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.
H
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.
H
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.
4
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

2915904 10
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 11111
Operation, flame ok vvvvvvvvvvvv
Operating with weak flame signal v1v1v1v1v1
Electrical supply lower than ~170V 
Lock-out 
Extraneous light vvvvv
Key: 1Off Yellow vGreen 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 gas 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 gas oil);
– faulty or soiled oil valves;
– short circuit between photocell and earth.
8 flashes – Not used.
10 flashes – Wiring error or internal fault.
– Presence of electromagnetic disturbance. Use the radio disturbance protection kit.
RED LED on
wait at least 10 s Press button for > 3 s Signal Signal
Interval
3 s

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