Riello GAS 4/2 Technisches Datenblatt

Installation, use and maintenance instructions

2915866 (4) - 07/2015

Forced draught gas burner

Two stage operation

CODE MODEL TYPE

3752282 GAS 4/2 522 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 4/2

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

5866

TECHNICAL DATA

BURNER DESCRIPTION

OVERALL DIMENSIONS

Thermal output 2

stage 180 - 470 kW - 154.800 - 404.200 kcal/h

Operation Two stages, high and low flame

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 value of

8600 kcal/m

Maximum gas pressure 150 mbar

Electrical supply Three phase 380 V + 10% - 10% ~ 60Hz with neutral

Motor 1.5A / 380V

Ignition transformer Primary: 1.8A / 220V - Secondary: 1 x 8 kV - 30 mA

Absorbed electrical power 0.6 kW

1– Air damper controlling motor

2– Control box re-set button

3– Fair leads

4– Wiring terminal block

5– Re-set push-button of the

motor overload relay

6– Air pressure switch

7– Gas pressure test-point Fig. 1

S7530

Boiler front-plate

drilling

Length available with special blast tube to be separately required.

Burner

160

165 M10

410 610187

320

397

292

165

ø 150

Rp 1

1/2

S7515 S7520

D1785

5866

STANDARDS 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 withdrawing the group A) from

the holding bars 3).

Fix the group B) to the boiler front plate 4)

using the gasket 5) provided as accessory.

2 3 5 4

A B

S7499

8 11 5

94 3 12 2 1

S7534

1- Gas pipe line 7- Gas safety shut off valve

2- Cock valve 8- 1

stage gas shut off valve

3- Filter 9- 2

stage gas shut off valve

4- Pressure stabilizer 10 - Burner

5- Pressure test-point 11 - Gas leak control device

6- Minimal gas pressure switch 12 -Isolator joint

5866

WORKING RANGE

COMBUSTION CHAMBER PRESSURE 2nd STAGE OUTPUT

(in compliance with DIN 4788)

Min. output at 1

stage: 115 kW - 99.000 kcal/h.

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 8.

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 8)

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

5866

BURNER ELECTRICAL WIRING

(carried out in the factory)

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 Thermal overload

SM Servomotor

SO Ionisation probe

TA Ignition transformer

TB Burner earth

KEY TO LAYOUT

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.

20107484

5866

ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK

(to be carried out by the installer)

NOTICE

- Theelectric wiring carried out bythe installer mustbe in compliancewith the rules in force in the Country.

- Leads minimal section 1 mm

- Burners with non-stop operation. For safety reasons, this type of burner must be stopped every 24

hours of operation, by means of an hours-counter to be connected in series with the adjustment

devices.

FLAME MODULATION

The flame modulation is obtainable through the thermostat, controlling the second valve, connected

to the terminals 10 and 11.

D2662

HRemote lock-out signal

H1 Remote lock-out signal of leak detection control device

Burner terminal strip

PG Minimum gas pressure swicth

TL Limit control device system

stage remote control system

TS Safety control device system

VS Gas safety shut off valve

VPS Leak detection control device

stage gas shut off valve

XP7 Plug for leak detection control device

220V 380V

F Ampere T6 T6

S mm

1,5 1,5

5866

FIXING OF THE ELECTRICAL WIRES

All the electrical wires, which are to be connected to

the terminal block 4) (fig. 1) shall pass through the fair

leads 3) (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

5-2

stage thermostat : fair lead Pg 13.5

6 / 7 - 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

BURNER START-UP CYCLE

Air-purge: loosen the screw placed on the

minimal gas pressure switch mounted on the

gas train

AIR PRESSURE SWITCH

The air pressure switch 6)(fig. 1) setting shall

be carried out after having set all other adjust-

ments 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.

S7523

Screw

Plug for pressure

Pressure switch

S7506

measure

1 ÷ 10

mbar

Adjustment knob

S7507

5866

PROBE - IGNITION ELECTRODE POSITION

CAUTION:

do not turn the ionization probe, maintain the drawing position; should it be close to the ignition

electrode, damage may occur to the control box amplifier.

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 boil-

er of 270 kW, assuming an ef-

ficiency of 90% the burner

output should be 300 kW.

From the diagram it can be

seen that the air and gas set-

tings for this rating should be

no. 3.

3 - 4 mm

2 - 4 mm

Probe position Ignition electrode position

S7524

25681

S7533

kcal/h kW

Burner output

Set-point number = for air and gas

D1792

5866

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

stage.

The black lever must anticipate the red one.

STAGE - Orange lever

The orange lever controls the air damper position for the

first flame, it is adjustable both for opening and closing.

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.

OPERATIONAL DIAGRAM

S7525

Black lever

Red lever

Orange lever

Blue lever

Opening +

–

Closing

S7526

Output gas

Time

Pre-purge

stage valve energizing

38 s

10 s

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