Riello PRESS 3G TC FS1 3/200/50-60 200/50-60 Installer Manual

20140894 (1) - 11/2017

Installation, use and maintenance instructions

Gas oil burners

Two-stage operation

CODE MODEL TYPE

3473787 PRESS GW 605 T85

3474587 PRESS 1G 606 T85

3474987 PRESS 2G 607 T85

3475987 PRESS 3G 608 T85

1 20140894

Contents

1 Declaration.................................................................................................................................................................................. 3

2 Information and general warnings............................................................................................................................................ 4

2.1 Information about the instruction manual.................................................................................................................... 4

2.1.1 Introduction.................................................................................................................................................................. 4

2.1.2 General dangers.......................................................................................................................................................... 4

2.1.3 Danger: live components............................................................................................................................................. 4

2.2 Guarantee and responsibility....................................................................................................................................... 5

3 Safety and prevention................................................................................................................................................................ 6

3.1 Introduction.................................................................................................................................................................. 6

3.2 Safety warnings........................................................................................................................................................... 6

3.3 Basic safety rules........................................................................................................................................................ 6

3.4 Personnel training ....................................................................................................................................................... 6

4 Technical description of the burner ......................................................................................................................................... 7

4.1 Burner designation...................................................................................................................................................... 7

4.2 Technical data............................................................................................................................................................. 8

4.3 Electrical data.............................................................................................................................................................. 8

4.4 Packaging - Weight..................................................................................................................................................... 9

4.5 Overall dimensions...................................................................................................................................................... 9

4.6 Firing rates ................................................................................................................................................................ 10

4.6.1 Burner firing rates according to air density................................................................................................................ 11

4.7 Test boiler.................................................................................................................................................................. 12

4.8 Burner description..................................................................................................................................................... 13

4.9 Standard equipment.................................................................................................................................................. 13

5 Installation ................................................................................................................................................................................ 14

5.1 Notes on safety for the installation............................................................................................................................ 14

5.2 Handling.................................................................................................................................................................... 14

5.3 Preliminary checks.................................................................................................................................................... 14

5.4 Operating position..................................................................................................................................................... 15

5.5 Boiler plate ................................................................................................................................................................ 15

5.6 Blast tube length........................................................................................................................................................ 16

5.7 Securing the burner to the boiler............................................................................................................................... 16

5.8 Nozzle installation ..................................................................................................................................................... 17

5.8.1 Choice of nozzles for 1st and 2nd stage................................................................................................................... 17

5.8.2 Nozzle ....................................................................................................................................................................... 18

5.8.3 Nozzle assembly....................................................................................................................................................... 19

5.9 Hydraulic connections............................................................................................................................................... 20

5.10 Gas oil supply............................................................................................................................................................ 20

5.10.1 Double-pipe circuit..................................................................................................................................................... 20

5.10.2 Single-pipe circuit...................................................................................................................................................... 22

5.10.3 The loop circuit.......................................................................................................................................................... 23

5.11 Pump......................................................................................................................................................................... 23

5.11.1 Technical data........................................................................................................................................................... 24

5.11.2 Pump priming............................................................................................................................................................ 24

6 Electrical system...................................................................................................................................................................... 25

6.1 Notes on safety for the electrical wiring..................................................................................................................... 25

6.2 Electrical connection ................................................................................................................................................. 26

6.2.1 PRESS GW electrical equipment factory-set (single-phase model).......................................................................... 26

6.2.2 PRESS 1G - 2G - 3G electrical equipment factory-set (three-phase model) ............................................................ 27

6.2.3 PRESS GW electrical connection of burner (single-phase model) ........................................................................... 28

6.2.4 PRESS 1G - 2G - 3G electrical connection of burner (three-phase model).............................................................. 29

6.2.5 Calibration of thermal cutout ..................................................................................................................................... 30

6.2.6 Electrical cable fastening........................................................................................................................................... 30

7 Start-up, calibration and operation of the burner ................................................................................................................. 31

20140894 2

Contents

7.1 Notes on safety for the first start-up...........................................................................................................................31

7.2 Calibrations before firing............................................................................................................................................31

7.2.1 Combustion head setting...........................................................................................................................................31

7.2.2 Pump adjustment.......................................................................................................................................................31

7.2.3 Fan gate adjustment..................................................................................................................................................32

7.3 Burner calibration.......................................................................................................................................................32

7.3.1 Firing..........................................................................................................................................................................32

7.3.2 Operation ...................................................................................................................................................................32

7.4 Combustion characteristics........................................................................................................................................33

7.5 Emissions into the atmosphere..................................................................................................................................33

7.6 Flue gas temperature.................................................................................................................................................34

7.7 Combustion chamber pressure..................................................................................................................................34

7.8 Loss of heat from the flue ..........................................................................................................................................34

7.9 Burner operation........................................................................................................................................................35

7.9.1 Burner starting ...........................................................................................................................................................35

7.9.2 Steady State Operation..............................................................................................................................................35

7.9.3 Firing failure...............................................................................................................................................................36

7.9.4 Undesired shutdown during operation .......................................................................................................................36

7.9.5 Final checks...............................................................................................................................................................36

8 Maintenance ..............................................................................................................................................................................37

8.1 Notes on safety for the maintenance.........................................................................................................................37

8.2 Maintenance programme...........................................................................................................................................37

8.2.1 Maintenance frequency..............................................................................................................................................37

8.2.2 Checking and cleaning...............................................................................................................................................37

8.2.3 Opening the burner....................................................................................................................................................39

9 Faults - Possible causes - Solutions.......................................................................................................................................40

9.1 Burner start-up cycle diagnostics...............................................................................................................................41

9.2 Operating fault diagnostics ........................................................................................................................................42

9.3 Control card ...............................................................................................................................................................43

3 20140894

Declaration

1 Declaration

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 7

37045 Legnago (VR)

Product: Gas oil burners

Model: PRESS GW

PRESS 1G

PRESS 2G

PRESS 3G

These products are in compliance with the following Technical Standards:

EN 267

EN 292

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, 01.12.2015 Executive General Manager

RIELLO S.p.A. - Burner Department Research & Development Director

RIELLO S.p.A. - Burner Department

Mr. U. Ferretti Mr. F. Comencini

20140894 4

Information and general warnings

2.1 Information about the instruction manual

2.1.1 Introduction

The instruction manual supplied with the burner:

is an integral and essential part of the product and must not

be separated from it; it must therefore be kept carefully for

any necessary consultation and must accompany the burner

even if it is transferred to another owner or user, or to

another system. If the manual is lost or damaged, another

copy must be requested from the Technical Assistance Ser-

vice of the area;

is designed for use by qualified personnel;

offers important indications and instructions relating to the

installation safety, start-up, use and maintenance of the

burner.

Symbols used in the manual

In some parts of the manual you will see triangular DANGER

signs. Pay great attention to these, as they indicate a situation of

potential danger.

2.1.2 General dangers

The dangers can be of 3 levels, as indicated below.

2.1.3 Danger: live components

Other symbols

Abbreviations used

Ch. Chapter

Fig. Figure

Page Page

Sec. Section

Tab. Table

Delivery of the system and the instruction manual

When the system is delivered, it is important that:

the instruction manual is delivered to the user by the system

manufacturer, with the recommendation to keep it in the

room where the heat generator is to be installed.

The instruction manual shows:

– the serial number of the burner;

– the address and telephone number of the nearest Assis-

tance Centre.

The system supplier must carefully inform the user about:

– the use of the system;

– any further tests that may be required before activating the

system;

– maintenance, and the need to have the system checked at

least once a year by a representative of the manufacturer

or another specialised technician.

To ensure a periodic check, the manufacturer recom-

mends the drawing up of a Maintenance Contract.

2 Information and general warnings

DANGER

Maximum danger level!

This symbol indicates operations which, if not car-

ried out correctly, cause serious injury, death or

long-term health risks.

WARNING

This symbol indicates operations which, if not car-

ried out correctly, may cause serious injury, death

or long-term health risks.

CAUTION

This symbol indicates operations which, if not car-

ried out correctly, may cause damage to the ma-

chine and/or injury to people.

DANGER

This symbol indicates operations which, if not car-

ried out correctly, lead to electric shocks with le-

thal consequences.

ENVIRONMENTAL PROTECTION

This symbol gives indications for the use of the

machine with respect for the environment.

This symbol indicates a list.

.........................................................................................

5 20140894

Information and general warnings

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the installa-

tion date, in accordance with the regulations in force and/or the

sales contract. At the moment of the first start-up, check that the

burner is integral and complete.

In particular, the rights to the guarantee and the responsibility will

no longer be valid, in the event of damage to things or injury to

people, if such damage/injury was due to any of the following

causes:

incorrect installation, start-up, use and maintenance of the

burner;

improper, incorrect or unreasonable use of the burner;

intervention of unqualified personnel;

carrying out of unauthorised modifications on the equipment;

use of the burner with safety devices that are faulty, incor-

rectly applied and/or not working;

installation of untested supplementary components on the

burner;

powering of the burner with unsuitable fuels;

faults in the fuel supply system;

continuation of use of the burner when a fault has occured

repairs and/or overhauls incorrectly carried out;

modification of the combustion chamber with inserts that

prevent the regular development of the structurally estab-

lished flame;

insufficient and inappropriate surveillance and care of those

burner components most likely to be subject to wear and

tear;

the use of non-original components, including spare parts,

kits, accessories and optional;

force majeure.

The manufacturer furthermore declines any and every re-

sponsibility for the failure to observe the contents of this

manual.

Riello warranty is subject to correct burner, appliance and appli-

cation matching, and set up in line with Riello's instructions and

guidelines. All components within the hydraulic circuit suitable for

bio fuel use and supplied by Riello will be identified as Bio com-

patible. No warranty is given in relation to the use of components

which are not so identified with bio fuel blends. If in any doubt

please contact Riello for further advice.

If any Riello burners are used with fuel with a bio content >10%

then the components within the hydraulic circuit maybe affected

and are not covered under warranty. The hydraulic circuit con-

sists of;

–Pump

– Hydraulic ram (where applicable)

– Valve block

– Flexible oil lines (considered as a consumable component)

1. Irrespective of any warranty given by Riello in relation to

normal use and manufacturing defects, when fuels not

meeting the relevant standards are used, or where fuel stor-

age issues have not been addressed correctly, or the equip-

ment used is not compatible, if failures occur which are

directly or indirectly attributed to such issues and/or to the

non-observance of this guidance, then no warranty or liabil-

ity is implied or accepted by Riello.

2. Riello have carefully chosen the specification of the bio

compatible components including the flexible oil lines to pro-

tect the pump, safety value and nozzle. The Riello warranty

is dependent upon the use of Riello genuine components

including the oil lines, being used.

3. Riello warranty does not cover defects arising from incorrect

commissioning or servicing by non Riello employed service

engineers, and any issues impacting the burner arising from

external site related issues.

WARNING

Failure to observe the information given in this

manual, operating negligence, incorrect installa-

tion and carrying out of non authorised modifica-

tions will result in the annulment by the

manufacturer of the guarantee that it supplies with

the burner.

20140894 6

Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance with

current regulations and directives, applying the known technical

rules of safety and envisaging all the potential danger situations.

It is necessary, however, to bear in mind that the imprudent and

clumsy use of the equipment may lead to situations of death risk for

the user or third parties, as well as the damaging of the burner or oth-

er items. Inattention, thoughtlessness and excessive confidence of-

ten cause accidents; the same applies to tiredness and sleepiness.

It is a good idea to remember the following:

The burner must only be used as expressly described. Any other

use should be considered improper and therefore dangerous.

In particular:

it can be applied to boilers operating with water, steam, diather-

mic oil, and to other uses expressly named by the manufacturer;

the type and pressure of the fuel, the voltage and frequency of the

electrical power supply, the minimum and maximum deliveries for

which the burner has been regulated, the pressurisation of the

combustion chamber, the dimensions of the combustion cham-

ber and the room temperature must all be within the values indi-

cated in the instruction manual.

Modification of the burner to alter its performance and desti-

nations is not allowed.

The burner must be used in exemplary technical safety con-

ditions. Any disturbances that could compromise safety must

be quickly eliminated.

Opening or tampering with the burner components is not

allowed, apart from the parts requiring maintenance.

Only those parts detailed as available as spare parts by the

Manufacturer can be replaced.

3.2 Safety warnings

The dimension of the boiler’s combustion chamber must respond

to specific values, in order to guarantee a combustion with the

lowest polluting emissions rate.

The Technical Service Personnel will be glad to give you all the

information for a correct matching of this burner to the boiler.

This burner must only be used for the application it was designed

for.

The manufacturer accepts no liability within or without the con-

tract for any damage caused to people, animals and property due

to installation, adjustment and maintenance errors or to improper

use.

3.3 Basic safety rules

Children or inexpert persons must not use the appliance.

Under no circumstances must the intake grids, dissipation

grids and ventilation vents in the installation room be cov-

ered up with cloths, paper or any other material.

Unauthorised persons must not attempt to repair the appli-

ance.

It is dangerous to pull or twist the electric leads.

Cleaning operations must not be performed if the appliance

is not disconnected from the main power supply.

Do not clean the burner or its parts with inflammable sub-

stances (e.g. petrol, alcohol, etc.). The cover must be

cleaned with soapy water.

Do not place anything on the burner.

Do not block or reduce the size of the ventilation vents in the

installation room.

Do not leave containers and inflammable products or com-

bustible materials in the installation room.

3.4 Personnel training

The user is the person, body or company that has acquired the

machine and intends to use it for the specific purpose. He is re-

sponsible for the machine and for the training of the people work-

ing around it.

The user:

undertakes to entrust the machine exclusively to suitably

trained and qualified personnel;

must take all the measures necessary to prevent unauthor-

ised people gaining access to the machine;

undertakes to inform his personnel in a suitable way about

the application and observance of the safety instructions.

With that aim, he undertakes to ensure that everyone knows

the use and safety instructions for his own duties;

must inform the manufacturer if faults or malfunctioning of

the accident prevention systems are noticed, along with any

presumed danger situation.

Personnel must always use the personal protective equip-

ment envisaged by legislation and follow the indications

given in this manual.

Personnel must observe all the danger and caution indica-

tions shown on the machine.

Personnel must not carry out, on their own initiative, opera-

tions or interventions that are not within their province.

Personnel must inform their superiors of every problem or

dangerous situation that may arise.

The assembly of parts of other makes, or any modifications,

can alter the characteristics of the machine and hence com-

promise operating safety. The manufacturer therefore

declines any and every responsibility for any damage that

may be caused by the use of non-original parts.

3 Safety and prevention

7 20140894

Technical description of the burner

4.1 Burner designation

4 Technical description of the burner

Series

:PRESS

Operation : GV or G24 One stage

GW or 1-2-3-4G Two stage

Emission : ... Class 1 EN267

Head : TC Standard head

TL Extended head

Flame control system : FS1 Standard (1 stop every 24 h)

FS2 Continuous working (1 stop every 72 h)

Electrical supply of the system : 1/230/50 1/230V/50Hz

1/210/60 1/210V/60Hz

1/220/60 1/220V/60Hz

1/200/50-60 1/200V/50-60Hz

3/230-400/50 3/230V/50Hz-3N/400V/50Hz

3/210/60 3/210V/60Hz

3/220-380/60 3/220V/60Hz-3N/380V/60Hz

3/200/50-60 3/200V/50-60Hz

Auxiliary voltage : 230/50 230V/50Hz

120/60 120V/60Hz

220/60 220V/60Hz

200/50-60 200V/50-60Hz

PRESS 1G TC FS1 1/200/50-60 200/50-60

20140894 8

Technical description of the burner

4.2 Technical data

Tab. A

(1) Reference conditions: ambient temperature 20 °C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

(2) Pressure at test point with zero pressure in the combustion chamber and maximum burner output.

(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated

output.

4.3 Electrical data

MODEL PRESS GW PRESS 1G PRESS 2G PRESS 3G

Type 605T85 606T85 607T85 608T85

Power (1)

Output (1)

2nd stage kW

kg/h 178 - 356

15 - 30 190 - 534

16 - 45 356 - 712

30 - 60 534 - 1168

45 - 100

1st stage kW

kg/h 107 - 178

9 - 15 130 - 267

11 - 22.5 214 - 356

18 - 30 273 - 593

23 - 50

Fuel Light oil

Gas oil net calorific

value density

viscosity at 20 °C

kWh/kg

kg/dm3

mm2/s max

11.8

0.82 - 0.85

6 (1.5 °E - 6 cSt)

Operation • Intermittent (min. 1 stop in 24 hours).

• Two-stage (high and low flame) and single-stage (all - nothing).

Pump output (at 12 bar)

pressure range fuel

temperature

kg/h

bar

°C max

195

10 - 21

Nozzles number 2

Standard applications Boilers: water, steam, diathermic oil

Ambient temperature °C 0 - 40

Combustion air temperature °C max 60

MODEL PRESS GW PRESS 1G PRESS 2G PRESS 3G

Electrical supply V

Hz 200 +/- 10%

60 (changing fan)

50 - single-phase

200 +/- 10%

60 (changing fan)

50 - triple-phase

Electric motor kW

0.37

200

2.9

0.45

230-260

1.8-1.6

0.74

230-260

2.6-2.3

1.5

200-220

7.1-7.4

Ignition transformer V1 - V2

I1 - I2 230 V - 8 kV

1.8 A - 30 mA

Electrical power consumption kW max 0.55 0.61 1.07 2.05

Protection level IP40

9 20140894

Technical description of the burner

4.4 Packaging - Weight

Approximate measurements.

• The burners are shipped in cardboard boxes with the maxi-

mum dimensions shown in Tab. B.

• The weight of the burner complete with packaging is indicat-

ed in Tab. B.

Tab. B

4.5 Overall dimensions

Approximate measurements.

The maximum dimensions of the burner are given in (Fig. 2).

Bear in mind that inspection of the combustion head requires the

burner to be opened and the rear part withdrawn on the slide

bars.

The maximum dimension of the burner when open is give by

measurement I.

Tab. C

mm ABCkg

PRESS GW 800 535 500 37

PRESS 1G 800 535 500 44

PRESS 2G 800 535 500 44

PRESS 3G 1000 790 550 55

Fig. 1

D88

Fig. 2

D320

mmABCDEFGH I

PRESS GW 234 205 292 140 185 473 59 397 688

PRESS 1G 270 205 292 150 236 473 59 307 688

PRESS 2G 270 205 332 155 237 506 89 437 721

PRESS 3G 406 205 370 175 227 570 88 485 761

20140894 10

Technical description of the burner

4.6 Firing rates

The PRESS G Model burners can work in two ways: one-stage

and two-stage.

In one-stage operation, only one control device is provided: TL

(See the wiring diagram on page 26).

The burner fires in the 1st stage, where it remains for 7 seconds

before passing to the 2nd stage when commanded by the control

box 8) (Fig. 7 on page 13).

When the boiler temperature or pressure exceeds the values set

on the control device TL, the burner shuts down.

In two-stage operation, two control devices are provided: TL and

TR.

The burner fires in the 1st stage but passes to the 2nd stage only

if control device TR is closed. Once the temperature or pressure

value set on control device TR has been reached, the burner re-

turns to the 1st stage.

The burner shuts down only when the boiler temperature or pres-

sure exceeds the value set on control device TL, even if the burn-

er is still operating in the 1st stage.

Two-stage operation ensures reduced boiler temperature or

pressure fluctuation and consequently lower operating costs.

MINIMUM 1ST STAGE DELIVERY (MIN) must be selected with-

in the range of the values listed above the adjacent diagrams.

Example:

for the PRESS 1G Model, the selection may range from 11 - 22.5

kg/h.

It is not necessary to know the pressure in the combustion cham-

ber in the 1st stage.

MAXIMUM 2ND STAGE DELIVERY (MAX) must be selected

within the range of the adjacent diagrams. This area is known as

the FIRING RATE and provides the maximum delivery of the

burner according to the combustion chamber pressure.

Example:

for the PRESS 1G Model, this area is delimited by:

– the 16 - 45 kg/h delivery line

– the 0 +6,5 mbar combustion chamber pressure line

– the combustion chamber maximum pressure curve.

The work point may be found by plotting a vertical line from the

desired delivery and a horizontal line from the pressure in the

combustion chamber. The intersection of these two lines is the

work point which must lie within the FIRING RATE area.

Example:

if the PRESS 1G Model has a delivery of 30 kg/h at a combustion

chamber pressure of 4 mbar, the work point will be found on the

maximum pressure curve.

Consult page 11, for operation at different surrounding tempera-

tures and/or altitudes.

The delivery of the burner to be coupled to the boiler must be se-

lected in the MAX. area - in other words, within the FIRING

RATE.

The burner can also operate in depression combustion cham-

bers.

WARNING

The firing rate value (Fig. 3) has been obtained

considering an ambient temperature of 20 °C, an

atmospheric pressure of 1013 mbar (approx. 0 m

above sea level), and with the combustion head

adjusted as shown on page 31.

Fig. 3

kg/h

PRESS 1G - MIN (1st stage) = 11 - 22,5 kg/h D392

MAX

PRESS 2G - MIN (1st stage) = 18 - 30 kg/h

kg/h

D393

MAX

PRESS 3G - MIN (1st stage) = 23 - 50 kg/h D394

kg/h

MAX

D395

PRESS 4G - MIN (1st stage) = 35 - 70 kg/h

kg/h

MAX

Combustion chamber pressure mbar Combustion chamber pressure mbar

Combustion chamber pressure mbarCombustion chamber pressure mbar

11 20140894

Technical description of the burner

4.6.1 Burner firing rates according to air density

The burner firing rate range provided in this Manual applies to op-

eration at a surrounding temperature of 20°C at an altitude of 100

meters above sea level (atmospheric pressure approx. 1000

mbar).

The burner may be required to operate with comburent air at a

higher temperature and/or at higher altitudes.

Heating of air and increase in altitude produce the same effect:

the expansion of the air volume, i.e. the reduction of air density.

The burner fan's delivery remains substantially the same, but the

oxygen content per cubic meter and the fan's head are reduced.

It is therefore important to know if the maximum output required

of the burner at a given combustion chamber pressure remains

within the burner's firing rate range even at different temperature

and altitude conditions. Proceed as follows to check the above:

1 -Find the correction factor F in the Tab. D for the plant's air tem-

perature and altitude.

(1)AVERAGE BAROM. PRESS.

Tab. D

2 -Divide the burner's delivery Q by F in order to obtain the equiv-

alent delivery Qe:

3 -In the firing rate range of the burner (Fig. 4), indicate the work

point defined by:

Qe = equivalent delivery

H1 = combustion chamber pressure

The resulting point A must remain within the firing rate

range.

4 -Plot a vertical line from Point A as shown in (Fig. 4) and find

the maximum pressure H2 of the firing rate.

5 -Multiply H2 by F to obtain the maximum reduced pressure H3

of the firing rate.

If H3 is greater than “H1”, as shown in (Fig. 4), the burner deliver

the output required.

If H3 is lower than H1, the burner's delivery must be reduced.

A reduction in delivery is accompanied by a reduction of the pres-

sure in the combustion chamber:

Qr = reduced delivery

H1r = reduced pressure

H1r = H1 x (Qr/Q)2

Example, a 5% delivery reduction:

Qr = Q x 0,95

H1r = H1 x (0,95)2

Steps 2-5 must now be repeated using the new Qr and H1r val-

ues.

Altitude

a.s.l. (1) Correction factor F

Air temperature °C

mmbar 0 5 10 15 20 25 30 40

01013 1,087 1,068 1,049 1,031 1,013 0,996 0,980 0,948

100 1000 1,073 1,054 1,035 1,017 1,000 0,983 0,967 0,936

200 989 1,061 1,042 1,024 1,006 0,989 0,972 0,956 0,926

300 978 1,050 1,031 1,013 0,995 0,978 0,962 0,946 0,916

400 966 1,037 1,018 1,000 0,983 0,966 0,950 0,934 0,904

500 955 1,025 1,007 0,989 0,972 0,955 0,939 0,923 0,894

600 944 1,013 0,995 0,977 0,960 0,944 0,928 0,913 0,884

700 932 1,000 0,982 0,965 0,948 0,932 0,916 0,901 0,872

800 921 0,988 0,971 0,954 0,937 0,921 0,906 0,891 0,862

900 910 0,977 0,959 0,942 0,926 0,910 0,895 0,880 0,852

1000 898 0,964 0,946 0,930 0,914 0,898 0,883 0,868 0,841

1200 878 0,942 0,925 0,909 0,893 0,878 0,863 0,849 0,822

1400 856 0,919 0,902 0,886 0,871 0,856 0,842 0,828 0,801

1600 836 0,897 0,881 0,866 0,851 0,836 0,822 0,808 0,783

1800 815 0,875 0,859 0,844 0,829 0,815 0,801 0,788 0,763

2000 794 0,852 0,837 0,822 0,808 0,794 0,781 0,768 0,743

Qe = Q : F (kg/h)

H3 = H2 x F (mbar)

CAUTION

The combustion head must be adjusted in respect

to the equivalent delivery Qe.

Qe kg/h

mbar

Fig. 4

D388

20140894 12

Technical description of the burner

Example

Delivery Q = 19 kg/h - Comb. chamber press. H1 = 5 mbar Delivery reduction 5%

Qr = 19 x 0,95 = 18 kg/h - H1r = 5 x (0,95)2 = 4,5 mbar

4.7 Test boiler

The firing rates were set in relation to special test boilers in ac-

cordance with the methods defined in EN 267 standards.

Fig. 6 indicates the diameter and length of the test combustion

chamber.

Example:

delivery 25 kg/hour:

diameter = 50 cm; length = 1 m.

Whenever the burner is operated in a much smaller commercial-

ly-available combustion chamber, a preliminary test should be

performed.

kg/h

mbar

4,6

5,7

21,1

5,5

6,1

mbar

kg/h

4,5

22,3

4,7

5,8

Fig. 5

D389

***

air 20 °C - altitude 1000 m a.s.l. - F = 0.898 *

Qe = Q : F = 19 : 0.898 = 21,1 kg/h 5 mbar A

H2 = 6.1 mbar

H3 = H2 x F = 6.1 x 0.898 = 5.5 mbar

H3 > H1 (5.5 > 5) OK

air 30 °C - altitude 1600 m a.s.l. - F = 0.808 *

Qe = Q : F = 19 : 0.808 = 23 kg/h 5 mbar B

H2 = 5,7 mbar

H3 = H2 x F = 5.7 x 0.808 = 4.6 mbar

H3 < H1 (4.6 < 5) IMPOSSIBLE

Qe = Q : F = 18 : 0.808 = 22.3 kg/h 4.5 mbar C **

H2 = 5.8 mbar

H3 = H2 x F = 5.8 x 0.808 = 4.7 mbar

H3 > H1 (4.7 > 4.5) OK

Fig. 6

D449

Combustion chamber length m

13 20140894

Technical description of the burner

4.8 Burner description

1 Slide bars for opening the burner and inspecting the

combustion head

2 Combustion head

3 Air inlet to fan

4 Motor capacitor

(PRESS GW)

5 Motor contact-maker and thermal cut out with reset button

(PRESS 1G-2G-3G)

6 Terminal strip

7 Fairleads for wiring carried out by the installer

8 Control box with lock-out pilot light and lock-out reset

button

9 Fan pressure test point

10 Pump (see ‘Pump” on page 23)

12 Electrical motor

13 Screw for combustion head adjustment

14 Sensor for flame presence control

15 Fan rotation direction

16 Variable stroke hydraulic cylinder.

Opens the fan gate valve to the value necessary at the

2nd stage of operation.

17 Indexed selector.

This selector adjusts the opening of the fan gate to the

value necessary at the 1st stage of functioning.

Two types of burner failure may occur:

- CONTROL BOX LOCK-OUT:

if the control box 8) (Fig. 7) pushbutton lights up, it indicates that

the burner is in lock-out.

To reset, press the pushbutton for a minimum of three seconds.

- MOTOR TRIP (PRESS 1-2-3 G):

release by pressing the pushbutton on thermal relay 5)(Fig. 7).

4.9 Standard equipment

2 - Hoses

2 - Gaskets for hoses

2 - Nipples for hoses

1 - Reducer with gasket for connection of flexible suction hose

to pump (PRESS 1G-2G)

1 - Thermal insulation screen

4 - Screws to secure the burner flange to the boiler:

M10 x 25 for GW - 1G - 2G

M12 x 40 for 3G

1 - Instruction booklet

1 - Fan for 60Hz use

S8281

S9704

Fig. 7

WARNING

You must replace burner fan in application with 60

Hz power supply.

20140894 14

Installation

5.1 Notes on safety for the installation

After carefully cleaning all around the area where the burner will

be installed, and arranging the correct lighting of the environ-

ment, proceed with the installation operations.

5.2 Handling

The packaging of the burner includes a wooden platform, so it is

possible to move the burner (still packaged) with a transpallet

truck or fork lift truck.

5.3 Preliminary checks

Checking the consignment

Checking the characteristics of the burner

Check the identification label of the burner, showing:

the model (A) (Fig. 8) and type of burner (B);

the year of manufacture, in cryptographic form (C);

the serial number (D);

the data for electrical supply and the protection level (E);

the absorbed electrical power (F);

the types of fuel used and the relative supply pressures (G);

the data of the burner's minimum and maximum output pos-

sibilities (H) (see Firing rate).

5Installation

DANGER

All the installation, maintenance and disassembly

operations must be carried out with the electricity

supply disconnected.

WARNING

The installation of the burner must be carried out

by qualified personnel, as indicated in this manual

and in compliance with the standards and regula-

tions of the laws in force.

WARNING

The handling operations for the burner can be

highly dangerous if not carried out with the great-

est attention: keep any unauthorised people at a

distance; check the integrity and suitableness of

the available means of handling.

Check also that the area in which you are working

is empty and that there is an adequate escape

area (i.e. a free, safe area to which you can quick-

ly move if the burner should fall).

When handling, keep the load at not more than

20-25 cm from the ground.

CAUTION

After positioning the burner near the installation

point, correctly dispose of all residual packaging,

separating the various types of material.

Before proceeding with the installation operations,

carefully clean all around the area where the burn-

er will be installed.

CAUTION

After removing all the packaging, check the integ-

rity of the contents. In the event of doubt, do not

use the burner; contact the supplier.

The packaging elements (wooden cage or card-

board box, nails, clips, plastic bags, etc.) must not

be abandoned as they are potential sources of

danger and pollution; they should be collected and

disposed of in the appropriate places.

WARNING

A burner label that has been tampered with, re-

moved or is missing, along with anything else that

prevents the definite identification of the burner

makes any installation or maintenance work diffi-

cult.

Fig. 8

S8268

15 20140894

Installation

5.4 Operating position

The burner is designed to work only in the positions 1, 2, 3 and 4.

Installation 1 is preferable, as it is the only one that allows per-

forming maintenance operations as described in this manual.

Installations 2, 3 and 4 permit operation but make maintenance

and inspection of the combustion head difficult, page 37.

5.5 Boiler plate

Drill the combustion chamber locking plate as shown in Fig. 10.

The position of the threaded holes can be marked using the ther-

mal screen supplied with the burner.

Tab. E

WARNING

Any other position could compromise the correct

working of the appliance.

Installation 5 is prohibited for safety reasons.

Fig. 9

2 3 4 51

S8269

mm A B C D

PRESS GW 155 160 160 M10

PRESS 1G 165 160 160 M10

PRESS 2G 165 160 160 M10

PRESS 3G 185 195 195 M12

D329

Fig. 10

20140894 16

Installation

5.6 Blast tube length

The length of the blast tube must be selected according to the in-

dications provided by the manufacturer of the boiler, and in any

case it must be greater than the thickness of the boiler door com-

plete with its fettling.

The range of lengths available, L (mm), is as follows:

For boilers with front flue passes 9) or flame inversion chambers,

protective fettling in refractory material 7) must be inserted be-

tween the boiler's fettling 8) and the blast tube 6).

This protective fettling must not compromise the extraction of the

blast tube.

5.7 Securing the burner to the boiler

Disassemble the blast tube 6) from the burner by proceeding as

follows:

– Remove the screws 2) from the two slide bars 3).

– Remove the screws 1) that secure the blast tube 6) to the

burner 4).

– Now disassemble the blast tube complete with the slide bars.

Fasten the blast tube 6) to the boiler plate (Fig. 10 on page 15),

inserting the gasket provided 5). Use the 4 screws provided after

having protected the thread with antiscruffing products (high-tem-

perature grease, compounds, graphite). The burner-boiler seal

must be airtight.

Reassemble the burner 4) on the slide bars 3) and re-insert the

screws 2).

Leave the burner open as shown in (Fig. 11).

Blast tube GW 1G 2G 3G

shortened 43 mm 94 mm 95 mm 85 mm

standard 185 mm 236 mm 237 mm 237 mm

lengthened 320 mm 369 mm 395 mm 384 mm

Fig. 11

D330

17 20140894

Installation

5.8 Nozzle installation

5.8.1 Choice of nozzles for 1st and 2nd stage

The burner complies with the emission requirements of the

EN 267 standard.

In order to guarantee that emissions do not vary, recommended

and/or alternative nozzles specified by Riello in the Instruction

and warning booklet should be used.

The nozzle must be chosen from among those listed in (Tab. F).

Use nozzle with atomization angle of 60° and, if possible, at a

pressure of 12 bar.

Example with the Press 1G Model:

Boiler output = 270 kW - efficiency 90 %

Output required by the burner =

270 : 0.9 = 300 kW;

300 : 2 = 150 kW per nozzle;

therefore, two equal, 60°, 12 bar nozzles are required:

1° = 3.00 GPH - 2° = 3.00 GPH,

or the following two different nozzles:

1° = 2.50 GPH - 2° = 3.50 GPH, or

1° = 3.50 GPH - 2° = 2.50 GPH.

NOTE:

Other information regarding nozzles may be found on ‘Noz-

zle” on page 18.

(1) We get the indicated delivery when both nozzles are working

and gas oil has the following characteristics:

density 0.84 kg/dm3 - viscosity 4.2 cSt/20 °C - temperature

10 °C

Tab. F

WARNING

It is advisable to replace nozzles every year

during regular maintenance operations.

CAUTION

The use of nozzles other than those specified by

Riello S.p.A. and inadequate regular maintenance

may result into emission limits non-conforming to

the values set forth by the regulations in force, and

in extremely serious cases, into potential hazards

to people and objects.

The manufacturing company shall not be liable for

any such damage arising from non-observance of

the requirements contained in this manual.

GPH Delivery kg/h (1) kW

12 bar

10 bar 12 bar 14 bar

PRESS GW

2.00 7.7 8.5 9.2 100.8

2.25 8.6 9.5 10.4 112.7

2.50 9.6 10.6 11.5 125.7

3.00 11.5 12.7 13.8 150.6

3.50 13.5 14.8 16.1 175.5

4.00 15.4 17.0 18.4 201.6

PRESS 1G

2.00 7.7 8.5 9.2 100.8

2.25 8.6 9.5 10.4 112.7

2.50 9.6 10.6 11.5 125.7

3.00 11.5 12.7 13.8 150.6

3.50 13.5 14.8 16.1 175.5

4.00 15.4 17.0 18.4 201.6

4.50 17.3 19.1 20.7 226.5

5.00 19.2 21.2 23.0 251.4

5.50 21.1 23.3 25.3 276.3

PRESS 2G

4.00 15.4 17.0 18.4 201.6

4.50 17.3 19.1 20.7 226.5

5.00 19.2 21.2 23.0 251.4

5.50 21.1 23.3 25.3 276.3

6.00 23.1 25.5 27.7 302.4

6.50 25.0 27.6 30.0 327.3

7.00 26.9 29.7 32.3 352.3

PRESS 3G

6.00 23.1 25.5 27.7 302.4

6.50 25.0 27.6 30.0 327.3

7.00 26.9 29.7 32.3 352.3

7.50 28.8 31.8 34.6 377.2

8.30 31.9 35.2 38.3 417.5

9.50 36.5 40.3 43.8 478.0

10.50 40.4 44.5 48.4 527.8

12.00 46.1 50.9 55.3 603.7

D339

20140894 18

Installation

5.8.2 Nozzle

The spray patterns in relation to the leading brands of nozzle on

sale are shown in (Tab. G).

The nozzle deliveries indicated in the Tab. F are the rated values.

In reality, the delivery may differ by +/- 10% due to the reasons

below:

• tolerance values indicated by the manufacturer;

• temperature variation:

delivery decreases with a rise in temperature and vice-versa;

• variations in fuel viscosity:

delivery decreases with a decrease of viscosity and vice-ver-

sa.

A burner's exact delivery can only be determined by weighing.

Suck the fuel from a recipient mounted on a weighing machine,

or attach hoses to the nozzles and weigh the fuel that flows out.

A liter counter can be applied to the pump's suction line if a sin-

gle-pipe supply system has been provided.

NOTE:

Nozzle manufacturers discourage opening of the nozzle to

clean its internal parts and especially its calibrated hole. The

filter, on the other hand, may be cleaned or replaced as re-

quired. Grip the nozzle on its hexagonal part when handling.

Tab. G

Spray Delevan Monarc

hDanfoss Steinen

hollow APLHH - PH

solid BARS Q

universal W NS - PLP B SS

semi-

solid ER-S

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Riello PRESS 3G TC FS1 3/200/50-60 200/50-60, PRESS 1G, PRESS 1G TC FS1 3/200/50-60 200/50-60, PRESS 2G, PRESS 2G TC FS1 3/200/50-60 200/50-60, PRESS GW TC FS1 1/200/50-60 200/50-60 Installer Manual

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