Riello RG1F Quick start guide

OBSOLETE DOCUMENT

End validity date 05/2011

Refer to document code:

20039735

2902888 (2)

Installation, use and maintenance instructions

Instrucciones para la instalación, uso y mantenimiento

Light oil burner

Quemador de gasóleo

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3736370 RG1F 363T1

One stage operation

Funcionamiento de una sola llama

2888

DECLARATION OF CONFORMITY

RIELLO S.p.A. hereby declares under its sole responsibility that the Gulliver series burner model RG1F

conforms to the following European Directives:

- Council Directive 73/23/EEC of 19th February 1973 - relating to Electrical Equipment

- Council Directive 98/37/EEC of 29th June 1998 – relating to Machinery

- Council Directive 89/336/EEC of 3rd May 1989 - relating to Electromagnetic Compatibility

and to the following Technical Standards:

EN 267, EN 60730-5, EN 60529 (IP X0D).

➤CE Certification No.: 0036 0341/03 as 92/42/EEC.

DECLARACIÓN DE CONFORMIDAD

RIELLO S.p.A. declara, bajo su responsabilidad, que el quemador serie Gulliver modelo RG1F es con-

forme a las siguientes Directivas Europeas:

- Directiva del Consejo 73/23/CEE del 19 Febrero 1973 – relativa al Material Eléctrico

- Directiva del Consejo 98/37/CEE del 29 Junio 1998 - en materia de Seguridad de las Máquinas

- Directiva del Consejo 89/336/CEE del 03 Mayo 1989 – relativa a la Compatibilidad Electromagnética

y a las siguientes Normas Técnicas:

EN 267, EN 60730-5, EN 60529 (IP X0D).

➤CE Reg. N.: 0036 0341/03 según 92/42/EEC.

RIELLO S.p.A.

2888 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 the heat generator . . 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 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 Maintenance position . . . . . . . . . . . . . . . 9

4.4 Setting of diffuser disc / electrodes . . . . . 10

4.5 Pump pressure . . . . . . . . . . . . . . . . . . . . 10

4.6 Combustion head setting. . . . . . . . . . . . . 10

4.7 Air damper adjustment . . . . . . . . . . . . . . 10

4.8 Burner start-up cycle. . . . . . . . . . . . . . . . 10

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

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

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

1– Oil pump

– Control-box

3– Reset button with lock-out

lamp

– Flange with insulating

gasket

5– Air damper adjustment assembly

6– Nozzle holder assembly

7– Photoresistance

Fig. 1

S7194

2888 2GB

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.

PRE-HEATER KIT

There is a special kit available that, when installed in the combustion head, allows fuel to be heated so as

to assure regular burner firing and operation. It can basically be used in special atmospheric conditions (low

temperatures), with high diesel oil viscosity and with low deliveries. Refer to the instructions supplied with

the “pre-heater 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 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 220/230V ±10%

Single phase

~60Hz 220/230V ±10%

Motor Run current 0.7 A – 2800 rpm

294 rad/s

Run current 0.9A – 3230 rpm

339 rad/s

Capacitor 4 µF

Ignition transformer Secondary 8 kV −16 mA

Pump Pressure: 8 −15 bar

Absorbed electrical power 0.155 kW 0.2 kW

2888 3GB

2.3 OVERALL DIMENSIONS

2.4 FIRING RATE

Firing rate has been determined in conformity with the provision of standard EN 267 (from 0,7 to - 0,2 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.

196 93 122 180

130

150

210

254

7272

45°

D5699

112

ø84

Light oil output – kg/h

Thermal power – kW

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

D4466

EN 267

33.5

30 40

2.5 4.5

35 45 55

EN 746-2

2888 4GB

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 (5).

➤Fix the flange (1) to the heat generator door (4) using screws (2) and (if necessary) the nuts (3) inter-

posing the insulating gasket (5), (see fig. 2).

3.2 WORKING POSITION

Fig. 2

Fig. 3 S7189

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

2888 5GB

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

3.4 HYDRAULIC SYSTEMS

➤It is necessary to install a filter on the fuel supply

line.

■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) 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 (4).

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.

D5700

221 1

Fig. 4

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

PUMP (see fig. 5)

2888 6GB

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. 6, 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

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

Depressurised systems have a negative fuel pressure (de-

pression) on intake to the burner. Usually the tank is lower

than the burner.

In the systems in figs. 7 and 8, the table shows the maxi-

mum 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. 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.

In two pipe 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 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. 6)

meter

L meters

I. D.

8 mm

I. D.

10 mm

0.5

1.5

100

SYSTEM NOT PERMITTED

IN GERMANY

Fig. 6

max. 4 m

D5703

DEPRESSURISED SYSTEMS (fig. 7 and 8)

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.

Fig. 7 Fig. 8

max. 4 m

D5705

2888 7GB

3.5 ELECTRICAL WIRING

CONTROL BOX (see fig. 9)

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

D1913

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

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

552SE

CONTROL BOX

Photoresistance

PE L N

Blue

TESTING

Check the shut-down of the burner by opening

the thermostats and the lock-out by darkening

the photoresistance.

Safety thermostat

~50/60Hz 220/230V

CARRIED-OUT

IN THE FACTORY

TO BE DONE

BY THE INSTALLER

S7186

Fig. 9

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