Riello RG1F Quick start guide

OBSOLETE DOCUMENT
End validity date 05/2011
Refer to document code:
20039735

2902888 (2)
Installation, use and maintenance instructions
Instrucciones para la instalación, uso y mantenimiento
Light oil burner
Quemador de gasóleo
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3736370 RG1F 363T1
GB
E
One stage operation
Funcionamiento de una sola llama

2888
4
DECLARATION OF CONFORMITY
RIELLO S.p.A. hereby declares under its sole responsibility that the Gulliver series burner model RG1F
conforms to the following European Directives:
- Council Directive 73/23/EEC of 19th February 1973 - relating to Electrical Equipment
- Council Directive 98/37/EEC of 29th June 1998 – relating to Machinery
- Council Directive 89/336/EEC of 3rd May 1989 - relating to Electromagnetic Compatibility
and to the following Technical Standards:
EN 267, EN 60730-5, EN 60529 (IP X0D).
➤CE Certification No.: 0036 0341/03 as 92/42/EEC.
DECLARACIÓN DE CONFORMIDAD
RIELLO S.p.A. declara, bajo su responsabilidad, que el quemador serie Gulliver modelo RG1F es con-
forme a las siguientes Directivas Europeas:
- Directiva del Consejo 73/23/CEE del 19 Febrero 1973 – relativa al Material Eléctrico
- Directiva del Consejo 98/37/CEE del 29 Junio 1998 - en materia de Seguridad de las Máquinas
- Directiva del Consejo 89/336/CEE del 03 Mayo 1989 – relativa a la Compatibilidad Electromagnética
y a las siguientes Normas Técnicas:
EN 267, EN 60730-5, EN 60529 (IP X0D).
➤CE Reg. N.: 0036 0341/03 según 92/42/EEC.
RIELLO S.p.A.

2888 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 the heat generator . . 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 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 Maintenance position . . . . . . . . . . . . . . . 9
4.4 Setting of diffuser disc / electrodes . . . . . 10
4.5 Pump pressure . . . . . . . . . . . . . . . . . . . . 10
4.6 Combustion head setting. . . . . . . . . . . . . 10
4.7 Air damper adjustment . . . . . . . . . . . . . . 10
4.8 Burner start-up cycle. . . . . . . . . . . . . . . . 10
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 11
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 12
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
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
Fig. 1
S7194

2888 2GB
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.
PRE-HEATER KIT
There is a special kit available that, when installed in the combustion head, allows fuel to be heated so as
to assure regular burner firing and operation. It can basically be used in special atmospheric conditions (low
temperatures), with high diesel oil viscosity and with low deliveries. Refer to the instructions supplied with
the “pre-heater 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 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 220/230V ±10%
Single phase
~60Hz 220/230V ±10%
Motor Run current 0.7 A – 2800 rpm
294 rad/s
Run current 0.9A – 3230 rpm
339 rad/s
Capacitor 4 µF
Ignition transformer Secondary 8 kV −16 mA
Pump Pressure: 8 −15 bar
Absorbed electrical power 0.155 kW 0.2 kW

2888 3GB
2.3 OVERALL DIMENSIONS
2.4 FIRING RATE
Firing rate has been determined in conformity with the provision of standard EN 267 (from 0,7 to - 0,2 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.
196 93 122 180
130
150
4
22
210
254
11
7272
91
45°
45°
D5699
112
ø84
Light oil output – kg/h
Thermal power – kW
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
D4466
EN 267
33.5
30 40
4
50
5
60
2.5 4.5
35 45 55
EN 746-2

2888 4GB
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 (5).
➤Fix the flange (1) to the heat generator door (4) using screws (2) and (if necessary) the nuts (3) inter-
posing the insulating gasket (5), (see fig. 2).
3.2 WORKING POSITION
Fig. 2
Fig. 3 S7189
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

2888 5GB
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 closing plate (2) should be reversed, (see fig. 4).
3.4 HYDRAULIC SYSTEMS
➤It is necessary to install a filter on the fuel supply
line.
■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) 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 (4).
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.
D5700
221 1
Fig. 4
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
PUMP (see fig. 5)

2888 6GB
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. 6, 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
(5, fig. 5) and wait until oil flows out.
Depressurised systems have a negative fuel pressure (de-
pression) on intake to the burner. Usually the tank is lower
than the burner.
In the systems in figs. 7 and 8, the table shows the maxi-
mum 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. 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.
In two pipe 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 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. 6)
H
meter
s
L meters
I. D.
8 mm
I. D.
10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
SYSTEM NOT PERMITTED
IN GERMANY
Fig. 6
H
max. 4 m
D5703
DEPRESSURISED SYSTEMS (fig. 7 and 8)
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.
Fig. 7 Fig. 8
H
max. 4 m
max. 4 m
H
H
H
D5705

2888 7GB
3.5 ELECTRICAL WIRING
CONTROL BOX (see fig. 9)
To remove the control-box from the burner, loosen screw (A) 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.
D1913
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
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
552SE
CONTROL BOX
Photoresistance
PE L N
Blue
TESTING
Check the shut-down of the burner by opening
the thermostats and the lock-out by darkening
the photoresistance.
Safety thermostat
~50/60Hz 220/230V
CARRIED-OUT
IN THE FACTORY
TO BE DONE
BY THE INSTALLER
S7186
Fig. 9
A