Riello Burners PRESS 45N Quick start guide

2915894 (2) - 01/2009
Installation, use and maintenance instructions
Heavy oil burner
CODE MODEL TYPE
3434585 PRESS 45N 615 T80
3434586 PRESS 45N 615 T80

5894 1
1- Suction line
2- Return line
3- Pump pressure adjustment screw
4- Manometer plug (G 1/8)
5- Vacuometer plug (G 3/8)
6- Air shutter opening motor
7- Control box reset push-button and lock-out lamp
8- Reset push-button of the motor overload relay
9- Regulating bush for combustion head
10 - Sheathed filter for the thermometer
11 - Valves group
12 - Manometer with protection valve 16 - Wiring terminal board
13 - Adjustment thermostat 17 - Fair leads
14 - Pre-heater relay 18 - Back-pressure valve
15 - Ignition transformer
DIMENSIONS
Thermal power - Output 114 / 205 - 513 kW - 10 / 18 - 45 kg/h
Operation Two stages
Fuel Oil with max. viscosity at 50 °C: 150 mm2/s (20 °E)
Electrical supply Three phase 220V +10% -10% ~ 60Hz without neutral
380V +10% -10% ~ 60Hz with neutral
Motor 2.4 A / 220V - 1.5 A / 380V
Ignition transformer Primary: 2 A - Secondary: 2x 6.5 kV / 35 mA
Heaters 2.8 kW
Absorbed electrical power 3.7 kW
Pump 65 Kg/h at 20 bar
Fig. 1
*For extended - head version
Quantity Accessories
2 Flexibles tubes
2 Nipples
2Seals
4Screws
1 Gasket for flange
2 * Extensions for bars

5894 2
COMBUSTION CHAMBER PRESSURE - MAXIMUM OUTPUT
(two nozzles in operation)
When the burner operates with only one nozzle, the pressurization conditions are improved and no problems arise.
Minimal fuel capacity with only one nozzle: 10 kg/h - 114 kW
Note for the extend. combustion head version
Apply the extensions provided as accessories for the burner withdrawing.
Front plate detail for
boiler mounting

5894 3
FUEL OIL GRAVITY FEED SYSTEMS
GRAVITY SYSTEM (fuel oil with viscosity max. 7°E at 50°C)
Pump priming: loose the tap of the
vacuometer plug 5) (fig. 1) and wait
for the fuel flow.
H: Difference in the pipes height.
L: Length of the suction pipe.
SUCTION SYSTEM (fuel oil with viscosity max. 7°E at 50°C)
Not advised, to be used only in case of previously existing system.
Never overcome the max. de-
pression of 0.5 bar (38 cm Hg).
With higher values the fuel em-
anates gas.
The pipes shall be perfectly
sealed. When the tank is
placed below of the burner lev-
el, the return pipe should reach
the same level of the suction
pipe.
In this case the foot valve is not
required.
RING SYSTEM (for heavy oil with viscosity up to 20°E/50°C)
1- Tank (properly heated for heavy oil) 5- Forwarding pump
2- Filter (with resistance for oil > 7°E/50°C) 6- Manometer
3- Burner 7- Burner pump
4- Couple of cocks (excluding the burner) 8- Pressure adjuster
Notice: All the pipes have to be properly seized, sealed and heated (elect. resistance or hot steam or water) to
let the fuel flow.
Warning: Before to put the burner in operation verify that no obstruction exists into the pipes, any obstruction may
damage the sealing of the pump.
H
meters
L meters
ø 3/4”
gas ø 1” gas
0510
0.5 9 15
11120
1.5 14 25
21730
H
meters
L meters
ø 1”
gas ø11/4” gas
02445
0.5 21 40
11835
1.5 15 30
21225
2.5 9 20
3615

5894 4
ELECTRICAL WIRING CONNECTIONS
(carried out by the factory)
LEGEND
TB
F
MB
S
CR
A2
A1
426
135
A1
13
14
3
M
531
A2
96
95
642
MV
TM
RT
R
TE
V2
7
8
6
11
2
5
3
4
1
+
-
MV2HS1
ST0
ST1ST2
R1
R2
M
SM
FR
TB
V1
411 85918 13 17 10
TB
1612 15
TA
1
RMO88.53A2
Tm
RMO88.53A2
L1R
NLS3 T1 30 T2 T6 T8
V2 1 V2 2
L1 L3L2 N
CMV
D2599
CMV Fan motor contactor
CR Pre-heart contactor
FSuppressor
FR Photoresistance
MB Wiring terminal board
MV Fan motor
RResistence
RMO Control box
RT Therminal overload
S Pre-heart
SM Servomotor
TA Ignition transformer
TB Earth of the burner
TE Start-up and adjustment thermostat
Tm Minimum value contact thermostat
TM Maximum value contact thermostat
V… Electromagnetic valves

5894 5
ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BOARD
(to be carried out by the installer)
NOTICE: Leads minimal section 1,5 mm2.
TWO STAGE OPERATION
It can be achived by the thermostat connected to 12 and 13 wiring terminal board (removing the bridge) controlling
2nd valve
PRE-HEATER RESISTANCES CONNECTIONS
D2643
HRemote lock-out signal
IN Manual burner stop switch
MB Wiring terminal board
TL Limit control device system
TR High-low mode control device system
TS Safety control device system
KEY TO LAYOUT
220V 380V
A Ampere T10 T6
B mm21,5 1,5

5894 6
FASTENING OF THE ELECTRICAL WIRES
All the wires, which have to be connected to the wiring terminal board 16) (fig. 1) shall pass through the fair leads
17) (fig. 1) as per this scheme.
1- Pre-heating resistances single phase supply: fair lead Pg 21
2- Motor three phase supply: fair lead Pg 16
3- Single phase supply and safety thermostat: fair lead Pg 13.5
4- Control thermostat: fair lead Pg 13.5
5- 2nd stage thermostat:fair lead Pg 13.5
6- 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
- 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.

5894 7
CHOICE OF NOZZLES - OF THE PUMP PRESSURE
OF THE COMBUSTION HEAD ADJUSTMENT
Advise pressure
- Light oil: 20 bar
- Heavy oil: 25 bar
Rated deliveries of the nozzles are indicated on the above list and refer to a light oil having viscosity from 3 to 5° E at
50° C pre-heated at 100° C.
The effective delivery may vary of ± 5% against the rated one.
In case of requirement of intermediate values, the pump pressure or the nozzles match could be changed.
The pump is set by the factory at 20 bar.
Combustion head adjustment
Turn the screw A till the set-point, detected from the diagram,
is on line with the washer B.
In case of very heavy oil it is advised to use high wear
resistance nozzles (for instance Monarch F 80 H0)
Nozzles delivery
Pump pressure Combustion head adjustment Maximum output
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 -
Set-point
B
Set-point 4
A

5894 8
ADJUSTMENT OF THE AIR DAMPER MOTOR
STOP - Blue lever
This lever leaves the factory vertically positioned and
corresponds to the complete closing of the air damper.
A partial opening of the air damper might be obtained by
moving leftwards this lever (+ on the label).
The new position the air damper is detectable when the
burner is off. Do not overcome 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 both for opening and closing.
2nd STAGE - Red and black levers
The red lever controls the air damper position for the second flame, it is adjustable both for closing and opening.
The black lever controls the opening of the second oil valve and it must always anticipate - for a bit - the red lever,
but never the orange one.
BURNER START-UP PROGRAM
MOTOR LOCK-OUT
It is caused by the motor overload relay if overload occurs or no phase.
Reset: push the buttons 7) and 8) fig. 1.
Orange lever
Opening +-Closing
Red lever
Blue lever
Black lever
Thermostat
Motor
Ignition transformer
1st flame valve
2nd flame valve
Lock-out lamp
Lock-out because
no ignition
Normal
D2894

5894 9
SPRAY TEMPERATURE ADJUSTMENT
Thermostats for adjustment - maximum value - minimum value
Adjustment thermostat it prevents the burner start up if the fuel temperature has not reached the required value for
a good spray as indicated in the diagram below.
Example: fuel oil with 7 °E viscosity 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
approx. 100° C at the nozzles).
The value read has to be done after some minutes of performance and later the necessary adjustments could be
carried out.
Minimum value contact thermostat: it intervenes by stopping the burner if the fuel temperature decreases under the
value necessary for a good combustion.
Maximum value thermostat: it switches off the resistances 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 resistance in
contact with the probe of the thermostat.
NOTICE
If the pre-heater thermostat or the resistance con-
tacting the probe should be replaced, the probe
has to be positioned in contact with the resistance
and with the pipe of the last aluminium plate, after
loosening of the fixing screws of the aluminium
plate, see drawing. - If during the operation ex-
ceptional changes or too much high temperatures
should be detected, verify the continuity of the re-
sistance, using and ohmmeter, contacting the
temperature probe (approximately 35 Ohm).
Viscosity at 50° C
Spray temperature
thermometer
Pre-heater
Sheath for
of thermostat
Adjusting knob
Purge
Resistance
Aluminium
plate
Thermostat probe
Tubes into aluminium plate

5894 10
NOTE
1- The pre-heater might be provided with a second thermostat of maximum value with manual reset.
That thermostat can be used as a switch operating by means of an external commutator, which can take off the
current from the pre-heater in case of over-temperature. (Kit code no. 3000800).
2- The resistance R placed on the nozzle-holder is wired to the supply line of the pre-heater (see drawing page 4).
When the burner is off, the pre-heater supply line shall remain fed.
Should the pre-heaterline beturnedoff, the fuel must be pre-heated forapprox. 30 minutes before the burnerstart-
up.
On the contrary, the nozzle-holder resistance shall be supplied with an independent single-phase line, protected
by a fuse of 1 A.
This line shall never be switched off, when the burner is off.
3- Before the burner start-up, verify that the pump is filled of fuel in order to avoid any idling for too long time.
4- Filters cleaning: periodically clean the filters in order to avoid any trouble at the burner operation.
Supply line filter: positioned on the suction line, it causes the increase of the depression in the pump with the
consequent flow of gas and noise. Do not overcome the depression of 38 cm Hg (5 m W.c.)
(fig. 1 pos. 5).
Pre-heater filter: (fig. 1 pos. 10) positioned in the delivery line, it causes a decrease of the spraying pressure
which is detectable by use of a manometer (fig. 1 pos. 12).
MANOMETER PROTECTION VALVE
After spray pressure check, it is recommended to cut out the manometer (fig. 1 pos. 12) to avoid pressure shock
that it can suffer at every burner starting.
Close protection valve when the burner is not working and the manometer indicate 0 bar.

5894 11
BURNER START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the followin table:
OPERATING FAULT DIAGNOSTICS
The control box has a self-diagnostic system, which easily allows identifying the operating faults (RED LED signal).
ITo use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a minimum of 3 sec-
onds.
After releasing the button, the RED LED starts flashing as shown in the diagram below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will provide the information on the possible faults, according to the table below:
COLOUR CODE TABLE
Sequences Colour code
Pre-purging
Ignition phase
Operation, flame ok
Operating with weak flame signal
Electrical supply lower than ~170V
Lock-out
Extraneous light
Key: Off Yellow Green Red
SIGNAL PROBABLE CAUSE
2 flashes The flame does not stabilise at the end of the safety time:
– faulty photocell;
– faulty or soiled oil valves;
– neutral/phase exchange;
– faulty ignition transformer
– poor burner regulation (insufficient heavy oil).
3 flashes Min. air pressure switch (if installed) does not close:
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– max. air pressure switch triggered (if installed).
4 flashes Min. air pressure switch (if installed) does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
7 flashes Loss of flame during operations:
– poor burner regulation (insufficient heavy oil);
– faulty or soiled oil valves;
– short circuit between photocell and earth.
8 flashes – Faulty thermostat for oil permissive signal;
– Heating resistances blown.
10 flashes – Wiring error or internal fault.
RED LED on
wait at least 10 s Press button for > 3 s Signal Signal
Interval
3 s

RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com
Subject to modifications