Riello GAS 4 Quick start guide

Installation, use and maintenance instructions

2915860 (4) - 07/2015

Forced draught gas burner

One stage operation

CODE MODEL TYPE

3751682 GAS 4 516 T80

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

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Forced draught gas burner

Model: GAS 4

These products are in compliance with the following Technical Standards:

EN 676

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

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

Legnago, 21.05.2015 Executive General Manager

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

RIELLO S.p.A. - Burner Department

Mr. U. Ferretti Mr. F. Comencini

5860

TECHNICAL DATA

BURNER DESCRIPTION

OVERALL 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

2 1

S7513

Boiler front-plate

drilling Burner

160

165 M10

D1785

410 610187

320

397

292

165

ø 150

Rp 1

1/2

S7497 S7498

Length available with special blast tube to be separately required.

5860

STANDARD EQUIPMENT

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.

FIXING TO THE BOILER

GAS SUPPLY

Quantity Description

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.

2 3 5 4

A B

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

7 9 5

4 3

2 1

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)

20107483

CMV Fan motor contactor

F1 Protection against radio interference

K1 Relay

MB Burner terminal strip

MV Fan motor

PA Air pressure switch

RMG Control box

RT Overload

SO Ionisation probe

TA Ignition transformer

TB Burner earth

TTENTION

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

- TheelectricwiringcarriedoutbytheinstallermustbeincompliancewiththerulesinforceintheCountry.

FIXING OF THE ELECTRICAL WIRES

All the electrical wires, which are to be connected to the termi-

nal block 5) (fig. 1) shall pass through the fair leads 4) (fig. 1) as

for this scheme.

1- Single phase supply : fair lead Pg 13.5

2- Adjustment thermostat : fair lead Pg 13.5

3- Safety thermostat : fair lead Pg 13.5

4- 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.

- Check the stop of the burner,by opening the boiler thermostat and the burner 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

D2657

F Ampere T6

S mm

S7505

5860

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 mbar and repeat the

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

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

COMBUSTION CHECKS

It is advisable to not exceed 10% of CO

(gas with calorific value of 8600 kcal/m

), 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

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