Riello G10 Quick start guide

2903442 (0) - 05/2008

Installation, use and maintenance instructions

Oil - kerosene burners

One stage operation

CODE MODEL TYPE

3746467 G10 464T52

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3442 1

TECHNICAL FEATURES

Burner with CE marking in conformity with EEC directives: EMC89/336/EEC - 2004/108/EC,

Low Voltage 73/23/EEC - 2006/95/EC, Machines 98/37/EEC and Efficiency 92/42/EEC

The burner meets protection level of IP 40, EN 60529.

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

Fuel Light oil, max. viscosity at 20 °C: 4 ÷ 6 mm2/s (Hi= 11.86 kWh/kg)

Kerosene, max. viscosity at 20 °C: 1.6 ÷ 6 mm2/s (Hi= 11.97 kWh/kg)

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

Motor Run current 0.85A – 2800 rpm – 293 rad/s

Capacitor 4 µF

Ignition transformer Secondary 8 kV – 16 mA

Pump Maximum pressure 14 bar (203 psi)

Absorbed electrical power 0.18 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

EQUIPMENT

Quantity Description

Flexible pipe with nipple

Flange with insulating gasket

Screws and nuts for flange

Maintenance assembly

Screw of pump by-pass

Cable gland

Screw with two nuts for flange

D8067

Fig. 1

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3442 2

WORKING RANGE

DIMENSIONS

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

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3442 3

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).

D5012

Fig. 2

Fig. 3

E9022

D8058

Fig. 4

Fig. 5

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

D8056 D8057

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3442 4

OIL LINES

WARNING

The pump is supplied for use with

a one pipe system. For use on a two pipe system, it

is necessary to screw the by-pass screw (A) sup-

plied as burner’s accessory. (See figure).

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.

Should however the return line arrives over the fuel level, the non-

return valve is indispensable.

This solution however is less safe than previous one, due to the possi-

bility of leakage of the valve.

WARNING:

Check periodically the flexible pipes conditions. Using kerosene, they have to be replaced at

least every 2 years.

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.

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

tion would cause the pump seals to break.

meters

L meters

I. D.

8 mm I.D.

10 mm

0.5

1.5

100

PRIMING THE PUMP

Loosen the plug of the vacuum

gauge (5, fig. 1) and wait until the

fuel flows out.

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

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3442 5

BURNER ELECTRICAL WIRING

S7029

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Switch with fuse

6A max.

Black

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.

– 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

control-box (underneath the ignition-trans-

former) on a plug-in support.

TESTING

Check the shut-down of the burner by opening the

thermostats.

CARRIED-OUT IN THE FACTORY

WARNING

Do not exchange the neutral with the phase.

230V ~50Hz

Limit thermostat

with manual resetting

Remote lock-out lamp

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

123456789

Blue

Brown

Terminal block of

control-box 530SE*

Valve

RUN OF THE ELECTRICAL CABLE

1- Cable gland N- Neutral

2- Cable clamp L- Phase

3- Terminal block - Burner-earth

D5228

Black

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3442 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.

NOZZLES RECOMMENDED: Monarch type R

Delavan type W - B

Steinen type S - Q

Danfoss type S - B

PRESSURE: 8 bar : the pump leaves the factory set at this value, which is suit-

able only for kerosene.

FOR LIGHT OIL INCREASE PRESSURE

12 bar : pressure suitable for light oil in most cases.

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 car-

ried out by rotating the regulating rod, till the terminal plane

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

the schedule.

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 4.72 2 3

1.25 60° 12 5.37 2.5 3.4

1.50 60° 12 6.44 3 3.8

1.75 60° 12 7.51 4 4

2.00 60° 12 8.59 5 5

2.25 60° 12 9.66 6 6

FUEL LIGHT OIL

1 2 3 4

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.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5398

135

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3442 7

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.

NOZZLES RECOMMENDED: Monarch type R

Delavan type B - W

Steinen type S - Q

Danfoss type S - B

PRESSURE: 8 bar : the pump leaves the factory set at this value.

10 bar : maximum pressure for kerosene.

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 car-

ried out by rotating the regulating rod, till the terminal plane

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

the schedule.

Nozzle Pump pressure Burner output Comb. head

adjustment Air damper

adjustment

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

1.50 60° 8 4.43 1.5 2.6

1.75 60° 8 5.17 2 2.9

2.00 60° 8 5.91 2.5 3.3

2.25 60° 8 6.64 3.5 3.5

2.50 60° 8 7.38 4 3.8

3.00 60° 8 8.86 5 5

3.00 60° 10 9.99 6 6

FUEL KEROSENE

1 2 3 4

1For 2.50 - 3.00 GPH nozzles it is

advisable to use, if possible,

full cones.

In the sketch on the left, the combustion

head is set for an output of 2.25 GPH

at 8 bar, while the shutter is level with

set-point 3.5, as required by the above

schedule.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5676

135

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3442 8

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:

TURN TO THE RIGHT: (sign +)

In order to increase the volume of air entering the combustion 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 combustion chamber and thus increasing its pres-

sure. The CO2improves and the adhesion of the flame to the diffuser tends to reduce. (This setting is

not advisable for ignitions at low temperatures).

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:

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 unpredictable working conditions: actual nozzle output; positive

or negative pressure in the combustion-chamber, the need of excess air, etc. All these conditions may

require a different air-damper setting.

D5782

A B

2 3

D8068

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3442 9

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 (4);

– mount the cover, simply by means of the upper

screw;

– check smoke number;

– should it become necessary to modify the air out-

put, 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).

ELECTRODE SETTING

BURNER START-UP CYCLE

PANEL

D5287

Attention:

Before assembling or removing the nozzle, loosen

the screw (A) and move the electrodes ahead.

4± 0.3 mm

D5288 A4.5 ± 0.5 mm

MOVE THE ELECTRODE

HOLDER BACKWARDS TO

THE END

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

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