Riello Burners PRESS 60 N 616 M Quick start guide

2915895 (2) - 01/2009
Installation, use and maintenance instructions
Heavy oil burner
CODE MODEL TYPE
3434985 PRESS 60 N 616 T80
3434986 PRESS 60 N 616 T80

5895 1
1- Suction line
2- Return line
3- Pump pressure adjustment screw
4- Manometer plug (G 1/8)
5- Vacuometer plug (G 1/2)
6- Air shutter opening motor
7- Control box reset push-button and lock-out lamp
8- Reset push-button of the motor over load 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 171 / 342 - 684 kW - 15 / 30 - 60 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 4.8 A / 220V - 2.8A / 380V
Ignition transformer Primary: 2 A - Secondary: 2 x 6.5 kV / 35 mA
Heaters 4.2 kW
Absorbed electrical power 5.8 kW
Pump 110 kg/h at 20 bar
Fig. 1
Fig. 1
*For extended - head version
Quantity Accessories
2 Flexibles tubes
2 Nipples
2 Seals
4Screws
1 Gasket for flange
2 * Extensions for bars

5895 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: 15 kg/h - 171 kW
Note for the extended combustion head version
Apply the extensions provided as accessories for the burner withdrawing.
mbar
kg/h
kW
Front plate detail for
boiler mounting

5895 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 ema-
nates gas.
The pipes shall be perfectly
sealed. When the tank is placed
below of the burner level, the re-
turn 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 65°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 1”
gas ø11/4” gas
0610
0.5 11 17
11624
1.5 21 31
22638
H
meters
L meters
ø11/4”
gas ø11/2” gas
02245
0.5 19 39
11633
1.5 13 27
21021
2.5 7 15
308

5895 4
ELECTRICAL WIRING CONNECTIONS
(carried out by the factory)
KEY TO LAYOUT
CMV Fan motor contactor
CR Pre-heart contactor
FSuppressor
FR Photoresistance
MB Wiring terminal board
MV Fan motor
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
Tm
1
246 95
96
A2
135
M
3
14
13 A1
TB
F
TM
654321987
S
CR
A2
A1
426
135
3
5
2
11
6
8
7
V2
TE
RT
MV
V1
TB
FR
SM
M
R2
R1
ST2
ST1
ST0
HS1
MV2
-+
1
4
171318 9 5 8114
TB
10
TA
1512 16
MB
RMO88. 53A2RMO88. 53A2
L1R L2R L3R
NL1 L2 L3 L S3 T1 30 T2 T6 T8
V2 1 V2 2
CMV
N
D2613

5895 5
ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BOARD
(to be carried out by the installer)
NOTICE
- Leads minimal section: 1,5 mm2.
WARNING
For supply at 220 Vmakethe triangle connection on the pre-heater andonthe motor (the original connection is “star”
for 380 V).
TWO STAGE OPERATION
It can be achived by the thermostat connected to 14-15 wiring terminal board (removing the bridge) controlling 2nd
valve.
PRE-HEATER RESISTANCES CONNECTIONS
D2644
220V 380V
A Ampere T10 T6
B mm21,5 1,5
C Ampere T16 T10
D mm242,5
KEY TO LAYOUT
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

5895 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 three 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.
- Check the stop of the burner, by opening the boiler thermostat and the burner lock-out, by disconnecting the lead
from the flame probe.

5895 7
CHOICE OF NOZZLES - OF THE PUMP PRESSURE
OF THE COMBUSTION HEAD ADJUSTMENT
Advised 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
Turnthescrew 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
kg/h
Set-point
Nozzle
GPH (45° - 60°) 20 bar kg/h 25 bar kg/h
2,50 + 2,50 30,00 34,00
3,00 + 3,00 36,00 40,60
3,50 + 3,50 42,00 47,40
4,00 + 4,00 48,00 54,20
4,50 + 4,50 54,00 61,00
5,00 + 5,00 60,00 -
Set-point 4
B
A

5895 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 of 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.
Black lever
Red lever
Orange lever
Blue lever
-Closing
Opening +
Lock-out because
no ignition
Normal
Thermostat
Motor
Ignition transformer
1st flame valve
2 nd flame valve
Lock-out lamp
D2894

5895 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 viscosity of 7 °E at 50 °C is pre-heated at 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.
The thermostat is calibrated by the factory at 180° C.
IMPORTANT NOTICES
Pre-heater thermostats substitution.
Replace the probe of the new thermostat, after the
loosening of the fixing screws of the plates pack, tak-
ing care of good contact between the probe and the
tubes and the resistance, see drawing.
Similarly for the resistance substitution.
- If during the operation exceptional changes or too
much high temperatures should be detected, verify
the continuity of the resistance, using and ohmme-
ter, contacting the temperature probe (approximate-
ly 35 Ohm).
Sheath for
thermometer
Adjusting knob
of thermostat
Pre-heater
Purge
Spray temperature
Viscosity at 50° C
Tubes into aluminium plate
Resistance
Thermostat probe
Aluminium
plate

5895 10
NOTE
- 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).
- Before the burner start-up, verify that the pump is filled of fuel in order to avoid any idling for too long time.
- 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.

5895 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