Riello GAS 4 Quick start guide

2915860 (0)

Installation, use and maintenance instructions

Gas burner

CODE MODEL TYPE

3751682 GAS 4 516 T80

5860

TECHNICAL FEATURES

DIMENSIONS

Thermal output

180 - 470 kW 154.800 - 404.200 kcal/h

Fuel

Natural gas Pci 8 - 10 kWh/m

= 7000 - 8600 kcal/m

Minimum gas pressure

For maximum output 9.8 mbar are needed measured at the coupling

with nil pressure in the combustion chamber and gas with caloriﬁc val-

ue of 8600 kcal/m

Maximum gas pressure 150 mbar

Electrical supply Three phase 380 V + 10% - 10% ~ 60Hz with neutral

Motor 1.5 A / 380 V

Ignition transformer Primary: 1.8A / 220V - Secondary: 1 x 8 kV - 30 mA

Absorbed electrical power 0.6 kW

1– Air shutter control

2– Air shutter lock-nut

3– Control box re-set button

4– Fair leads

5– Wiring terminal block

6– Re-set push-button of the motor

overload relay

7– Air pressure switch

8– Gas pressure test-point Fig. 1

S7513

Boiler front-plate

drilling

*Length available with special blast tube to be separately required.

Burner

410 610187

*320

397

292

165

ø 150

Rp 1 1/2

S7497 S7498

160

165 M10

D1785

5860

EQUIPMENT

FIXING TO THE BOILER

GAS SUPPLY

Quantity Burner accessories

1 Flange

1 Gasket

8 Screws

1 Flange gasket

Separate the combustion head from the

burner body by loosening the screws 1)

and 2) and with drawing the group A)

from the holding bars 3).

Fix the group B) to the boiler front plate 4)

using the gasket 5) provided as acces-

sory.

23 5 4

S7499

1- Gas pipe line 7- Gas shut off valve

2- Cock valve 8- Burner

3- Filter 9- Gas safety shut off valve

4- Pressure stabilizer 10 - Gas leak control device

5- Pressure test-point 11 - Isolator joint

6- Minimal gas pressure switch

S7514

5860

WORKING RANGE

COMBUSTION CHAMBER PRESSURE - MAXIMUM OUTPUT

(in compliance with DIN 4788)

MINIMUM GAS PRESSURE - OUTPUT

Pressure

: detected at the pressure test-point 7) (fig. 1) with nil mbar into the combustion chamber.

Should the combustion chamber be pressurized, the pressure necessary will be that of the

graph plus the pressurization value.

Example

: to obtain 350 kW it is necessary a gas pressure of 7 mbar and the combustion head set as

indicated at page 7.

If the combustion chamber is pressurized at 2 mbar, the pressure detected at the test-point

7) is: 7 + 2 = 9 mbar.

If this value is too high, for very low gas pipework pressures, the gas gear 6) (page 7) could

be more open.

Do not decrease the pressure at the coupling under the values shown in the diagram.

Output

: the maximum value is obtainable with gas Pci 8600 kcal/m

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

kcal/h

mbar

D1786

kcal/h

mbar

D1787

5860

BURNER ELECTRICAL WIRING

(carried out in the factory)

D2656

CMV Fan motor contactor

F1 Protection against radio interference

MB Burner terminal strip

MV Fan motor

PA Air pressure switch

RMG Control box

RT Overload

SSuppressor

SO Ionisation probe

TA Ignition transformer

TB Burner earth

KEY TO LAYOUT

ATTENTION

In the case of phase-phase feed, a

bridge must be fitted on the control box

terminal board between terminal 6 and

the earth terminal.

5860

ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK

(to be carried out by the installer)

Notice

- Leads minimal section 1 mm

- The electric wiring carried out by the installer must be in compliance with the rules in force in the Coun-

try.

FIXING OF THE ELECTRICAL WIRES

All the electrical wires, which are to be connected to

the terminal block 5) (fig. 1) shall pass through the fair

leads 4) (fig. 1) as for this scheme.

- Single phase supply : fair lead Pg 13.5

- Adjustment thermostat : fair lead Pg 13.5

- Safety thermostat : fair lead Pg 13.5

- Gas train : fair lead Pg 13.5,

sheath ø 13

5 / 6 / 7 /8

- Pre-sheared holes

Further prospective signals or controls can be connected to the burner wiring terminal board by removing

the metal weldnuts from the pre-sheared holes and inserting a commun fair lead for the passage and the

clamping of the leads.

NOTES

- Do not exchange the neutral wire with the phase (avoid the plug-pin connection).

- Carry out a safe earth connection.

- Checkthe stopof theburner, byopening theboiler thermostatand theburner lock-out,by disconnecting

the lead from the flame probe.

WARNING

When closing the burner on its slide-bars, pull towards the outside the high voltage cable and the cable

of the flame detection probe, till to little tension.

HRemote lock-out signal

H1 Remote lock-out signal of leak

detection control device

IN Burner manual stop switch

MB Burner terminal strip

PG Min. gas pressure switch

TL Limit control device system

TS Safety control device system

VPS Leak detection control device

VR Gas adjustment valve

VS Gas safety valve

XP7 Plug for leak detection control device

KEY TO LAYOUT

D2657

S7505

F Ampere T6

S mm21

5860 6

BURNER START-UP CYCLE

Air-purge: loosen the screw placed on the minimal gas pressure switch mounted on the gas train.

AIR PRESSURE SWITCH 7) (fig.1)

The air pressure switch setting shall be carried out after having

set all other adjustment of the burner and the air pressure switch

shall be at its lowest set-point.

When the burner is operating, increase the adjustment pressure

by turning - slowly - clockwise the knob till reaching the burner

lock-out.

Thereafter,turn the knob anticlockwise for 1 mbarand repeatthe

burner start-up for checking the regularity: if lock-out intervenes

turn the knob anticlockwise for 0.5 mbar.

CAUTION:

do not turn the ionization probe, maintain the drawing position; should it be close to the ignition elec-

trode, damage may occur to the control box amplifier.

Screw

Plug for pressure measure

Pressure switch

S7506

1 ÷ 10

mbar

Adjustment knob

S7507

0 - 1 mm

2 - 4 mm

Probe position Ignition electrode position

S7508

5860 7

COMBUSTION HEAD ADJUSTMENT

Two separate adjustments have to be made: air and gas.

These adjustments can be carried out when the burner is still open, during the installation (see page 2

- Fixing to the boiler).

Air setting

Loosen the two screws 1) and move the internal

part of the combustion head 2) so that its rear

edge 3) is coincident with the desired set-point

on the plate 4). Tighten the screws 1).

Gas setting

Loosen the screw 5), move the ring 6) so that the

pointer 7) is coincident with the desired set-point

8). Tighten the screw 5).

Attention:

the set-point number is the same for air and gas

setting and is given by the following diagram.

Example:

the burner is installed on a boiler of 270 kW, assuming an efficiency of 90% the burner output should

be 300 kW.

From the diagram it can be seen that the air and gas settings for this rating should be no. 3.

25681

S7518

kcal/h kW

Burner output

Set-point number = for air and gas

D1792

5860 8

COMBUSTION CHECKS

CO2

It is advisable to not exceed 10% of CO2(gas with calorific value of 8600 kcal/m3), in order to avoid

the risk that small changes of the adjustments due, for instance, at draught variation, may cause com-

bustion with insufficient air and consequently formation of CO.

For safety reason the value of 0.1% (one thousand p.p.m.) must not be exceeded.

IONIZATION CURRENT

The minimum current necessary for the control box operation is 3 µA.

The burner normally supplies a higher current value, so that no check is needed.

However, if a measurement of the ionization current is required, it is necessary to disconnect the

probe lead and insert a d.c. microamperometer.

MOTOR LOCK-OUT

This is caused by the thermal protector relay, in case of overloading, or by the lacking of the phase. To

clear, pushdown the appropriate knob, after having removed the protective cover

BURNER START-UP

If during operation the flame shuts off, lock-out occurs within 1 sec.

Lead Probe

S7511

Normal Lock-out because no ignition

Thermostat

Motor

Ignition transf.

Start valve

Adjust. valve

Lock-out

2 s 40 s 10 s 2 s 40 s 3 s max.

D1798

5860 9

BURNER STARTING DIFFICULTIES AND THEIR CAUSES

OPERATING FAULTS

Lock-out may occur, because of: - flame failure;

- ionization probe earthed;

- air pressure switch open.

Shut-off may depend on the gas pressure switch opening.

DIFFICULTIES CAUSES

The burner goes through

the purge period normally,

the flame ignites, but the

burner goes to lock-out,

within two seconds after

the ignition if:

The ionization probe is earthed or not in contact with the flame, or

its wiring to the control box is broken, or there is a fault on its insu-

lation to earth.

The ionization current is weak (lower than 3 µA).

The burner goes to lock-

out, after the purge period,

because the flame does not

ignite; the causes may be:

The valve is passing too little gas (low pressure in the gas pipe-

work).

The valve is defective.

The pipe has not been purged from the air.

The ignition arc is irregular or has failed.

The burner does not pass

through the pre-purge peri-

od and the control box

goes to lock-out:

The air pressure switch does not change over: it has failed or the air

pressure is too low (combustion head bad set).

Flame simulation exists (or the flame really lights).

The burner does not start at

the thermostat closing, be-

cause of:

Gas is not supplied.

The gas pressure switch does not close: incorrectly adjusted.

The air pressure switch is changed over to the operational position.

The fuse of the control box is broken.

The burner repeats the

start-up cycle without oc-

curring the lock-out:

This particular trouble is caused by the gas pipework pressure that

is very close to the value of the gas pressure switch setting, owing

to the sudden pressure decrease the valve opens and actuates -

onlytemporaneously -the opening ofthe pressureswitch, thereafter

the valve closes, the motor stops and the pressure increases again;

the pressure switch closes and the start-up cycle is repeated and so

forth.

To prevent this trouble, setting the gas pressure switch at a lower

value.

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