Riello Gulliver RG3 Quick start guide

20210619 (1) - 06/2023

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

20024111 RG3 393 T1

One stage operation

一段火运行

20210619

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 Working field . . . . . . . . . . . . . . . . . . . . . 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 Electrodes adjustment. . . . . . . . . . . . . . . 7

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

4.5 Combustion head setting. . . . . . . . . . . . . 7

4.6 Air damper adjustment . . . . . . . . . . . . . . 7

4.7 Burner start-up cycle . . . . . . . . . . . . . . . . 7

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

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

1 – Oil pump

2 – Flame control

3 – Reset button with lock-out lamp

4 – Flange with insulating gasket

5 – Air damper adjustment assembly

6 – Nozzle holder assembly

7 – Flame sensor

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

S7179

20210619

2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD (as EN 267)

TYPE 393 T1

Output - Thermal power 7 –15 kg/h - 83 –178 kW

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

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

Motor Run current 1.9 A – 2750 rpm – 289 rad/s

Capacitor 6.3 F

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.385 kW

003241822 213

160

190

285

345

9999

127

45°

123

D5353

678

80 100 120

2,0

1,6

1,2

0,8

0,4

910

140 160

11 12 13 14 15 16

180

2,4

Light oil output – kg/h

Thermal power – kW

Pressure in combustion

chamber – mbar

D5086

20210619

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 (4).

Fix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the

insulating gasket (4), (see Fig. 2).

After installation ensure that burner is lightly inclined as in Fig. 4.

3.2 FUEL SUPPLY

T he b u r n e r i s d es ig n e d t o a l l o w e n t r y o f t h e o il s u p pl y p i p e s o n e i t h er si d e .

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. 5).

Fig. 5

D5012

Fig. 4

D5025

Fig. 2

Fig. 3

S7071

Fig. 5

D5542

20210619

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.

PRIMING PUMP:

On the system in Fig. 7 it is sufficient to loosen the suc tion gauge

connection (5, Fig. 6) and wait until oil flows out.

On the systems in Fig. 8 and 9 start the burner and wait for the priming.

Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds be-

fore 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. 9) 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. 6).

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. 7

max. 4 m

D5744

Fig. 8 Fig. 9

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 gauge

Fig. 6

234 5 6 7

D5026

D5745

max. 4 m

The suction plug 4)(Fig. 6) is made of plastic. Once removed, it

must not be used again.

In single-pipe installations, the plug in the return line 2) must be to-

tally in steel.

WARNING

20210619

5GB

3.4 ELECTRICAL WIRING

Flame control

To remove the flame control from the burner, loosen screw (A, Fig.

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

the 7 pin plug and earth wire.

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

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

Fig. 10

D1913

ESEGUITO IN FABBRICA

NOTES:

– Wires of min. 1 mm2 section.

(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

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

Flame control

Flame sensor

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 flame sensor.

Safety thermostat

S7072 A

20210619

6GB

4. WORKING

4.1 COMBUSTION ADJUSTMENT

In conformity with EN 267 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.

T h e v al u es s h o w n i n t h e t a b l e a r e m e a s ur e d o n a C EN b o i le r ( as p e r E N 2 6 7) .

They refer to 12.5% CO2 at sea level and with gas oil and room temperature of 20 °C.

4.2 RECOMMENDED NOZZLES

Delavan type W - B ; Danfoss type S - B

Monarch type R ; Steinen type S - Q

For 3.00 - 3.50 GPH nozzles it is advisable to use

full cones.

TO FIT NOZZLE CARRY OUT THE FOLLOW-

ING ACTIONS (See Fig. 11):

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

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

cables (4) from the flame control and the flame

sensor (6).

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

trodes, remove the diffuser disc-holder assembly

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

loosing screw (3, Fig. 12, page 7).

Screw the nozzle (11) correctly and tighten it as

shown in the figure.

ATTENTION

During the reassembly of the nozzle-holder assem-

bly screw the nut (3) as shown in the figure below.

Nozzle Pump

pressure

Burner

output

Combustion head

adjustment

Air damper

adjustment

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

1.75 60° 12 7.0 0 1.3

2.00 60° 12 8.0 1 2.3

2.25 60° 12 9.0 3 2.6

2.50 60° 12 10.0 3.5 3.0

3.00 60° 12 12.0 5 3.5

3.50 60° 12 14.0 6 4.4

3.50 60° 14 15.2 6 5.6

S7180

Fig. 11



TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

20210619

7GB

4.3 ELECTRODES ADJUSTMENTS (see Fig. 12)

4.4 PUMP PRESSURE

T he pu mp l e a v e s th e f a c t or y s e t a t 1 2 b ar .

To change it act on pump pressure adjust screw (4, Fig. 6, page 4).

4.5 COMBUSTION HEAD SETTING (see Fig. 11, page 6)

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 2.25 GPH at 12 bar.

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

bly (1) as shown in the schedule.

4.6 AIR DAMPER ADJUSTMENT (see Fig. 11, page 6)

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 flame control (3, Fig. 1, page 1).

4,5

– 0,5 mm

Lean the diffuser disc-holder assembly (1) on the nozzle-holder (2) and lock it by screw (3).

For prospective adjustments loosen screw (4) and move the electrodes assembly (5).

ATTENTION

To have access to the electrodes

carry out operation as described in

chapter “4.2 RECOMMENDED

NOZZLES” (page 6).

WARNING

D5085

MEASURES MUST BE

RESPECTED

Fig. 12

Lock-out due to failure to light

Normal

~12s~12s 5s

D5029

Thermostat

Motor

Ignition transformer

Valve

Flame

Lock-out lamp

20210619

8GB

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 flame sensor, (7, Fig. 1, page 1).

Check for correct fuel consumption.

Replace the nozzle (see Fig. 11, 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; Content of CO2 ( % ); Content of CO (ppm);

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

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