Riello G10 Quick start guide

20013656 (3) - 04/2011

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 - 类型

20013638 G10 464T1

One stage operation

一段火运行

20013656

INFORMATION ABOUT THE INSTRUCTION MANUAL

INTRODUCTION

The instruction manual supplied with the burner:

- is an integral and essential part of the product and must not be sepa-

rated from it; it must therefore be kept carefully for any necessary

consultation and must accompany the burner even if it is transferred

to another owner or user, or to another system. If the manual is lost

or damaged, another copy must be requested from the Technical

Assistance Service of the area;

- is designed for use by qualified personnel;

- offers important indications and instructions relating to the installation

safety, start-up, use and maintenance of the burner.

DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-

UAL

When the system is delivered, it is important that:

- The instruction manual is supplied to the user by the system manu-

facturer, with the recommendation to keep it in the room where the

heat generator is to be installed.

- The instruction manual shows:

- the serial number of the burner;

- the address and telephone number of the nearest Assistance

Centre;

- The system supplier carefully informs the user about:

- the use of the system,

- any further tests that may be necessary before the system is

started up,

- maintenance and the need to have the system checked at least

once a year by the manufacturer or another specialised techni-

cian.

To ensure a periodic check, recommends the drawing up

of a Maintenance Contract.

..................................................................................

1 20013656

TECHNICAL DATA

OFor use on hot air generator the burner must be fitted with control box type 479SE or 539SE.

OBurner with CE marking in conformity with EEC directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,

Machines 2006/42/EC.

OThe burner meets protection level of IP 40, EN 60529.

TYPE 464T1

Thermal power – output 54 – 120 kW – 4.5 – 10 kg/h

Fuel Light oil, max. viscosity at 20 °C: 6 mm2/s

Electrical supply Single phase, 230V ±10% ~50Hz

Motor Run current 0.8A – 2850 rpm – 298 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure 7 – 15 bar

Absorbed electrical power 0.170 kW

1– Return line

2– Suction line

3– Gauge connection

4– Pump pressure regulator

5– Vacuum gauge connection

6– Screws fixing air damper

7– Hydraulic jack with air damper

8– Lock-out lamp and reset button

9– Flange with insulating gasket

10 – Combustion head adjustment screw

HYDRAULIC JACK OPERATION 7)(Fig. 1)

It is strongly recommended a periodic check of the

pump pressure operation (annually or better every

six months, if the burner operation is continuous).

If the value is lower than 1 bar, compared to that one

of the initial setting, please check the cleaning of the

pump and line filters.

In case the pressure setting was not restorable,

please replace the pump, in order to guarantee that

the pump pressure during the pre-purge time is at

least 3.7 bar.

DANGER

D8067

Fig. 1

123

20013656 2

EQUIPMENT

WORKING FIELD (as EN 267)

OVERALL DIMENSIONS

Quantity Description

Flexible oil pipes with nipples

Flange with insulating gasket

Screws and nuts for flange

to be fixed to boiler

Maintenance assembly

Screw and nuts for flange

0.8

0.4

4 5 6 Fuel output - kg/h

50 60 120 Thermal power - kW

D5669 70 80 90 100 110

0.2

0.6

Pressure in the combustion

chamber – mbar

78910

Flange Burner

305 108 261

140

45°

262

204

D5670

189

83 83

170

45°

ø105

3 20013656

INSTALLATION

BOILER FIXING

Put on the flange (1) the screw and two nuts, (see fig. 2).

Widen, if necessary, the insulating gasket holes (5), (see fig. 3).

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. 4).

MAINTENANCE POSITION

Access to the combustion head, diffuser disc / electrodes unit and nozzle, (see fig. 5).

Remove the burner out of the boiler, after loosing the fixing nut to the flange.

Hook the burner to the flange (1), by removing the combustion head (6) after loosing the fixing screws (7).

Remove the diffuser disc-holder assembly (9) from the nozzle-holder (8) after loosing its fixing screw.

Screw the nozzle (10).

Fig. 6

Verify that the installed burner is lightly leaned towards the

button.

(See figure 6).

The burner is designed to allow entry of the flexible oil-lines

on either side of the burner.

D5572

D5012

Fig. 2

Fig. 3

E9022

D8058

Fig. 4

110

Fig. 5

D8056 D8057

20013656 4

HYDRAULIC SYSTEMS

Warning: before starting the burner make sure that the return pipe-line is not clogged: any obstruction

would cause the pump seals to break.

The pump vacuum should not exceed a

maximum of 0.4 bar (30 cm Hg).

Beyond this limit gas is released from

the oil.

Oil lines must be completely airtight.

The return line should terminate in

the oil tank at the same level as the

suction line; in this case a non-return

valve is not required.

When the return line arrives over the

fuel level, a non-return valve must be

used.

This solution however is less safe than

previous one, due to the possibility of

leakage of the valve.

PRIMING THE PUMP

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.

A filter must be installed on the suction fuel line.

meters

Lmeters

I. D.

8 mm I.D.

10 mm

0.5

1.5

100

WARNING

The pump is supplied for use with a two pipe system.

For use on a one pipe system, it is necessary to remove the by-pass

screw (A), (see figure).

meters

Lmeters

I. D.

8 mm I.D.

10 mm

0.5

1.5

3.5

100

H max. 4 m

max. 4 m

min. 0.1 m

D5219

D5220

D5199

H=Difference of level.

L=Max.length of the

suction line.

I.D.=Internal diameter of the

oil pipes.

PRIMING THE PUMP

Loosen the plug of the vacuum gauge (5, fig. 1) and

wait until the fuel flows out.

SYSTEM NOT PERMITTED IN GERMANY

5 20013656

ELECTRICAL WIRING

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Switch with fuse

max.

Grey

230V ~ 50Hz

Limit thermostat

with manual resetting

Remote lock-out lamp

(230V - 0.5A max.), if required

1NT1T2S3B4

Brown

Valve

D5334

Black

TERMINAL

CONTROL-BOX

7 pin plug

7 pole socket

3456789

Yellow/Green

Blue

Brown

Black

Hour counter

Black

Do not exchange the neutral with the phase

WARNING

NOTES:

– Wires of 1 mm2section.

– The electrical wiring carried out by the

installer must be in compliance with the

rules in force in the Country.

TESTING

Check the shut-down of the burner by opening

the thermostats.

S7183

CONTROL BOX

- To remove the control-box from the burner,

loosen screw (A) (see figure) and pull towards

the arrow.

- The photoresistance is fitted directly into the con-

trol-box (underneath the ignition-transformer) on a

plug-in support.

RUN OF THE ELECTRICAL CABLE

1- Grommet N- Neutral

2- Cable-clamp L- Phase

3- Terminal block - Burner-earth

- Lock-out lamp

ATTENTION

Do not connect burner’s grounding, to fail-

ure indicator terminal . This may result

the destroy of the control box.

CARRIED-OUT BY THE INSTALLER

CARRIED-OUT IN THE FACTORY

BLOCK OF

530SE*

20013656 6

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 CO2concentration in the flue gases, their temperatures and the average temperature of the

water in the boiler.

To suit the required appliance output, fit the nozzle then 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.

RECOMMENDED NOZZLES: Monarch type R

Delavan type W - B

Steinen type S - Q

Danfoss type S

PUMP PRESSURE: 12 bar : The pump leaves the factory set at this value.

14 bar : Improves flame retention; it is therefore suitable for ignitions at

low temperatures.

COMBUSTION HEAD SETTING:

This is done when fitting the nozzle, with the

blast tube removed. It depends on the output of

the burner and is carried out by rotating the reg-

ulating rod, till the terminal plane of the blast

tube is level with the set-point, as indicated in

the schedule.

In the sketch on the left, the combustion head is

set for an output of 1.50 GPH at 12 bar, while

the shutter is level with set-point 3, as required

by the above schedule.

Combustion head settings indicated in the

schedule are valid for most cases.

The setting of the fan output according to the installation should normally be done only through the air

damper. Should one subsequently want to retouch also the setting of the combustion head, with the

burner running, operate on the rod (1) with a 6 mm spanner (2) as follows (see fig. 7, page 7).

Nozzle Pump pressure Burner output Comb. head

adjustment Air damper

adjustment

GPH Angle bar kg/h ± 4% Set-point Set-point

1.10 60° 12 4.4 2 3

1.25 60° 12 5.0 2.5 3.4

1.50 60° 12 6.0 3 3.8

1.75 60° 12 7.0 4 4

2.00 60° 12 8.0 5 5

2.25 60° 12 9.0 6 6

2.50 60° 12 10.0 6 7

For 2.00 - 2.25 GPH nozzles it is

advisable to use, if possible,

full cones.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5398

135

7 20013656

TURN TO THE RIGHT: (sign +)

In order to increase the volume of air entering the com-

bustion chamber and thus diminishing its pressure.

There is a reduction of CO2and the adhesion of the

flame to the air diffuser disc improves.

(Setting advisable for ignitions at low temperatures).

TURN TO THE LEFT: (sign –)

In order to reduce the volume of air entering the com-

bustion chamber and thus increasing its pressure. The

CO2improves and the adhesion of the flame to the dif-

fuser tends to reduce.

(This setting is not advisable for ignitions at low temper-

atures).

In any case do not bring the combustion head setting

more than one point away from that indicated in the

schedule. One set-point corresponds to 3 turns of the

rod; a hole (3) at its end facilitates counting the number

of turns.

AIR DAMPER ADJUSTMENT: (fig. 8)

The mobile air damper (A) operated by the jack (B)

assures the complete opening of the air intake.

The regulation of the air-rate is made by adjusting the

fixed air damper (C), after loosing the screws (D). When

the optimal regulation is reached, screw tight the

screws (D) to assure a free movement of the mobile air

damper (A).

The settings indicated in the schedule refer to the burner

with its metal cover fitted and the combustion chamber

with “zero” depression. These regulations are purely

indicative. Each installation however, has its own unpre-

dictable working conditions: actual nozzle output; posi-

tive or negative pressure in the combustion-chamber,

the need of excess air, etc.

All these conditions may require a different air-damper

setting.

It is important to take account of the fact that the air

output of the fan differs according to whether the

burner has its metal cover fitted or not.

Therefore we recommended to proceed as follows:

– adjust the air damper as indicated in the schedule at

page 6;

– mount the cover, simply by means of the upper

screw;

– check smoke number;

– should it become necessary to modify the air output,

remove the cover by loosening the screw, adjust the

air damper, remount the cover and finally recheck the

smoke number.

NOTE: When the burner works at a firing rate higher

than 9 kg/h remove the panel fitted inside the

metal cover. (See figure 9).

2 3

D8068

D5555

A B

PANEL

D5287

Fig. 7

Fig. 8

Fig. 9

20013656 8

ELECTRODES SETTING (See fig. 10)

BURNER START-UP CYCLE

ADJUSTMENTS, TO AVOID FLAME - DETACHMENT, AT BURNER - IGNITION

This inconvenience can occur, when the temperature of the gas-oil decreases below + 5 °C.

1) CORRECT POSITIONING OF THE ELECTRODES

See figure 10.

2) PUMP - SETTING

The pump is factory set, at a pressure of 12 bar.

When the temperature of the light oil decreases below + 5 °C, increase the pressure to 14 bar.

3) COMBUSTION-HEAD SETTING

Regulate the combustion-head one set-point further ahead than indicated in the instructions.

Example: the instructions require to set the combustion-head on set-point 3.

Instead, the setting is made on set-point 4.

4) FAN - AIR DAMPER ADJUSTMENT

Adjust the damper, reducing the excess air until the Bacharach number is not near 1

(i.e. a combustion with the lowest possible excess-air).

Attention:

Before assembling or remo-

ving the nozzle, loosen the

screw (A) and move the elec-

trodes ahead.

0.3 mm

D5288

A4.5

0.5 mm

MOVE THE ELECTRODE

HOLDER BACKWARDS TO

THE END

Fig. 10

Normal Lock-out, due to failure to light

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp

~12s D5229

~12s ~5s

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