Riello Gulliver RG5DF Quick start guide

Installation, use and maintenance instructions

Instrucciones de instalación, montaje y funcionamiento

2902902 (3) - 10/2014

Light oil burner

Quemador de gasóleo

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3739870 RG5DF 398T1

Two stage operation

Funcionamiento de dos llamas

2902

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Light oil burner

Model: Gulliver RG5DF

These products are in compliance with the following Technical Standards:

EN 267

EN 12100

and according to the European Directives:

MD 2006/42/EC Machine Directive

LVD 2006/95/EC Low Voltage Directive

EMC 2004/108/EC Electromagnetic Compatibility

Such products are marked as follows:

The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.

Legnago, 03.09.2014 Executive General Manager

RIELLO S.p.A. - Burner Department Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. U. Ferretti Mr. R. Cattaneo

Declaración de conformidad según ISO / IEC 17050-1

Fabricante: RIELLO S.p.A.

Dirección: Via Pilade Riello, 7

37045 Legnago (VR)

Producto: Quemador de gasóleo

Modelo: Gulliver RG5DF

Estos productos están conformes con las siguientes Normas Técnicas:

EN 267

EN 12100

y según lo dispuesto por las Directivas Europeas:

MD 2006/42/CE Directiva Máquinas

LVD 2006/95/CE Directiva Baja Tensión

EMC 2004/108/CE Compatibilidad Electromagnética

Estos productos están marcados como se indica a continuación:

La calidad está garantizada mediante un sistema de calidad y management certificado según UNE EN ISO 9001.

Legnago, 03.09.2014 Director general

RIELLO S.p.A. - Dirección Quemadores Director Investigación y Desarrollo

RIELLO S.p.A. - Dirección Quemadores

Ing. U. Ferretti Ing. R. Cattaneo

CE - 0036 0325/01

2902

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 the heat generator. . 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 Accessories . . . . . . . . . . . . . . . . . . . . . . 2

2.3 Overall dimensions . . . . . . . . . . . . . . . . 3

2.4 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . 3

3. INSTALLATION. . . . . . . . . . . . . . . . . . . 4

3.1 Heat generator fixing . . . . . . . . . . . . . . . 4

3.2 Working position . . . . . . . . . . . . . . . . . . 4

3.3 Fuel supply . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Hydraulic systems . . . . . . . . . . . . . . . . . 5

3.5 Electrical wiring . . . . . . . . . . . . . . . . . . . 7

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Combustion adjustment. . . . . . . . . . . . . . 8

4.2 Recommended nozzles. . . . . . . . . . . . . . 8

4.3 Combustion head setting. . . . . . . . . . . . . 9

4.4 Electrodes adjustment. . . . . . . . . . . . . . . 9

4.5 Pump pressure and air output . . . . . . . . . 10

4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 10

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 11

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 12

1– Pump

2– Electronic start delaying device

3– Control-box

4– Reset button with lock-out lamp

5– Flange with insulating gasket

6– 2

stage air damper adjustment

assembly

7– Nozzles holder assembly

8– Photoresistance

9– Hydraulic jack

10 – 4 pole socket

11 – 2

stage valve

12 – 1

stage valve

13 – Valve casing assembly

S7111

Fig. 1

If the burner is to be combined with a hot air generator in Germany (WLE according to DIN 4794), the con-

trol box must be replaced with a Riello 550 SMD control box (remove the bridge), and the flame sensor

must be replaced with the amplified type (both fully interchangeable). This control box, combined with the

“remote reset kit” (which can be ordered separately), means that the burner can be reset by remote control.

ATTENTION

2902

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 ACCESSORIES (optional):

EXTENDED HEAD KIT

The burner’s combustion head can be replaced by the long-headed version using a special kit, to be ordered

separately.

Refer to the instructions supplied with it for installation.

The kit must be installed in conformity with laws and local regulations.

SPACER KIT

There is a special kit available that, when mounted on the burner, lets you reduce head penetration in the

combustion chamber.

Refer to the instructions supplied with the “spacer kit” for installation.

The kit must be installed in conformity with laws and local regulations.

550 SMD CONTROL BOX AND INFRARED FLAME SENSOR

A more efficient control box is available on request, for teaming with hot air generators, with the following

features:

- spark reset function;

- switch for post-firing and recycle;

- indicator LED reporting various operating stages:

(green LED = motor operating; yellow LED = pre-heating stage; red LED = post-combustion);

- socket for remote reset and reset function in case of failed shutdown.

Refer to the instructions supplied with the control box for installation.

The kit must be installed in conformity with laws and local regulations.

REMOTE RESET KIT

There is a special kit available that, when mounted on the 550 SMD control box, lets you reset the burner

by remote control.

The kit must be installed in conformity with laws and local regulations.

TYPE 398T1

Output - Thermal power 8/12 −25 kg/h – 95/142 −296 kW

Fuel Light oil, viscosity 4 – 6 mm

/s at 20 °C

Electrical supply Single phase

50Hz 220/230V ±10% Single phase

60Hz 220/230V ±10%

Motor Run current 1.8A – 2750 rpm

289 rad/s Run current 2.6A – 2940 rpm

309 rad/s

Capacitor 8 µF

Ignition transformer Secondary 8 kV – 16 mA

Pump Pressure: 8 −15 bar

Absorbed electrical power 0.4 kW 0.575 kW

2902

2.3 OVERALL DIMENSIONS

2.4 FIRING RATE

Firing rate has been determined in conformity with the provision of standard EN 267 (from 3.1 to - 0.3 mbar).

In addition, burner can be applied for operation with the combustion chamber featuring negative pressure

(up to - 2 mbar) according to the approval terms provided for in standard EN 746-2 for the whole unit com-

plete with equipment.

247 159 300 213

160

190

12.5

285

345

127

45°

D5390

125

Fuel output – kg/h

Thermal power – kW

Pressure in combustion

chamber – mbar

3.0

2.0

1.0

-1.0

-2.0

8 10 12 14

100

D4444

16 18

120

140 160 180 220 240200

22 24 26

260 280 300

EN 267

EN 746-2

2902

3. INSTALLATION

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

3.1 HEAT GENERATOR FIXING

➤

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

➤

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

➤

Fix the flange (1) to the heat generator door (3) using screws (5) and (if necessary) the nuts (2) inter-

posing the insulating gasket (4), (see fig. 2).

➤

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

3.2 WORKING POSITION

Fig. 5

D5012

Fig. 4

D5025

Fig. 2

Fig. 3

S7112

The burner is designed to work only in the po-

sitions 1, 2, 4 and 6.

Any other position could compromise the cor-

rect working of the appliance.

Installations 3and 5are forbidden for safety

reasons.

D4420

1 2 3

4 5 6

2902

3.3 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).

3.4 HYDRAULIC SYSTEMS

➤

It is necessary to install a filter on the fu-

el supply line.

■

The pump is designed to allow working with

two pipes.

■

In order to obtain one pipe working it is nec-

essary to unscrew the return plug (2),

remove the by-pass screw (3) and then

screw again the plug (2) with a torque of

0.5 Nm.

■

Before starting the burner make sure that

the return pipe-line is not clogged. An

excessive back pressure (Š1 bar) would

cause the damage of the pump seal, with

subsequent fuel leaks inside the burner.

The pump has a delivery pressure regulation

device (5). Pressure increases if turned in a

clockwise direction, and decreases if turned in

the other direction.

An indication of sensitivity is 1 bar per turn.

The pressure can be regulated in a range of

8 - 15 bar.

Do not loosen the knob (11) and periodically

check that it is firmly fixed, for safety reasons.

D5392

Fig. 6

D5405

Fig. 7 5

1 - Suction line

2 - Return line

3 - By-pass screw

4 - Gauge connection

5 - 2nd stage pressure adjuster

6 - Suction gauge connection

7 - 1st stage valve

8 - Valve casing assembly

9 - 2nd stage valve

10 - Auxiliary pressure test point

11 - Knob

PUMP (see fig. 7)

2902

Pressurised systems have a positive fuel pressure on in-

take to the burner. Usually the tank is higher than the

burner, or the fuel pumping systems are on the outside of

the heat generator.

In the system in fig. 8, the table shows the maximum indi-

cated lengths for the supply line, depending on the differ-

ence in level, length and the diameter of the oil pipes.

PRIMING PUMP

It is sufficient to loosen the suction gauge connection

(6, fig. 7) and wait until oil flows out.

Depressurised systems have a negative fuel pressure

(depression) on intake to the burner. Usually the tank is

lower than the burner.

In the systems in figs. 9 and 10, the table shows the max-

imum indicated lengths for the supply line, depending on

the difference in level, length and the diameter of the oil

pipes.

PRIMING PUMP

On the systems in figs. 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.

In two pipe 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 required.

Should however the return line arrive over the fuel level, a non-return valve is required. This solution is

less reliable than the previous one, as the valve seal could be damaged.

PRESSURISED ONE PIPE SYSTEMS (fig. 8)

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

100

D5395

max. 4 m

Fig. 8

SYSTEM NOT PERMITTED

IN GERMANY

DEPRESSURISED SYSTEMS (fig. 9 and 10)

max. 4 m

D5393

Fig. 9 Fig. 10

meters

L meters

I. D.

8 mm I. D.

10 mm

0.5

1.5

3.5

100

NOTES VALID FOR ALL SYSTEMS

The installer must ensure that the supply depression is not above 0.4 bar

(30 cm Hg). Above that level, gas leaks out from the fuel.

The pipes must all be perfectly sealed.

H= difference of level; L= max. length of the suction line;

I. D. = internal diameter of the oil pipes

2902

3.5 ELECTRICAL WIRING

DO NOT EXCHANGE

NEUTRAL WITH PHASE

WARNING

CONTROL BOX

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

7 pin plug

7 pole socket

L1 B4S3

Black

White

Blue

Capacitor

Burner-earth

Main switch

T6A

Neutral

CONTROL BOX

552SE

50/60Hz 220/230V

123

Photoresistance

Blue

Ignition

electrodes

Brown

stage oil valve

T6B5

4 pin plug

4 pole socket

Blue

Black

White

Blue

Brown

2 1 3 2 1

ELECTRONIC

DELAYING DEVICE

●

stage

Motor

thermostat

12123

CARRIED-OUT IN THE FACTORY

stage oil valve

D4958

Limit thermostat Remote lock-out signal

(230V - 0.5A max.)

Safety

stage

hour counter

(230V - 0.1A max.)

stage hour counter

(230V - 0.1A max.)

Brown

Blue

S7120

Fig. 11

NOTES:

– Wires of min. 1 mm

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.

●

Connect 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.

thermostat

TO BE DONE BY THE INSTALLER

2902

4. WORKING

4.1 COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive EEC/92/42, the installation of the burner to the heat generator, setting

and testing must all be performed in respect of the instruction manual for the heater, including the controls

on the concentration of CO and CO

in the flue gases, the flue gas temperature and the average water and

air temperatures in the generator.

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 given in the table refer to a CEN boiler (in accordance with EN 267). They refer to 12.5% of

, at sea level, room temperature and light oil temperature at 20°C, 50 Hz power frequency and com-

bustion chamber counterpressure at 0.

The values given in the table are just an indication; to get the best performance from the burner, the

regulations should be made on the basis of the effective requirements of the generator.

With 60Hz power frequency, the burner must be re-set, closing the air damper, so that the amount of

intake air is reduced.

4.2 RECOMMENDED NOZZLES

Delavan type W - B; Steinen type Q; Danfoss type S.

NOTE

If necessary, the 1st stage nozzle can have a capacity 50% above the total capacity.

The 1

stage nozzle should not have a capacity 50% less than the total capacity, as the flame could be unstable.

REPLACE THE NOZZLES

(fig. 12 and 13)

To replace the nozzles proceed as fol-

lows:

➤

Disconnect the rubber coated leads

(4) from the control box and slide out

the photocell (5).

➤

Loosen the screws (2) and unscrew

the nuts (3).

➤

Slide out the rubber coated leads (4)

from the electrodes, unscrew and re-

move the screws (9, fig. 13, page 9)

in the diffuser disc unit (8, fig. 13,

page 9).

➤

Pull out the nozzle holder assembly

(1) turning it slightly in a clockwise

direction.

Nozzles Pump

pressure Burner

output Combustion

head

adjustment

Air damper

adjustment

GPH Angle kg/h ± 4% 1

stage 2

stage

stage 2

stage bar 1

stage 2

stage Set-point Set-point Set-point

2.00 1.00 60° 12 8.0 12.4 0 0.25 2.1

2.00 2.00 60° 12 8.0 16.4 3 0.15 3.0

2.50 2.50 60° 12 10.3 20.5 6 0.3 4.4

3.00 3.00 60° 12.5 12.6 25.0 8 0.6 6.0

ATTENTION

2 6

02468

S7763

7Fig. 12

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