Riello G 24 Quick start guide

2915388 (5) - 10/2013

Installation, use and maintenance instructions

Light oil burner

Two-stage operation

G 24

CODE MODEL TYPE

3473000 G 24 651 M

1 Declaration

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: G 24

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

The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.

Legnago, 19.11.2012 Executive Director

RIELLO S.p.A. - Burner Department

Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. I. Zinna Mr. R. Cattaneo

CONTENTS

1. BURNER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. HYDRAULIC SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.1 Electrical system factory-set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.2 Electrical connection to the terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5. BURNER ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.1 Combustion head adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.2 Air damper adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.3 Positioning of electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6. PRIMING THE PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7. BURNER START-UP CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. BURNER DESCRIPTION

1 - Suction line fitting

2 - Return line fitting

3 - Suction gauge fixing point (G 1/8)

4 - Pressure gauge fixing point (G 1/8)

5 - Pump pressure adjuster

6 - Wiring terminal block

7 - Fairleads

8 - Control box reset-button with signal of

lock-out

9 - Combustion head control shaft

10 - Photoresistance

11 - Flange with thermal insulation screen

12 - Air damper

13 - Screw for fixing air damper and as point of

reference for its adjustment

1.1 STANDARD EQUIPMENT

Flexibles oil-lines with nipples and gaskets . N° 2

Flange with thermal insulation screen. . . N° 1

Screws and nuts for flange . . . . . . . . . . . N° 4

Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . N° 2

Screws with two nuts for flange. . . . . . . . N° 1

Hinge. . . . . . . . . . . . . . . . . . . . . . . . . . . . N° 1

Fig. 1

2. TECHNICAL DATA

2.1 DIMENSIONS

2.2 FIRING RATE

MODEL G 24

TYPE 651 M

THERMAL POWER 140 ÷ 237 kW / 120.000 ÷ 240.000 kcal/h

OUTPUT 12 ÷ 24 kg/h

FUEL Gas oil, max. viscosity at 20 °C: 6 mm2/s (1.5 °E)

ELECTRICAL SUPPLY single-phase 220 V +10% -15% ~ 50 Hz

MOTOR 1.85 A / 220 V

CAPACITOR 8 F / 450 V

IGNITION TRANSFORMER Primary 1.6 A / 220 V - sec. 30 mA / 1x8 kV

ABSORBED ELECTRICAL POWER 0.4 kW

WEIGHT 21.6 kg

ELECTRICAL PROTECTION IP 40

Burner

Flange

* with long combustion head kit

OUTPUT - PRESSURE IN THE COMBUSTION CHAMBER

3. HYDRAULIC SYSTEMS

GRAVITY FEED from the bottom of the oil storage tank

GRAVITY FEED over the top of the oil storage tank

SUCTION FEED

H= Difference in height;

L= Total lenght of the suction line, including the vertical section;

The copper pipes of 8 mm and 10 mm I.D., as shown on the tables above, may be replaced by steel pipes of 1/4” or 3/8” Gas.

The dimension P should not exceed 10 m, to

avoid breakage of pump seals.

meters

L meters

øi øi

8 mm 10 mm

0.5 5 10

110 20

1.5 15 30

220 40

The dimension P should not exceed 10 m, to

avoid breakage of pump seals.

meters

L meters

øi øi

8 mm 10 mm

032 70

0.5 28 62

124 55

1.5 20 48

216 40

37 25

3.5 - 10

meters

L meters

øi øi

8 mm 10 mm

032 70

0.5 28 62

124 55

1.5 20 48

216 40

37 25

3.5 - 10

Oil lines must be perfectly

sealed. The use of cop-

per pipe is therefore rec-

ommended.

The pump suction must

not exceed 4 m w.c. (30

cm Hg) because beyond

this value the pump

becomes noisy.

The return line must ter-

minate at the same level

as the foot valve; other-

wise the pump may

become air-locked.

4. ELECTRICAL SYSTEM

4.1 ELECTRICAL SYSTEM FACTORY-SET

KEY TO LAYOUT

C- Capacitor

FR - Photoresistance

MB - Burner terminal strip

MV - Motor

TA - Ignition transformer

TB - Burner ground (earth)

connection

V1 - 1st stage solenoid

valve

V2 - 2nd stage solenoid

valve

4.2 ELECTRICAL CONNECTION TO THE TERMINAL STRIP

(installer-set)

NOTE

- Do not exchange the neutral wire with the phase (avoid the

plung-pin connection).

- Carry out a safe earth connection.

- Cable section not indicated: 1 mm2.

- All the electrical wires, which are to be connected to the termi-

nal block shall pass through the fair leads 7 (Fig. 1) to guaran-

tee the electrical protection IP 40.

- Verify the burner stop by opening the boiler thermostat and

the burner lock-out by darkening the photoresistance.

- The burner has been type approved for intermittent operation.

This means it should compulsorily be stopped at least once

every 24 hours to enable the control box to perform checks of

its own efficiency at start-up.

Burner halts are normally provided for automatically by the

boiler load control system.

If this is not the case, a time switch should be fitted in series

to TL to provide for burner shut-down at least once every 24

hours.

(A)

S8981

BLUE

BROWN

BLACK

KEY TO LAYOUT

MB - Burner terminal strip

S- Remote lock-out signal

TB - Burner ground (earth) connection

TL - Limit control device system

TS - Safety control device system

S8982

5. BURNER ADJUSTMENT

Establish, on the basis of the output desired, and in accordance with the table and the diagram underneath:

- the type of nozzle;

- the pump pressure;

- the combustion head setting.

EXAMPLE

The burner has to be matched with a boiler of 220 kW.

Assuming an efficiency of 90%, we need to develop approximately 245 kW i.e. burning reughly 21 kg/h.

Starting from 21 kg/h in the delivery column, we find in the other columns the nozzle necessary (two 2.50 GPH - or

one 3.00 GPH and one 2.00 GPH - with 60° atomisation angle), the pump pressure (12 bar), and the position of the

combustion head (notch 5).

(1) The indicated outputs are drawn from the average statistical data of our tests. Real output may well vary by

+10%.

(2) Nozzles of the major existing makers may be used.

It might well be possible however, that for certain specific outputs, one type of nozzle is less suitable than others.

It is recommended not to change the atomizing angle.

(3) The pressure is adjusted by turning screw 5 (Fig. 1) on the pump; it is monitored by installing a pressure gauge

on connection 4 (Fig. 1).

The measurement indicated (12 bar) can be varied by +2 bar (e.g. to adjust the delivery); a pressure of 14 bar

for low temperature firing is advised.

(4) See below.

5.1 COMBUSTION HEAD ADJUSTMENT

This is effected when the nozzle is fitted, with the blast tube disassembled.

The adjustment depends on the required delivery to the burner and it is done by turning adjustment bar 9 (fig. 1)

untill the edge of the blast tube is aligned with the notch indicated by the table on this page (see above).

In figure 3, for example, head is set for a delivery 3.50 GPH at 12

bar; notch 3 on the indicator in fact coincides with the edge of blast

tube.

Head adjustments shown on the table on the previous page are

correct in the majority of cases; adapting the fan delivery to the

burner is normally done only with the air gate valve.

If revision of the head adjustment is required, remember that by

turning the adjustment bar clockwise the air delivery is increased.

By turning the adjustment bar anti-clockwise the air delivery is

reduced.

Do not under any circumstances move the head adjustment more

than one notch either side of the measurement obtained from the

table.

The burner leaves the factory with the head set at notch 4.

Burner delivery (1)

kg/h +10%

Nozzle (2) Pump pressure (3)

bar

Combustion head

setting (4)

Notch

GPH Angle

12 1.50 + 1.50

1.75 + 1.25 60° 12 1

15 1.75 + 1.75

2.00 + 1.50 60° 12 2

17 2.00 + 2.00

2.25 + 1.75 60° 12 3

19 2.25 + 2.25

2.50 + 2.00 60° 12 4

21 2.50 + 2.50

3.00 + 2.00 60° 12 5

24 3.00 + 3.00

3.50 + 2.50 60° 12 6

Fig. 3

5.2 AIR DAMPER ADJUSTMENT

Adjusting the air delivery effected on the air damper 1 (Fig. 4) after loosening screws 2 and 3.

Once the air damper has been adjusted, tighten 2 and 3 fully down.

5.3 POSITIONING OF ELECTRODES

Make sure that the electrodes are positioned as shown in Fig. 5.

Fig. 4

Fig. 5

6. PRIMING THE PUMP

In case of a gravity feed system, from the bottom of the oil-storage tank (see page 4), loosen the screw of the

suction-gauge fixing point 3 (Fig. 1), until the fuel flows out.

In the other two cases, start the burner and bleed the air from the pressure gauge connection by loosening

plug 4 (Fig. 1).

Do not illuminate the photoresistance as this would cause an immediate lock-out.

If, during these operations, the burner locks out, reset it and repeat the cycle as many times as necessary.

CAUTION!

Check, before starting the burner, that the return line to the oil-storage tank is not in any way obstructed.

Any obstruction would cause the breakage of the pump seals.

7. BURNER START-UP CYCLE

NORMAL LOCK-OUT BECAUSE NO IGNITION

THERMOSTAT

MOTOR

IGNITION TRANSFORMER

1st VALVE

VALVE

LOCK-OUT LAMP

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