Riello G20KI User manual

Installation, use and maintenance instructions

2902403 (6) - 05/2011

Light oil - kerosene burner

One stage operation

CODE MODEL TYPE

3747455 G20KI 474T52

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 separated 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 mainte-

nance of the burner.

DELIVERY OF THE SYSTEM AND THE INSTRUC-

TION MANUAL

When the system is delivered, it is important that:

- The instruction manual is supplied to the user by the

system manufacturer, 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 technician.

To ensure a periodic check, recommends

the drawing up of a Maintenance Contract.

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

2403

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.

Thermal power – output 95 – 213 kW – 8 – 18 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 1.4A – 2750 rpm – 288 rad/s

Capacitor 5 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Maximum pressure 14 bar (203 psi)

Absorbed electrical power 0.320 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

7– Flange with insulating gasket

10 – Combustion head adjustment screw

D8067

Fig. 1

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

2403

BURNER EQUIPMENT

FIRING RATE

OVERALL DIMENSIONS

Quantity Description

Flexible pipes with nipples

Flange with insulating gasket

Screws and nuts for flange

Maintenance assembly

Cable gland

Screw with two nuts for flange

Pressure in the combustion

chamber – mbar

Fuel output - kg/h

Thermal power - kW

D5683

0.4

8101214

90 110 230130 150 170 190 210

0.6

0.2

0.8

1.0

Flange Burner

350 118 295

160

45°

ø125

298

230

D5283

213

99 99

190

45°

2403

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. 3

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

Fig. 2

E9022

2403

HYDRAULIC SYSTEM

WARNING ONLY FOR TWO PIPE SYSTEM: 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 metal bowl filter with replaceable micronic filter must be fitted in the oil supply pipe.

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

least every 2 years.

meters

Lmeters

I. D.

8 mm I.D.

10 mm

0.5

1.5

100

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), hang up to the pump.

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.

2403

BURNER ELECTRICAL WIRING

Brown

White (50V)

Blue

Motor

Capacitor

Limit thermostat

Neutral

Main switch

T6A

S7029

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.

240V ~50Hz

Safety thermostat

Remote lock-out signal

(240V - 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

2403

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.

FUEL LIGHT OIL

FUEL KEROSENE

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

Steinen type S - SS ; Danfoss type S - B

Angle 60°: in most cases.

Particularly suitable to avoid flame-detachment during ignition.

45°: for narrow and long combustion-chamber.

PRESSURE:

8 bar: the pump leaves the factory set at this value, which is suitable only for kerosene.

10 bar: maximum pressure for kerosene.

FOR LIGHT OIL INCREASE PRESSURE

12 bar: in most cases.

14 bar: improves flame retention; it is therefore suitable for ignitions at low temperatures.

1 2 34

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 8.6 1 3

2.25 60° 12 9.7 1.5 3.2

2.50 60° 12 10.7 2 3.5

3.00 60° 12 12.9 2.5 4.3

3.50 60° 12 15.0 3.5 5.5

4.00 60°/45° 12 17.2 5 6.5

4.00 60°/45° 13 17.9 6 7

1 2 34

Nozzle Pump pressure Burner output Comb. head

adjustment Air damper

adjustment

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

2.75 60° 8 8.1 0.5 2.2

3.00 60° 8 8.9 1 2.4

3.50 60° 8 10.3 1.5 3.0

4.00 60° 8 11.8 2.5 3.2

4.50 60° 8 13.3 3 4.0

5.00 60° 8 14.8 3.5 6.0

5.50 60°/45° 8 16.2 5 6.5

6.00 60°/45° 8 17.7 6 7.0

2403

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 regulating rod, till the terminal plane of the blast tube is level

with the set-point, as indicated in the schedule.

In the sketch below, the combustion head is set for an output of 3.50 GPH at 12 bar (for light oil)

or 5.00 GPH at 8 bar (for kerosene).

The shutter is level with set-point 3.5, as required by the schedule at page 6.

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.

2 3

D8068

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5676

135

2403

AIR DAMPER ADJUSTMENT:

The mobile air damper (1) operated by the jack (2)

assures the complete opening of the air intake.

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

fixed air damper (3), after loosing the screws (4). When

the optimal regulation is reached, screw tight the

screws (4) to assure a free movement of the mobile air

damper (1).

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.

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

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 17 kg/h remove the panel

fitted inside the metal cover (see figure).

ELECTRODE SETTING

PANEL

D5682

D5550

1 2

Attention:

Before assembling or removing the nozzle, loosen the

screw (A) and move the electrodes ahead.

4± 0.3 mm

D5288 A6.5 ± 0.5 mm

MOVE THE ELECTRODE HOLDER

BACKWARDS TO THE END

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