Riello G5 Quick start guide

20013752 (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

20013633 G5 445T1

One stage operation

一段火运行

20013752

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 20013752

TECHNICAL DATA

Burner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,

Machines 2006/42/EC.

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

TYPE 445T1

Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h

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

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

Motor Run current 0.75A – 2850 rpm – 298 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure 7 – 15 bar

Absorbed electrical power 0.130 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

Fig. 1

D5553 12

20013752 2

BURNER EQUIPMENT

FIRING RATE

OVERALL DIMENSIONS

Quantity Description

Flexible oil pipes with nipples

Flange with insulating gasket

Screws and nuts for flange

to be fixed to boiler

Hinge

Screw and nuts for flange

Grommet

0.8

0.4

Pressure in the combustion

chamber – mbar

2 3 4 5 Fuel output - kg/h

25 30 60 Thermal power - kW

D5226 35 40 45 50 55

0.2

0.6

2.3

272 107 236

130

45°

ø89

233

180

D5554

180

75 72

150

45°

Flange Burner

3 20013752

BOILER FIXING

It is necessary that the insulating gasket

(9, fig. 1) is placed between the boiler door

and the burner flange.

This insulating gasket has six holes,

which, if necessary, can be modified as

shown on the drawing on the right.

D5242

Fig. 2

Verify that the installed

burner is lightly leaned

towards the button.

(See figure 2).

The burner is designed to

allow entry of the flexible

oil-lines on either side of

the burner.

D5572

BURNER FIXING AND

HINGE ASSEMBLY

S7384

20013752 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,

page 1) and wait until the fuel flows out.

5 20013752

ELECTRICAL WIRING

Brown

White (50V)

Blue

Motor

Capacitor

Regulating thermostat

Neutral

Switch with fuse

6A max.

S7026

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 con-

trol-box (underneath the ignition-transformer) on

a plug-in support.

TESTING

Check the shut-down of the burner by opening the

thermostats.

ATTENTION

Do not connect burner’s grounding, to failure

indicator terminal . This may result the destroy

of the control box.

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- Grommet N- Neutral

2- Cable-clamp L- Phase

3- Terminal block - Burner-earth

A321

D5228

Black

CARRIED-OUT BY THE INSTALLER

CARRIED-OUT IN THE FACTORY

20013752 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 - NS; Delavan type W - A - E

Steinen type H - Q ; Danfoss type H

Angle:60°:in most cases.

80° : in case of flame detachment, during ignitions at low temper-

atures.

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 regulating rod, till the terminal

plane of the blast tube is level with the set-point, as indi-

cated in the schedule.

Nozzle Pump pressure Burner output Comb. head

adjustment Air damper

adjustment

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

0.60 60°/80° 11 2.3 1.5 2

0.65 60°/80° 12 2.6 2 2.2

0.75 60° 12 3.0 2.5 2.5

0.85 60° 12 3.4 3 3

1.00 60° 12 4.0 4 4.5

1.10 60° 12 4.4 5 6

1.25 60° 12 5.0 6 7

In the sketch on the left, the combustion

head is set for an output of 0.85 GPH at

12 bar, while the shutter is level with set-

point 3, as required by the above sched-

ule.

Blast tube

Regulating rod

Shutter

Terminal plane of the blast tube

D5232

135

7 20013752

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 vol-

ume 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 increas-

ing its pressure. 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) as-

sures 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 mo-

bile 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.

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 5);

– 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.

D5551

D5555

A B

20013752 8

ELECTRODE SETTING (See fig. 3)

BURNER START-UP CYCLE

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

This inconvenience can occur, when the temperature of the light-oil decreases below +8 °C.

1) CORRECT POSITIONING OF THE ELECTRODES

See fig. 3.

2) PUMP - SETTING

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

When the temperature of the light oil decreases below +8 °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).

2 – 2.5 mm

4± 0.3 mm

IMPORTANT:

THESE DIMENSIONS

MUST BE OBSERVED

D5230 A

Attention:

Before removing or assembling the

nozzle, loosen the screw (A) and

move the electrodes ahead.

Fig. 3

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s D5229

~12s ~5s

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