Riello PRESS 4G Quick start guide

2915904 (3) - 03/2012

Installation, use and maintenance instructions

Light oil burner

CODE MODEL TYPE

3476582 PRESS 4G 609 T80

2915904 1

DIMENSIONS (mm)

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

TECHNICAL DATA

Thermal power 415 / 830 -1660 kW - 356.900 / 713.800 - 1.427.600 kcal/h

Output 35 / 70 - 140 kg/h

Fuel Gas oil, max. viscosity at 20 °C: 6mm2/s (1.5 °E)

ELECTRICAL DATA

MOTOR IE1 MOTOR IE2

Electrical supply Three-phase 220V +10% -10% ~ 60Hz without neutral

380V +10% -10% ~ 60Hz with neutral

Motor 10 A / 220V - 5.8 A / 380V 10 A / 230V - 5.8 A / 400V

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

Absorbed electrical power 3.8 kW 4.1 kW

1- Suction line fitting

2- Return line fitting

3- Valve group return connection

4- Pressure gauge fixing point (G 1/8)

5- Pump pressure adjuster

6- Wiring terminal block

7- Combustion head control shaft

8- Fair leads

9- Control box reset button with signal of lock-out

10-Motor relay lock-out reset button

Quantity Accessories

2 Flexibles oil-lines

2 Connectors for flexibles

2 Gasket for flexibles

1 Flange gasket

4Screws

Fig. 1

Burner

Boiler front plate

drilling

2915904 2

PRESSURE IN THE COMBUSTION CHAMBER - OUTPUT

(in compliance with DIN 4787)

The burner is drawn for on-off operation and high-low operation.

Minimum firing-rate at on-off operation is 70 kg/h (two nozzles) and 35 kg/h (one nozzle) with high-low operation.

DIMENSIONS OF THE TEST COMBUSTION-CHAMBER (DIN 4787)

Pressure in the combustion

chamber in mbar

Burner output kg/h

D = Boiler diameter in mm

P = Position of the mobile

back in mm Specific thermal test load

2915904 3

HYDRAULIC SYSTEM

Gravity feed from the bottom of the oil storage tank

Gravity feed over the top of the oil storage tank

H= Difference in height; L= The total length of the suction line, including the vertical section.

The copper pipes of 12 mm and 14 mm I.D., as shown on the tables above, may be replaced by steel pipes of 1/2”

or 3/4” Gas.

The dimension P should not exceed 10 m, to avoid

breakage of pump seals.

meters L meters

I.D. 12 mm I.D. 14 mm

0.5 4 10

1820

1.5 12 30

21640

2.5 20 50

The dimension P should not exceed 10 m, to avoid

breakage of pump seals.

Oil lines must be perfectly sealed. The use of copper

pipe is therefore recommended. The pump suction

must not exceed 4.5 m w.c. (30 cm Hg) because be-

yond this value the pump becomes noisy.

The return line must terminate at the same level as the

foot valve; otherwise the pump may become air-locked.

meters L meters

I.D. 12 mm I.D. 14 mm

04570

0.5 40 60

13550

22030

31015

3.5 - 7

Suction feed

2915904 4

BURNER ELECTRICAL WIRING

(carried out by the factory)

KEY TO LAYOUT

CMV Fan motor contact - maker RT Thermal cutout

FR Photocell TA Ignition transformer

MB Wiring terminal block TB Burner ground (earth) connection

MV Fan motor V1 1st stage solenoid valve

RMO Control box V2 2nd stage solenoid valve

SSuppressor

D10671

2915904 5

ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK

(to be carried out by the installer)

NOTICE

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

- Leads minimal section 1 mm2.

- Adjustment for the motor thermal relay:

- at the beginning of the scale for 380V

- at the end of the scale for 220V

FLAME MODULATION

The flame modulation is obtainable through the thermostat, controlling the second valve, connected to the terminals

10 and 11, removing the existing bridge.

2647

KEY TO LAYOUT

HRemote lock - out signal TL Limit control device system

MB Wiring terminal block TR High - low mode control device system

PS Lock - out reset button TS Safety control device system

TB Burner ground (earth) connection

220V 380V

F Ampere T25 T16

S mm21,5 1,5

2915904 6

FIXING OF THE ELECTRICAL WIRES

All the electrical wires, which are to be connected to the terminal block 6) (fig. 1) shall pass through the fair leads 8)

(fig. 1) as per this scheme.

1- Three phase supply: fair lead Pg 21

2- Single phase supply: fair lead Pg 13.5

3- Adjustment thermostat: fair lead Pg 13.5

4- Safety thermostat: fair lead Pg 13.5

5- 2nd stage thermostat:fair lead Pg 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 thepassage 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.

- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photo-resistance.

ACCESSORIES

RADIO DISTURBANCE PROTECTION KIT : CODE 3010386

If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m)

owing to the presence of an INVERTER, or in applications where the length of the thermostat connections exceeds

20 metres, a protection kit is available as an interface between the control box and the burner.

2915904 7

BURNER ADJUSTMENT

Establish, on the basis of the output desired, and in accordance with the table and the diagram underneath:

- the type of nozzle;

- the pump pressure;

- the combustion head setting.

EXAMPLE

The burner has to be matched with a boiler of 1000 kW.

Assuming an efficiency of 90%, we need to develop approximately 1112 kW i.e. burning reughly 95 kg/h.

In the output columnwe find, corresponding to 95, on the left,the required nozzles (2of 12.00 GPH at 60°) the pump

pressure (12 bar), and on the right the correct position of the combustion head (4 set-points).

(1) Nozzles of the major existing makers may be used.

It might well be possible however, that for certain specific outputs, one type of nozzle is less suitable than others.

It is recommended not to change the atomizing angle.

(2) It is recommended not to goes down to the 10 bar, otherwise the jack controlling the air damper will open with

difficulty.

The pump pressure may be varied by acting on the screw 5) (fig. 1) and it can be controlled by placing a pressure

switch on the pressure gauge 4) (fig. 1).

Output in kg/h

(4) Adjustment of the head (N° of set - points)

2915904 8

(3) The indicated outputs are drawn from the average statistical data of

our tests.

Real output may well vary by ± 5%.

(4) The rear level of the control-shaft (7) (fig. 1) must line-up with the

set-point number, indicated by the diagram.

In the sketch on theright, the shaft is shown, in the position required

by the example on page 7.

AIR DAMPER ADJUSTMENT

Air damper adjustment for the first flame

Loosen the screw (1), the nut (3) and move the graduated scale (2) so that the pointer (4) lines-up with the set-point

desired; then tighten the screw (1) and the nut (3). A sufficiently exact control, valid for 12 bar and for the different

boilers pressurizations is given by the following table:

NOTE

For any necessary combustion adjustment, at the first flame stage, remove the bridge or the second stage thermo-

stat (see page 5).

Regulation of the air damper for the second flame

Loosen the threaded locking-ring (1) and tighten the hexagon (2) in order to reduce flow; slacken the hexagon to

increase flow.

This adjustment shall be modified, from time to time, in relation to the various combustion chambers pressurizations.

Set - point 4

On the sketch the graduated scale is shown, in

the position required by the example on page 7.

Set - point 2

2915904 9

All burner controls are clearly indicated into the instruction.

Only the air damper adjustment for the second flame, is determined at the place of installation, depending on

the boiler pressure.

ATTENTION

At the first ignition, passing from the first to the second flame, the oil pressure decrease noticeably because of the

filling of the second nozzle line - this decreasing can cause the burner shutdown, sometimes with strong pulsations.

PRIMING THE PUMP

In case of a gravity feed system, from the bottom of the oil-storage tank (see page 3), loosen the screw of the suc-

tion-gauge fixing point 3 (fig. 1), until the fuel flows out.

In the other two cases, remove the high voltage cable from the ignition transformer and release air from the pressure

gauge fixing point, by loosening the screw 4 (fig. 1) do not light on the photo-resistor, because lock-out immediately

will occur.

Should the burner go to lock-out re-set the control-box and repeat the cycle as often as necessary.

CAUTION

Check, before starting the burner, that the return line to the oil-storage tank is not in any way obstructed.

Any obstruction would cause the breakage of the pump seal.

BURNER START-UP CYCLE 60Hz

MOTOR LOCK-OUT

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

To reset pushdown the appropriate knob, after having removed the protective cover.

MOTOR LOCK-OUT

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

To reset pushdown the appropriate knob, after having removed the protective cover.

Lock-out because

no ignition

Normal

Thermostat

Motor

Ignition transformer

1st Solenoid valve

2nd Solenoid valve

Lock-out lamp

D2713

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