tank is
lower than the burner.
In the systems in figs. 9 and 10, the table shows the max-
imum indicated lengths for the supply line, depending on
the difference in level, length and the diameter of the oil
pipes.
PRIMING PUMP
On the systems in figs. 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.
In two pipe 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 required.
Should however the return line arrive over the fuel level, a non-return valve is required. This solution is
less reliable than the previous one, as the valve seal could be damaged.
PRESSURISED ONE PIPE SYSTEMS (fig. 8)
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
D5395
H
max. 4 m
Fig. 8
SYSTEM NOT PERMITTED
IN GERMANY
DEPRESSURISED SYSTEMS (fig. 9 and 10)
H
max. 4 m
max. 4 m
H
H
H
D5393
Fig. 9 Fig. 10
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
NOTES VALID FOR ALL SYSTEMS
The installer must ensure that the supply depression is not above 0.4 bar
(30 cm Hg). Above that level, gas leaks out from the fuel.
The pipes must all be perfectly sealed.
H= difference of level; L= max. length of the suction line;
I. D. = internal diameter of the oil pipes

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3.5 ELECTRICAL WIRING
DO NOT EXCHANGE
NEUTRAL WITH PHASE
WARNING
CONTROL BOX
To remove the control-box from the burner, loosen screw (A, fig. 11) 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.
7 pin plug
7 pole socket
h
L1 B4S3 T2
T1
N
Black
White
Blue
Capacitor
Burner-earth
Main switch
T6A
Neutral
CONTROL BOX
552SE
~ 50/60Hz 220/230V
N
123
Photoresistance
T
Blue
Ignition
electrodes
Brown
L
T
h
T
2
nd
stage oil valve
T8
T7
T6B5
4 pin plug
4 pole socket
Blue
Black White Blue
Brown
2 1 3 2 1
M
~
ELECTRONIC
DELAYING DEVICE
● 2
nd
stage
Motor
thermostat
M
12123
M
CARRIED-OUT IN THE FACTORY
1
st
stage oil valve
D4958
Limit thermostat Remote lock-out signal
(230V - 0.5A max.)
Safety
1
st
stage
hour counter
(230V - 0.1A max.)
2
nd
stage hour counter
(230V - 0.1A max.)
Brown
Blue
S7120
Fig. 11
A
NOTES:
– Wires of min. 1 mm
2
section. (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.
● Connect 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.
thermostat
TO BE DONE BY THE INSTALLER

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4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive EEC/92/42, the installation of the burner to the heat generator, setting
and testing must all be performed in respect of the instruction manual for the heater, including the controls
on the concentration of CO and CO
2
in the flue gases, the flue gas temperature and the average water and
air temperatures in the generator.
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 given in the table refer to a CEN boiler (in accordance with EN 267). They refer to 12.5% of
CO
2
, at sea level, room temperature and light oil temperature at 20°C, 50 Hz power frequency and com-
bustion chamber counterpressure at 0.
The values given in the table are just an indication; to get the best performance from the burner, the
regulations should be made on the basis of the effective requirements of the generator.
With 60Hz power frequency, the burner must be re-set, closing the air damper, so that the amount of
intake air is reduced.
4.2 RECOMMENDED NOZZLES
Delavan type W - B; Steinen type Q; Danfoss type S.
NOTE
If necessary, the 1st stage nozzle can have a capacity 50% above the total capacity.
The 1
st
stage nozzle should not have a capacity 50% less than the total capacity, as the flame could be unstable.
REPLACE THE NOZZLES ,
(fig. 12 and 13)
To replace the nozzles proceed as fol-
lows:
➤ Disconnect the rubber coated leads
(4) from the control box and slide out
the photocell (5).
➤ Loosen the screws (2) and unscrew
the nuts (3).
➤ Slide out the rubber coated leads (4)
from the electrodes, unscrew and re-
move the screws (9, fig. 13, page 9)
in the diffuser disc unit (8, fig. 13,
page 9).
➤ Pull out the nozzle holder assembly
(1) turning it slightly in a clockwise
direction.
Nozzles Pump
pressure Burner output Combustion head
adjustment
Air damper
adjustment
GPH Angle kg/h ± 4% 1
st
stage 2
nd
stage
1
st
stage 2
nd
stage bar 1
st
stage 2
nd
stage Set-point Set-point Set-point
2.00 1.00 60° 12 8.0 12.4 0 0.25 2.1
2.00 2.00 60° 12 8.0 16.4 3 0.15 3.0
2.50 2.50 60° 12 10.3 20.5 6 0.3 4.4
3.00 3.00 60° 12.5 12.6 25.0 8 0.6 6.0
ATTENTION
3
4
2 6
02468
S7763
1
5
7Fig. 12