Riello Burners PRESS 45 N/ECO Quick start guide

2916193 (0)
Montage und Bedienungs Anleitung
Manuel d’entretien
Installation, use and maintenance instructions
Istruzioni per installazione, uso e manutenzione
Bruciatore di nafta
Heizölbrenner
Heavy oil burner
Brûleur à fioul lourd
CODICE
CODE
MODELLO - MODELL
MODELE - MODEL
TIPO - TYP
TYPE
3434623 PRESS 45 N/ECO 627 T
3434624 PRESS 45 N/ECO 627 T
I
D
GB
F
Funzionamento bistadio
Zweistufiger Betrieb
Two-stage operation
Fonctionnement à deux allures

6193 1GB
INDEX
1. BURNER DESCRIPTION
Two stage heavy oil burner.
1.1 EQUIPMENT
Flexible tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples. . . . . . . . . . . . . . . . . . . . . . . . No. 2
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 2 Screws . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Guide extensions (for the lengthened head version).No. 2 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fitting for operation with emulsified
oil fuel (see page 9) . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Field of operation . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3
3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 3
3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 4
3.3 Electrical connections . . . . . . . . . . . . . . . . 5
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 6
4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6
4.3 Combustion head setting. . . . . . . . . . . . . . . . 6
4.4 Adjustment of the air damper motor . . . . . . . 6
4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . 7
4.6 Atomisation temperature adjustment . . . . . . . 7
4.7 Start-up programme. . . . . . . . . . . . . . . . . . . . 9
4.8 Ecological oil burners . . . . . . . . . . . . . . . . . . 9
4.9 Emulsified fuel oil functioning . . . . . . . . . . . . 9
4.10 Start-up programme diagnostic . . . . . . . . . . 10
4.11 Operating fault diagnostics . . . . . . . . . . . . . 10
2893
OThe burner meets protection level of IP 40, EN 60529.
OBurner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage
73/23/EEC and Machines 98/37/EEC.
1 - Suction line
2 - Return line
3 - Pump pressure adjustment screw
4 - Manometer fitting (G1/8)
5 - Vacuometer fitting (G1/2)
6 - Air damper opening motor
7 - Control box reset push-button and
lock-out indication
8 - Fan overload cutout reset
9 - Combustion head regulating screw
10 - Double filter
11 - Valve assembly
12 - Manometer with protection valve
13 - Adjustment thermostat
14 - Pre-heater contact maker
15 - Ignition transformer
16 - Terminal strip
17 - Cable glands
18 - Antigas valve
19 - Thermometer
20 - Pump motor starter with reset
21 - Air pressure switch
Fig. 1

6193 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 DIMENSIONS
2.3 FIELD OF OPERATION (2 nozzles in operation)
TYPE 627 T
Thermal power - Flow rate 114/205 - 513 kW – 10/18 - 45 kg/h
Fuel Oil with max. viscosity at 50° C 115 sq. mm/sec (15° E)
Electrical supply Three-phase, 230V ±10% ~50Hz without neutral
400V ±10% ~50Hz with neutral
Motor 230V - 400V Fan: 2.4A - 1.4A
Pump: 2.1A - 1.2A
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 2.8 kW
Electrical intake power 4.1 kW
Pump 60 kg/h at 20 bar
D2715
D2628
BurnerBoiler plate
NOTE
The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised
to hold the burner while it is being extracted so as not damage the flame disc and the said guides.
For long - head version.
Use the pin extensions provided to move the burner back.
*
783 235
370
625
290
*
94
Diam.161
305
Burner capacity
Pressure in combustion
chamber – mbar
D2673
When the burner operates with only one nozzle, the pressurization conditions are better and no problems
arise. Minimal flow rate with one only nozzle: 10 kg/h - 114 kW.
kg/h
kW

6193 3GB
3. INSTALLATION
3.1 FUEL OIL SUPPLY SYSTEMS
GRAVITY SYSTEM
SUCTION SYSTEM
LOOP SYSTEM (max loop pressure 3 bar)
H
metres
L metres
diam.
3/4”
diam.
1” gas
0510
0.5 8 15
11120
1.5 14 25
21730
Pump priming:
loosen the cap of the vacuometer fitting
(5, fig. 1) and wait for the fuel to flow out.
H: Difference in height
L: Length of the suction tube
For light oil with viscosity max. 7°E at 50°C.
D2720
max. 30m
H
H
metres
L metres
diam.
1” gas
diam.
1 1/4”
02445
0.5 21 40
11835
1.5 15 30
21225
2.5 9 20
3615
Not advised, to be used only in case of
previously existing system.
Never exceed the max. vacuum of 0.5 bar
(38 cm Hg) measured at the vacuometer
fitting (5, fig. 1).
The pipes should be perfectly airtight.
When the tank is placed below of the burn-
er level, the return pipe should arrive at the
same level as the suction pipe.
In this case the foot valve is not required.
For light fuel oil with viscosity max. 7°E at 50°C.
D2721
max. 30m
HH
1- Tank (properly heated for heavy oil) 5- Transfer pump
2- Filter (with resistor for oil > 7°E / 50°C) 6- Check Manometer
3- Burner 7- Burner pump
4- Air dampers to exclude the burner (coupled) 8- Pressure adjuster
For heavy oil with viscosity up to 20°E / 50°C.
Important note: to let the fuel flow properly all the pipes have to be properly sized, insulated and heated
(with elec. resistor or steam or hot water).
Warning: before to starting up the burner, make sure that there are obstructions in the pipes.
A
ny obstruction may damage the sealing of the pump.
D2631

6193 4GB
3.2 BURNER ELECTRICAL SYSTEM (carried out in the factory)
RMO88.53A2
PA
PMP
246 96
95
A2
135
M
3
14
13 A1
TB
RT1
1
Tm
TA
1512 16
TB
10
171318 9 5 8114
V1
TB
FR
SM
M
R2
R1
ST2
ST1
ST0
HS1
MV2
-+
1
4
3
5
2
11
6
8
7
V2
TE
R2 R3
RT
TM
MV
246 95
96
A2
135
M
3
14
13 A1
531
624
A1
A2
CR
S
MB
F
R1
TB
A
P
12
L1R
NL1 L2 L3 LN S3 T1 30T2T6T8
V21 V22
L1P L2P L3P
CMP
CMV
CMP Pump motor contact maker
CMV Fan motor contact maker
CR Pre-heater contact maker
FSuppressor
FR Photocell
MB Burner terminal strip
MP Pump motor
MV Fan motor
PA Air pressure switch
R1 Atomiser holder resistor
R2 Pump resistor
R3 Valve assembly resistor
RMO Electrical control box
RT Fan motor thermal relay
RT1 Pump motor thermal relay
SPre-heater tank
SM Servomotor
TA Ignition transformer
TB Burner earth
TE Regulation thermostat and start-up enabling
signal
Tm Minimum contact thermostat
Tm Maximum contact thermostat
V1 1st stage valve
V2 2nd stage valve
2598

6193 5GB
3.3 ELECTRICAL CONNECTIONS TO THE TERMINAL STRIP (to be made by the installer)
FASTENING OF THE ELECTRICAL WIRES
All the wires, which have to be connected to the burner terminal strip (16, fig. 1) shall pass through the cable
glands (17, fig. 1), see the figure below.
Further prospective signals or controls can be connected to the burner terminal strip pushing out the pre-sheared
disc from the holes and inserting a common cable gland for the passage and the clamping of the leads. To ensure
the IP 40 degree of protection in compliance with EN 60529 close the passage holes of the cables and any un-
used cable entries with appropriate discs.
NOTES
- Make a safe earth connection.
- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.
IN Manual switch
MB Burner terminal strip
HLock-out signal
TL Limit remote control
TR Adjustment remote control
TS Safety remote control
NOTE
Wire cross sections: min. 1 sq. mm.
(Unless required otherwise by local standards
and legislation).
TWO STAGE OPERATION
This is achieved by the remote control device
connected to terminals 5-6 (removing the jump-
er), that controls the second valve. RESISTOR CONNECTIONS
D2634
PRE-HEATER
2610
230V 400V
A Ampere 10 6
B Ampere 6 4
C sq.mm 1.5 1.5
D sq.mm 2.5 1.5
D2635
1- Single phase pre-heated resistor
power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21
2 - Motor three-phase supply:. . . . . . . . . . . . .cable entry Pg 16
3 - Single phase power supply and
safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
4- Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
5- Second stage thermostat: . . . . . . . . . . . . .cable entry Pg 13.5

6193 6GB
4. OPERATION
4.1 CHOICE OF NOZZLES
Recommended nozzles:
- Monarch F 80 H0.
4.2 PUMP PRESSURE
Recommended pressure:
- Fluid oil: 20 bar
- Heavy oil: 25 bar
The flow rates of the nozzles indicated on the table are
nominal and refer to a light oil having viscosity from 3 to 5°E
at 50° C pre-heated to 100°C. The actual flow rate may vary
by ± 5% against the rated one.
If flowrate values between those in the table are required, the
pump pressure may be varied or the nozzles arranged
differently.
The pump leaves the factory set at 20 bar.
4.3 COMBUSTION HEAD ADJUSTMENT
Turn the screw A, fig. 2 till the set-point, shown in the diagram,
is in line with the level of the sleeve B, fig. 2.
4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR
PARK - Blue lever
This lever leaves the factory vertically positioned and corre-
sponds to the air damper completely closed.
A partial opening of the air damper might be obtained by mov-
ing this lever leftwards (+on the plate).
The new position of the air damper is detectable when the
burner is off.
Do not exceed the position of the orange lever for the 1st
stage.
1st STAGE - Orange lever
The orange lever controls the air damper position for the first
flame, it is adjustable on both opening and closing.
2nd STAGE - Red and black levers
The red lever controls the air damper position for the second
flame, it is adjustable on both closing and opening.
The black lever controls the opening of the second oil valve
and it must always be slightly earlier than the red lever, but
never the first stage orange one.
D2638
Black lever
Red lever
Orange lever
Blue lever
Opening +–Closure
Nozzle
GPH (45° - 60°)
20 bar
kg/h
25 bar
kg/h
1.50 + 1.50 18.00 20.30
1.75 + 1.75 21.00 23.80
2.00 + 2.00 24.00 27.10
2.25 + 2.25 27.00 30.50
2.50 + 2.50 30.00 34.00
3.00 + 3.00 36.00 40.60
3.50 + 3.50 42.00 –
3.50 + 4.00 45.00 –
kg/h
Set-points
D2677
D2637
B
Set-point 4
A
Fig. 2

6193 7GB
4.5 AIR PRESSURE SWITCH
4.6 ATOMISATION TEMPERATURE ADJUSTMENT
Thermostat for adjustment - maximum value - minimum value
Adjustment thermostat prevents burner start up if the fuel temperature has not reached the required value for
a better atomisation as indicated in the diagram below.
Example
Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.
The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob
to get approximately 100°C at the nozzles).
The value read has to be done after some minutes of operation and later the necessary adjustments could be
carried out.
Minimum value contact thermostat intervenes by stopping the burner if the fuel temperature decreases
under the value necessary for better combustion.
Maximum value contact thermostat switches off the resistors when in case of failure of the adjustment
thermostat, the temperature increases inside the pre-heater. In case of abnormal temperature, make sure
of the regular functioning of control thermostat and of the resistor in contact with the probe of the thermostat.
D2640
D2719
Thermostat
adjustment knob
Pre-heater
Purge
Atomisation temperature
Viscosity at 50° C
sq. mm/sec °E
°C
Carry out the regulation of the air pressure switch after
carrying out all the other regulations of the burner with
the air pressure switch adjusted to the beginning of the
scale.
With the burner operating at the MIN power increase
the pressure of the adjustment by slowly turning the
appropriate knob clockwise until the burner locks out.
Then turn the knob counterclockwise to a value equal
to about 20% of the regulated value and then check
the correct turning on of the burner. If the burner locks
out again turn the knob a bit further in a counterclock-
wise direction.
D521

6193 8GB
IMPORTANT NOTES
If the pre-heater thermostat or the resistor in contact with
the probe should be replaced, the probe has to be posi-
tioned in contact with the resistor and with the pipes of the
last aluminium plate, after loosening of the fixing screws
of the aluminium plate packs, see drawing.
If during the operation exceptional differences or temper-
ature peaks that are too high should be detected, verify
the continuity of the resistor, using and ohmmeter in con-
tact with the temperature probe (approximately 35 Ohm).
Use only filters marked with a groove on the tightening hexagon.
NOTES
yThe pre-heater might be fitted with a second maximum value contact thermostat.
That thermostat can be used to act on an external contact maker by means of a switch to cut off the current
from the pre-heater, in case of excess temperature (Kit code no. 3000800).
yThe resistor Rplaced on the atomiser holder is wired to the supply line of the pre-heater (see page 4).
When the burner is off, the pre-heater supply line shall remain fed.
Should the pre-heater line be turned off, the fuel must be pre-heated for approximately 30 minutes before the
burner start-up. On the contrary, the nozzle-holder resistor shall be supplied with an independent single-phase
line, protected by a fuse of 1A.
This line shall never be switched off, when the burner is off.
yBefore the burner start-up, verify that the pump is filled of fuel in order to avoid any idling for too long time.
yFilter cleaning:
periodically clean the filters in order to avoid any trouble in the burner operation.
ySupply line filter:
positioned on the suction line, it causes the increase of the vacuum in the pump with the consequent flow of
gas and noise. Do not exceed the vacuum of 38 cm Hg (5 m W.c.) (5, fig. 1).
yPre-heater filter (10, fig. 1):
positioned in the delivery line, it causes a decrease of the atomisationing pressure which is detectable by
use of a manometer (12, fig. 1).
MANOMETER PROTECTION VALVE
After atomisation pressure has been checked, it is recommended to cut out the manometer (12, fig. 1) to avoid
pressure shocks that it might be subjected to at every burner start up.
To achieve this, close the protection valve when the burner is not working and the manometer indicates 0 bar.
Thermostat probe
Resistor
Aluminium plate pipes
Plate
D2751

6193 9GB
4.7 START-UP PROGRAMME
Motor lock-out
It is caused by the motor overload relay if there is an overload or no phase.
4.8 ECOLOGICAL OIL BURNERS
WARNING
The transition from normal fuel oil to ecological fuel oil requires:
yThe tank to be emptied of normal fuel oil.
yCleaning of the cistern and the pipes that carry the fuel oil to the burner.
yApplication of a filter if there is not one already on the burner fuel line with a filtering grade of 0.3 mm maxi-
mum.
If this is not done, Riello S.p.A. declines all liability if the burner fails to work properly or wears out prematurely.
NOTES
These burners are the result of careful study that allows them to be used with ecological fuels as well; oils, that
in certain temperature and speed conditions, are particularly aggressive for the vital parts of the burner.
The objective has been achieved with the reduction of the transiting speed in some of the parts and an appropri-
ate choice of materials (in particular surface treatments) as well as a redefinition of the backlashes and coupling
tolerances.
The burners for ecological oils are very different from normal fuel oil burners because they have a separate
pump (worked by its own motor at 1400 rpm) and for the presence of double filtration between pump and nozzle.
4.9 EMULSIFIED FUEL OIL FUNCTIONING
Lock-out because there is no ignitionNormal
Thermostat
Motors
Ignition transformer
1st flame valve
2nd flame valve
Lock-out
2894
indicator light
D3435
WARNING
In the case of functioning with emulsi-
fied fuel oil it is necessary to change
the fitting on the burner (*) with the one
supplied with it.

6193 10 GB
4.10 BURNER START-UP PROGRAM DIAGNOSTICS
During start-up, indication is according to the following table:
4.11 OPERATING FAULT DIAGNOSTICS
The control box has a self-diagnostic system, which allows operating faults to be found easily: (RED LED)
signal.
To use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a
minimum of 3 seconds.
After releasing the button, the RED LED starts blinking as shown in the diagram below.
The pulses of the LED constitute a signal with intervals of approximately three seconds.
The number of pulses will provide the information on the possible faults, according to the table below:
COLOUR CODE TABLE
Sequences Colour code
Preventilation
Ignition phase
Operation with flame ok
Operation with weak flame
Electrical supply lower than ~170V
Lock-out
Extraneous light
Key: Off Yellow Green Red
SIGNAL PROBABLE CAUSE
2 blinks A stable flame is not detected in the safety time:
– faulty photocell;
– oil valve fault;
– neutral/phase reversal;
– faulty ignition transformer
– poor burner regulation (insufficient fuel oil).
3 blinks Min. air pressure switch (if installed) does not close:
– air pressure switch faulty;
– air pressure switch not regulated;
– max. air pressure switch triggered (if installed).
4 blinks Min. air pressure switch (if installed) does not open or light in the chamber before
ignition:
– air pressure switch faulty;
– air pressure switch not regulated.
7 blinks Loss of flame during operation:
– poor burner regulation (insufficient fuel oil);
– oil valve fault;
– short circuit between photocell and earth.
8 blinks – Not used.
10 blinks – Wiring error or internal fault.
RED LED on
wait at least 10 secs
Press button
for > 3 secs signal signal
Interval
3 secs

RIELLO S.p.A.
I - 37048 San Pietro di Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com
Con riserva di modifiche - Änderungen vorbehalten! - Subject modifications - Sous réserve de modifications