Riello Gulliver RG4D Quick start guide

20024120 (1) - 05/2010

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

20024122 RG4D 397 T1

Two stage operation

两段火运行

20024120

1GB

INDEX

1. BURNER DESCRIPTION

Two 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 4 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

2.4

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

4.4 Electrodes adjustment. . . . . . . . . . . . . . . 7

4.5 Pump pressure and air output. . . . . . . . . 7

4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8

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

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

1– Pump with pressure reducer

2– Electronic start delaying

device

3– Control-box

4– Reset button with lock-out

lamp

5– Flange with insulating

gasket

6– 2nd stage air damper

adjustment assembly

7– Nozzle holder assembly

8– Photoresistance

9– Hydraulic jack

10 – 4 pole socket

11 – 2nd stage valve

12 – 1st stage valve

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

Burner with CE marking in conformity with EEC Directives: Electromagnetic Compatibility 89/336/EEC -

2004/108/EC, Low Voltage 73/23/EEC - 2006/95/EC, Machines 2006/42/EC and Efficiency 92/42/EEC.

Fig. 1

S7242

20024120 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD (as EN 267)

TYPE 397T1

Output - Thermal power 9/ 11 – 20 kg/h - 106/ 130 – 237 kW

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

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

Motor Run current 2 A - 2730 rpm - 286 rad/s

Capacitor 6.3 F

Ignition transformer Secondary 8 kV - 16 mA

Pump Pressure: 8 –15 bar

Absorbed electrical power 0.39 kW

228 142 300 213

160

190

285

345

9999

127

45°

D5353

ø123

Light oil output – kg/h

Thermal power – kW

Pressure in combustion

chamber – mbar

8101214

100

2.4

1.8

1.2

0.6

D5355

16 18

120

3.0

140 160 180 220 240200

20024120

3GB

3. INSTALLATION

3.1 BOILER FIXING

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

OWiden, if necessary, the insulating gasket holes (4), (see fig. 4).

OFix 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).

OAfter installation ensure that burner is lightly inclined as in fig. 5.

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 cable clamp (2) should be reversed, (see fig. 6).

Fig. 5

D5012

Fig. 4

D5025

Fig. 2

Fig. 3 S7071

D5345

Fig. 6

20024120 4GB

3.3 HYDRAULIC SYSTEMS Fig. 8

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 suction gauge

connection (6, fig. 8) and wait until oil flows out.

On the systems in fig. 9 and 10 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. 10) 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

øi

8 mm øi

10 mm

0.5

1.5

100

OBefore 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.

OThe 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. 8).

WARNING:

1- Suction line

2 - Return line

3 - By-pass screw

4 - Gauge connection

5 -2

nd stage pressure adjuster

6- Suction gauge connection

7 -1

st stage pressure adjuster

8 - Pressure reducer piston

9 -2

nd stage valve

10 - 1st stage valve

11 -Auxiliary pressure test point

meters

L meters

øi

8 mm øi

10 mm

0.5

1.5

3.5

100

SYSTEM NOT PERMITTED

IN GERMANY

S7067

max. 4 m

D5744

Fig. 9 Fig. 10

Fig. 7

D5745

max. 4 m

20024120

5GB

3.4 ELECTRICAL WIRING

DO NOT EXCHANGE

NEUTRAL WITH PHASE

WARNING

To remove the control-box from the burner, loosen screw (A, fig. 11) 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.

NOTES:

– Wires of 1 mm2 section.

– The electrical wiring carried out by the installer must be in

compliance with the rules in force in the Country.

OConnect 2nd stage thermostat between clamps T6 - T8

by removing the bridge.

TESTING: Check the shut-down of the burner by opening

the thermostats and the lock-out by darkening

the photoresistance.

Fig. 11

S7072 A

7 pin plug

7 pole socket

L1 B4S3

Black

White

Blue

Capacitor

Burner-earth

Switch with fuse

6A max.

Neutral

CONTROL BOX

552SE

50Hz 230V

123

Photoresistance

Blue

Ignition

electrodes

Brown

2nd stage oil valve

B5 4 pin plug

4 pole socket

Blue

Black

White

Blue

Brown

21 321

ELECTRONIC

DELAYING DEVICE

O2nd stage

Motor

thermostat

12123

CARRIED-OUT IN THE FACTORY

1st stage oil valve

D5336

Regulating thermostat Remote lock-out lamp

(230V - 0.5A max.)

Limit thermostat

with manual

resetting

1st stage

hour counter

(230V - 0.1A max.)

2nd stage hour counter

(230V - 0.1A max.)

Brown

Blue

20024120 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

Monarch type R ; Delavan type W - E

Steinen type Q ; Danfoss type S

Satronic type S

TO FIT NOZZLE CARRY OUT THE FOLLOWING

ACTIONS:

Remove nozzle-holder assembly (1) after loosing

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

(4) from the control box and the photoresistance

(5), (see fig. 12).

Withdraw the small cables (4) from the electrodes,

remove the diffuser disc-holder assembly (8) from

the nozzle-holder assembly (1) after loosing screw

(3, fig. 13, page 7).

Screw the nozzle (9) correctly and tighten it as

shown in figure 12.

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 Comb. head

adjustment Air damper adjustment

bar kg/h ± 4% 1st stage 2nd stage

GPH Angle 1st stage 2nd stage 1st stage 2nd stage Set-point Set-point Set-point

2.50 60° 9 14 8.7 10.8 0 0.2 1.8

3.00 60° 9 14 10.4 13.0 1 0.5 2.7

3.50 60° 9 14 12.2 15.2 2.5 0.8 3.7

4.00 60° 9 14 13.9 17.3 4 1.0 4.5

4.50 60° 9 14 15.6 19.5 6 1.3 6.0

Fig. 12

S7238

TIGHTEN WITHOUT MOVING

BACKWARDS TO THE END

D5684

20024120

7GB

4.3 COMBUSTION HEAD SETTING (see fig. 12, page 6)

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

ting screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the

nozzle-holder assembly (1).

In the sketch the combustion head is set for an output of 3.50 GPH at 15 bar.

The set-point 2.5 of the regulating rod is at the same level with the outside plane of the nozzle-holder as-

sembly as shown in the schedule.

4.4 ELECTRODES ADJUSTMENT (see fig. 13)

Fig. 15

Fig. 14

S7064

Lean the diffuser disc-holder as-

sembly (1) on the nozzle-holder

(2) and lock it by screw (3). For

prospective adjustments loosen

screw (4) and move the elec-

trodes assembly (5).

ATTENTION

To have access to the electrodes

carry out operation as described in

chapter 4.2 (page 6) “RECOM-

MENDED NOZZLES”.

D5341

6 – 7

4.5

– 0.5 mm

Fig. 13

123

MEASURES MUST BE

RESPECTED

WARNING

4.5 PUMP PRESSURE AND AIR OUTPUT

O1st STAGE ADJUSTMENT

ADJUSTMENT OF AIR SHUTTER:

Unloosen the nut (1), turn the screw (2) until the indicator (3) reaches the

position desired. Then lock the nut (1), (see fig. 14).

PRESSURE REGULATION:

This is set at 9 bar at the factory.

Should it be necessary to re-set or alter such pressure, this can be done, by

adjusting screw (7).

The pressure gauge must be mounted in place of cap (8), (see fig. 15).

O2nd STAGE ADJUSTMENT

ADJUSTMENT OF AIR SHUTTER:

Unloosen the nut (4), turn the screw (5) until the

indicator (3) reaches the position desired.

Then lock the nut (4), (see fig. 14).

PRESSURE REGULATION:

This is set at 14 bar at the factory.

Should it be necessary to re-set or alter such pres-

sure, this can be done, by adjusting screw (9).

The pressure gauge must be mounted in place of

cap (8), (see fig. 15).

When burner shuts down the air damper automati-

cally closes till a max. chimney depressure of

0,5 mbar.

20024120 8GB

4.6 BURNER START-UP CYCLE

Lock out is indicated by a lamp on the control box (4, fig. 1, page 1).

5. MAINTENANCE

Burner requires a periodic maintenance carried out by a qualified and authorized technicians.

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:

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

OClean the filter in the oil suction line and in the pump.

OClean the photoresistance, (8, fig. 1, page 1).

OCheck for correct fuel consumption.

OReplace the nozzle (see fig. 12, page 6) and check the correct position of electrodes (fig. 13, page 7).

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

OLeave the burner working without interruptions for 10 min. and check the right settings at 1st and 2nd

stage of all 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

D6040

Lock-out due to failure to light

Normal

3 –28s ~12s 5s

1st stage thermostat

2nd stage thermostat

Motor

Ignition transformer

1st stage valve

1st stage flame

2nd stage valve

2nd stage flame

Lock-out lamp ~12s

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