Riello G20 Quick start guide

Installation, use and maintenance instructions

Instrucciones de instalación, montaje y funcionamiento

2902404 (5) - 05/2011

Light oil burner

Quemador de gasóleo

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3747459 G20 474T58

One stage operation

Funcionamiento de una llama

2404

1GB

ENGLISH

TECHNICAL DATA

Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 2004/108/EC,

Low Voltage 2006/95/EC, Machines 2006/42/EC.

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

TYPE 474T58

Thermal power – output 95 – 213 kW – 8 – 18 kg/h

Fuel Gas oil, viscosity 4 – 6 mm2/s at 20 °C

Electrical supply Single phase, 220V ±10% ~60Hz

Motor Run current 2.15A – 3250 rpm – 340 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure 8 – 15 bar

Absorbed electrical power 0.4 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– Reset button with lock-out lamp

9– Flange with insulating gasket

10 – Combustion head adjustment screw

D8067

Fig. 1

123

HYDRAULIC JACK OPERATION 7)(Fig. 1)

It is strongly recommended a periodic check of

the pump pressure operation (annually or bet-

ter 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 restora-

ble, please replace the pump, in order to guar-

antee that the pump pressure during the pre-

purge time is at least 3.7 bar.

DANGER

2404

2GB

BURNER EQUIPMENT

WORKING FIELD

OVERALL DIMENSIONS

Quantity Description

Flexible pipes with nipples

Flange with insulating gasket

Screws and nuts for flange

Maintenance assembly

Screw with two nuts for flange

Cable grommet

1.8

1.2

Pressure in the combustion

chamber – mbar

8 10 12 14 Fuel output - kg/h

90 110 230 Thermal power - kW

D5282 130 150 170 190 210

0.6

16 18 20

Flange Burner

350 118 295

160

45°

ø125

298

230

D5283

213

99 99

190

45°

2404

3GB

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

2404

4GB

HYDRAULIC SYSTEMS

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.

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

Hmax.4m

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.

2404

5GB

ELECTRICAL WIRING

S7029

Brown

White (50V)

Blue

Motor

Capacitor

Limit thermostat

Neutral

Main switch

6A max.

Black

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.

– 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.

TESTING

Check the shut-down of the burner by opening

the thermostats.

220V ~60Hz

Safety thermostat

Remote lock-out signal

(220V - 0.5A max.)

123456789

Blue

Brown

Terminal board of

control-box 530SE*

Valve

RUN OF THE ELECTRICAL CABLE

1- Cable grommet N- Neutral

2- Cable-clamp L- Phase

3- Terminal board - Burner-earth

ATTENTION

Do not connect burner’s grounding, to fail-

ure indicator terminal . This may result

the destroy of the control box.

D5228

Black

CARRIED-OUT IN THE FACTORY

WARNING

DO NOT EXCHANGE THE

NEUTRAL WITH THE PHASE.

2404

6GB

COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjust-

ment and testing must be carried out observing the instruction manual of the boiler, including verifica-

tion 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.

NOZZLES RECOMMENDED: Monarch type R - PLP ; Delavan type B - W

Steinen type S - SS ; Danfoss type S - B

Angle: 60° :in most cases. Particularly suited to avoid flame-detach-

ment during ignition.

45° : for narrow and long combustion-chambers.

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 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

2.00 60° 12 8.0 1 2.2

2.25 60° 12 9.0 1.5 2.6

2.50 60° 12 10.0 2 2.8

3.00 60° 12 12.0 2.5 3.5

3.50 60° 12 14.0 3.5 4.0

4.00 60°/45° 12 16.1 5 5.5

4.50 60°/45° 12 18.0 6 6.5

D5284

In the sketch on the left, the combustion

head is set for an output of 3.50 GPH at

12 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

135

2404

7GB

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 pres-

sure. 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.

2 3

D8068

D5775

2404

8GB

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, page 6);

– 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

17 kg/h remove the panel fitted inside the metal

cover. (See figure).

ELECTRODES ADJUSTMENTS

BURNER START-UP CYCLE

PANEL

D5682

Attention:

Before assembling or removing the noz-

zle, loosen the screw (A) and move the

electrodes ahead. 4± 0.3 mm

D6313

6.5 ± 0.5 mm

MOVE THE ELEC-

TRODE HOLDER BACK-

WARDS 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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