Riello GULLIVER RG1 Quick start guide

20024093 (2) - 01/2015

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 - 型号

20024095 RG1 363 T1

One stage operation

一段火运行

20024093

1GB

INDEX

1. BURNER DESCRIPTION

One stage light oil burner.

1.1 BURNER EQUIPMENT

Flange with insulating gasket. . . .No. 1 Screw and nuts for flange to be fixed to boiler . No. 4

Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples. . . . . . . . . . . . . . No. 2

7 pin plug. . . . . . . . . . . . . . . . . . .No.1

1. BURNER DESCRIPTION. . . . . . . . . . . . 1

1.1 Burner equipment . . . . . . . . . . . . . . . . . 1

2. TECHNICAL DATA . . . . . . . . . . . . . . . . 2

2.1 Technical data . . . . . . . . . . . . . . . . . . . . 2

2.2 Overall dimensions . . . . . . . . . . . . . . . . 2

2.3 Firing tare . . . . . . . . . . . . . . . . . . . . . . . 2

3. INSTALLATION . . . . . . . . . . . . . . . . . . . 3

3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 3

3.3 Hydraulic systems . . . . . . . . . . . . . . . . . 4

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Combustion adjustment. . . . . . . . . . . . . . 6

4.2 Recommended nozzles. . . . . . . . . . . . . . 6

4.3 Setting of diffuser disc / electrodes . . . . . 7

4.4 Pump pressure . . . . . . . . . . . . . . . . . . . . 7

4.5 Combustion head setting. . . . . . . . . . . . . 8

4.6 Air damper adjustment . . . . . . . . . . . . . . 8

4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8

6. FAULTS / SOLUTIONS. . . . . . . . . . . . . . 9

1– Oil pump

2– Control-box

3– Reset button with lock-out

lamp

4– Flange with insulating

gasket

5– Air damper adjustment assembly

6– Nozzle holder assembly

7– Photoresistance

The burner meets protection level of IP X0D (IP 40), EN 60529.

Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility - 2004/108/

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

Fig. 1

S7194

20024093 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 FIRING RATE, (as EN 267)

TYPE 363T1

Output - Thermal power 2.7 –5 kg/h - 32 –60 kW

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

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

Motor Run current 0.85A – 2750 rpm – 289 rad/s

Capacitor 4 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.17 kW

196 93 122 180

130

150

210

254

7272

45°

D5699

112

ø84

Pressure in combustion

chamber – mbar

0,6

0,4

0,2

-1,0

0,1

0,3

0,5

0,7

-2,0

-0,5

-1,5

20095949

EN 267

33,5

30 40

2,5 4,5

35 45 55

EN 746-2

Light oil output – kg/h

Thermal power – kW

20024093

3GB

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

3.1 BOILER FIXING

Put on the flange (1) the screw and two nuts, (see fig. 3).

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

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. 2).

3.2 FUEL SUPPLY

The burner is designed to allow entry of the oil supply pipes on either side.

Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate

(1) and closing plate (2) should be reversed, (see fig. 4).

Fig. 2

Fig. 3 S7189

D5700

221 1

Fig. 4

20024093 4GB

3.3 HYDRAULIC SYSTEMS

It is necessary to install a filter on the fuel supply line.

H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.

max. 4 m

D5705

Fig. 7 Fig. 8

PRIMING PUMP:

On the system in fig. 6 it is sufficient to loosen the suction gauge

connection (5, fig. 5) and wait until oil flows out.

On the systems in fig. 7 and 8 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.

The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).

Beyond this limit gas is released from the oil. Oil pipes must be completely tight.

In the vacuum systems (fig. 8) the return line should terminate within the oil tank

at the same level as the suction line. In this case a non-return valve is not re-

quired. Should however the return line arrive over the fuel level, a non-return

valve is required.

This solution however is less safe than previous one, due to the possibility of

leakage of the valve.

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

100

The pump is designed to allow working with two pipes.

In order to obtain one pipe working it is necessary to

unscrew the return plug (2), remove the by-pass screw

(3) and then screw again the plug (2). (See fig. 5).

Before starting the burner make sure that the return

pipe-line is not clogged. An excessive back pressure

would cause the damage of the pump seal.

WARNING:

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

3.5

100

SYSTEM NOT PERMITTED

IN GERMANY

Fig. 6

max. 4 m

D5703

1- Suction line

2- Return line

3- By-pass screw

4- Gauge connection

5- Pressure adjuster

6- Suction gauge connection

7- Valve

8- Auxiliary pressure test point

324

Fig. 5

D5487

20024093

5GB

3.4 ELECTRICAL WIRING

D1913

ESEGUITO IN FABBRICA

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.

WARNING

CONTROL BOX

To remove the control-box from the burner, loosen screw (A, fig. 9)

and pull to the arrow direction, after removing all components, the

7 pin plug and earth wire.

In case of disassembly of the control box, retighten the screw

(A) with a torque wrench setting of 1 – 1.2 Nm.

DO NOT EXCHANGE NEUTRAL WITH PHASE

7 pin plug

7 pole socket

Black

White

Capacitor

Main switch

T6A

Motor

Blue

Oil valve

Hour counter

(230V - 0.

max.)

Limit thermostat Remote lock-out signal

(230V - 0.5A max.)

Ignition

electrodes

Brown

Burner-earth

CARRIED-OUT IN THE FACTORY

552SE

CONTROL BOX

Photoresistance

PE L N

50Hz 230V

Blue

TESTING

Check the shut-down of the burner by opening

the thermostats and the lock-out by darkening

the photoresistance.

S7186

Fig. 9

Safety thermostat

20024093 6GB

4. WORKING

4.1 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 CO2

concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.

To suit the required appliance output, choose the proper nozzle and 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.

4.2 RECOMMENDED NOZZLES: Delavan type W- B ; Danfoss type S - B - H

Monarch type R - NS ; Steinen type S - Q - H

For ignitions at low temperature (lower than + 8 °C) act as follows:

Use nozzles with empty or half-empty cone of

the following type:

Delavan type W; Danfoss type H;

Monarch type NS ; Steinen type H,

or (as alternative) increase the pump pressure

up to 14 bar.

If necessary, adopt both solutions.

MAINTENANCE POSITION

THE ACCESSIBILITY TO THE NOZZLE, THE

DIFFUSER DISC AND THE ELECTRODES IS

MADE EASY IN 2 WAYS:

Fig. 10

Remove the burner out of the boiler, after loos-

ing the fixing nut to the flange.

Hook the burner to the flange (1), by remov-

ing the blast tube (2) after loosing the fixing

screws (3).

Remove the small cables (4) from the elec-

trodes and the diffuser disc-holder assembly (5)

from the nozzle-holder assembly after loosing

its fixing screw (3, fig. 12, page 7).

Screw the nozzle (6) correctly and tighten it

as shown in the figure.

Nozzle Pump

pressure Burner

output Combustion head

adjustment Air damper

adjustment

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

0.65 60° 12 2.7 2.5 1.5

0.75 60° 12 3.0 3 2.9

0.85 60° 12 3.4 3.5 4.2

1.00 60° 12 4.0 4 5.6

1.10 60° 12 4.4 4 6.3

1.10 60° 15 5.0 4 6.7

AFig. 10

S7477

20024093

7GB

Fig. 11

Remove nozzle-holder assembly (1) after loos-

ing screws (2) and nut (3), remove the small ca-

bles (4) from the control box and the

photoresistance (6).

Withdraw the small cables (4) from the elec-

trodes, remove the diffuser disc-holder assem-

bly (10) from the nozzle-holder assembly (1)

after loosing screw (3, fig. 12).

Screw the nozzle (11) correctly and tighten

it as shown in figure.

ATTENTION

During the reassembly of the nozzle-holder

assembly screw the nut (3) as shown in the figure

below.

4.3 SETTING OF DIFFUSER DISC /

ELECTRODES (see fig. 12)

4.4 PUMP PRESSURE

The pump leaves the factory set at 12 bar.

To change it act on pump pressure adjust screw (4, fig. 5, page 4).

S7206

BFig. 11

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

Loosen screw (3) to set the dif-

fuser disc-holder assembly (1)

and loosen screw (4) to set the

electrodes assembly (2).

ATTENTION

To have access to the electrodes

carry out operation as described in

chapter “4.2 RECOMMENDED

NOZZLES” (page 6).

WARNING MEASURES

MUST BE RESPECTED

D5028

4.5

– 0.5 mm

2.5

0.2 mm

+ 0.5 mm

Fig. 12

20024093 8GB

4.5 COMBUSTION HEAD SETTING (see fig. 11, page 7)

It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting

screw (5) until the set-point marked on the regulating rod (9) is level with the outside plane of the nozzle-holder

assembly (1).

In the sketch the combustion head is set for an output of 0.75 GPH at 12 bar.

The set-point 3of the regulating rod (9) is at the same level with the outside plane of the nozzle-holder as-

sembly (1) as shown in the schedule.

4.6 AIR DAMPER ADJUSTMENT (see fig. 11, page 7)

To vary the setting adjust the screw (7) after loosing the nut (8).

When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar.

4.7 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).

5. MAINTENANCE

The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity

with legislation and local standards.

Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and

consequent pollution.

Before carrying out any cleaning or control always first switch off the electrical supply to the burner

acting on the main switch of the system.

THE BASIC CHECKS ARE:

Check that there are not obstructions or dents in the supply or return oil pipes.

Clean the filter in the oil suction line and in the pump.

Clean the photoresistance, (7, fig. 1, page 1).

Check for correct fuel consumption.

Replace the nozzle (see fig. 10, page 6) and check the correct position of electrodes (fig. 12, page 7).

Clean the combustion head in the fuel exit area, on the diffuser disc.

Leave the burner working without interruptions for 10 min. and set rightly all the components stated in

this manual. Then carry out a combustion check verifying:

Smoke temperature at the chimney; Contentof CO2(%); ContentofCO(ppm);

Smoke value according to opacity smokes index according to Bacharach scale.

Lock-out due to failure to light

Normal

D5029

~12s

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp ~12s 5s

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