Riello PRESS 1G Installation, Use And Maintenance Instructions Download Page 1 | Manualshive

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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

GB

1
2
3
...
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Summary of Contents for PRESS 1G

Page 1: ...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 GB ...

Page 2: ......

Page 3: ...ks 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 Techni...

Page 4: ... 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 Ope...

Page 5: ... 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 Deve...

Page 6: ...elivered 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 activati...

Page 7: ...t 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 bi...

Page 8: ...nd 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 ...

Page 9: ... 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 5...

Page 10: ...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 73 20 60 95 20 60 195 10 21 90 Nozzles number 2 Standard applications Boilers water steam d...

Page 11: ... 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 A B C kg 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 mm A B C D E F G H I PRESS GW 234 205 292 140 ...

Page 12: ... 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 vert...

Page 13: ...e 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 ...

Page 14: ...ength 1 m Whenever the burner is operated in a much smaller commercial ly available combustion chamber a preliminary test should be performed kg h B mbar 4 6 5 7 23 21 1 5 5 5 6 1 A mbar kg h C 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 ...

Page 15: ...lue 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 ...

Page 16: ...s 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 w...

Page 17: ...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 5 1 S8269 mm A B C D P...

Page 18: ...ng 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 havin...

Page 19: ...ce 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 requi...

Page 20: ...nd 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...

Page 21: ...h as gaskets seal ing compound or tape The nozzle must be screwed into place tightly but not to the maximum torque value provided by the wrench Lastly close the burner by screwing in the two screws 1 Fig 15 WARNING Do not use any sealing products such as gaskets sealing compound or tape Be careful to avoid damaging the nozzle sealing seat The nozzles must be screwed into place tightly but not to t...

Page 22: ...released from the fuel the pump starts making noise and its working life span decreases It is good practice to ensure that the return and suction lines enter the burner from the same height in this way it will be more im probable that the suction line fails to prime or stops priming CAUTION The opening of the burner or the boiler door must not twist or strain the flexible hoses Arrange the flexibl...

Page 23: ...the boiler door must not twist the flexible hoses that connect the copper pipes to the pump If more than one burner is operating in the same room each one must be equipped with its own suction pipe the return pipe may be shared by all providing it is sufficiently sized The suction line must be perfectly airtight In order to check the seal close the pump s return line Install a union T on the vacuu...

Page 24: ...rn line connector must be plugged This solution is possible only with low pump depression values max 0 2 bar and perfectly sealed piping Key Fig 18 H Pump Foot valve height difference L Piping length values calculated for gas oil viscosity 6 cSt 20 C density 0 84 kg dm3 temperature 0 C max altitude 200 m a s l ø Inside pipe diameter 1 Burner 2 Pump 3 Filter 4 Manual on off valve 5 Suction line 6 F...

Page 25: ...between the pump and the foot valve must be corrected by the factor F see Tab J in order to obtain the equivalent height difference with which to determine the maxi mum piping length i e if a suction type system is involved equivalent He real H F if a siphon type system is involved equivalent He real H F where F real altitude m 200 1000 m Altitude in m a s l F Compensation factor Tab J Example Suc...

Page 26: ...ine are open and that there is sufficient fuel in the tank In order for self priming to take place the pressure gauge at tachment plug located on the pump or the gauge itself if ap plied Pump on page 23 must be loosened in order to bleed off the air contained in the suction line and bring the pump delivery pressure to zero Do not illuminate the sensor otherwise the burner will fail to start Start ...

Page 27: ...enable the control box to perform checks of its own start up efficiency Normally the boiler s thermostat pressure switch ensures the stopping of the burner If this is not the case it is necessary to apply in series with IN a timer switch that turns off the burner at least once every twenty four hours Refer to the wiring diagrams The electrical safety of the device is obtained only when it is corre...

Page 28: ... RT Thermal cutout TA Ignition transformer TB Burner ground earth connection V1 1st stage solenoid valve V2 2nd stage solenoid valve NOTE These models leave the factory preset for 200V power supply WARNING Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel Riello S p A declines all liability for modification...

Page 29: ...utout TA Ignition transformer TB Burner ground earth connection V1 1st stage solenoid valve V2 2nd stage solenoid valve NOTE These models leave the factory preset for 200V power supply 50Hz Fig 24 20141030 WARNING Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel Riello S p A declines all liability for modi...

Page 30: ...sary only for two stage operation TS Safety control device system This operates when TL is faulty NOTE the burner is delivered preset for single stage operation with a jumper inserted in the terminal strip see Fig 27 at page 29 If two stage operation is required remove the jumper between terminals 10 11 and insert the control device TR in its place to command the 2nd gas oil solenoid valve NOTE Th...

Page 31: ...on TS Safety control device system This operates when TL is faulty NOTE the burner is delivered preset for single stage operation with a jumper inserted in the terminal strip see Fig 27 If two stage operation is required remove the jumper be tween terminals 10 11 and insert the control device TR in its place to command the 2nd gas oil solenoid valve Fuse and cable sections cable section not indica...

Page 32: ... 5 2 Control devices TL Pg 13 5 3 Control devices TR Pg 13 5 4 Spare fairlead Pg 13 5 5 Fitting hole for fairlead if required Pg 21 6 Fitting hole for fairlead if required Pg 11 7 Fitting hole for fairlead if required Pg 11 The PRESS 1G 2G 3G Models Fig 29 1 Three phase power supply Pg 21 2 Single phase power supply Pg 13 5 3 Control devices TL Pg 13 5 4 Control devices TR Pg 13 5 5 Spare fairlead...

Page 33: ...of 25 4 kg h the burner requires the combustion head to be set to approx three notches as shown in Fig 32 7 2 2 Pump adjustment No presetting are required for the pump which is set to 12 bar by the manufacturer This pressure must be checked and adjusted if required after the burner has been ignited The only operation required in this phase is the application of a pressure gauge on the apposite pum...

Page 34: ...ation of the burner requires an analysis of the flue gases at the boiler outlet and interventions on the following points 1st and 2nd stage nozzles See the information listed on page 23 Pump pressure 12 bar this is the pressure calibrated in the factory which is usu ally sufficient for most purposes Sometimes this pressure must be adjusted to 10 bar in order to reduce fuel delivery This adjustment...

Page 35: ...defined by EC Norms EN 267 under the operating conditions established by these standards see Tab M Tab M Commercial boilers emissions of Bacharach CO2 CO CxHy NOx must not exceed the limits imposed by locally applicable regulations for burner installations In particular the CO2 level should not be higher than 13 5 in order to prevent variations in the draught and air temperature or dirty burner co...

Page 36: ... man ufacturer Chamber pressure is lowered with reduced burner delivery and higher CO2 levels If the combustion chamber pressure is significantly higher than expected and the burner s delivery is correct make sure that the boiler is not dirty that the flue gas duct is not obstructed and that the flue gas stack has been correctly sized 7 8 Loss of heat from the flue Heat losses from the flue gas st...

Page 37: ...pens the fan air gate valve in the 2nd stage After 60 sec The starting cycle comes to an end 7 9 2 Steady State Operation System equipped with one control device TR Once the starting cycle has come to an end the command of the 2nd stage solenoid valve passes on to the control device TR that controls boiler temperature or pressure When the temperature or the pressure increases until the control dev...

Page 38: ...he burner shuts down au tomatically within 1 second and automatically attempts to start again by repeating the starting cycle 7 9 5 Final checks Shine a light on the sensor and close the control devices the burner should not start Obscure the sensor while the burner is working the burner should stop and automatically repeat the starting operation Switch off control device TL while the burner is op...

Page 39: ...ot dirty The vacuum meter is installed upstream from the filter and consequently will not indicate whether the filter is clogged or not Contrarily if the problem lies in the suction line check to make sure that the filter is clean and that air is not entering the piping Filters Fig 38 Check the following filter boxes on line 1 in the pump 2 at the nozzle 3 and clean or replace as required If rust ...

Page 40: ...ng must be equipped with a foot valve 5 Fuel tank Approximately every 5 years or whenever necessary suck any water or other impurities present on the bottom of the tank using a separate pump Boiler Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics in tact especially the flue gas temperature and combustion cham ber pressu...

Page 41: ...heet on page 41 Significant differences with respect to the previous measure ments indicate the points where more care should be exercised during maintenance Once these controls and measurements have been performed stop the burner disconnect the power supply and close the man ual valves on the fuel lines and open the burner DANGER Disconnect the electrical supply from the burner D397 Fig 41 ...

Page 42: ... Filters dirty line pump nozzle Clean Incorrect motor rotation direction Change motor electrical connections 1st stage sol valve coil defective Replace Presence of electromagnetic disturbance Use the radio disturbance protection kit The burner goes to lock out right after flame appearance Delayed firing by electrodes or poorly adjusted head Adjust Defective sensor or control box Replace Dirty sens...

Page 43: ...rach Boiler room air vents insufficient Increase Too much air Adjust head and fan gate according to Manual Dirty combustion head Nozzle or filter dirty Replace Unsuitable nozzle delivery or angle See Recommended nozzles Loose nozzle Tighten Impurities on flame stability spiral Clean Erroneous head adjustment or not enough air Adjust as per Manual instructions open gate valve Blast tube length unsu...

Page 44: ... least 10s Press reset for 3s Pulses Interval 3s Pulses SIGNAL PROBABLE CAUSE 2 flashes The flame does not stabilise at the end of the safety time faulty sensor faulty or soiled light oil valves neutral phase exchange faulty ignition transformer poor burner regulation insufficient gas oil 3 flashes Min air pressure switch does not close air pressure switch faulty air pressure switch incorrectly re...

Page 45: ...ure at stack T1 Temperature PV Fan pressure RT Combustion head adjustment RS Fan gate valve adjustment T P Temperature or pressure PC Comb chamber pressure Qs Heat loss at stack BURNER MODEL TYPE CODE BOILER COMPANY MODEL kW Fig 42 D390 NOZZLE PUMP FLUE GASES AIR BOILER STACK Q T PP VP BACH CO2 CO NOx CxHy T2 PF T1 PV RT RS T P PC Qs GPH bar bar N ppm ppm ppm C mbar C mbar n n C bar mbar NOZZLE PU...

Page 46: ...talling a degassing unit near the burner in single pipe installations Degassing units are provided in two versions Code 3010054 without filter Code 3010055 with filter For burner deliveries higher than 80 kg h install two parallel de gassing units Kit for lengthening the combustion head L Standard length L1 Length obtainable with the kit Spacer for shortening the combustion head L Spacer thickness...

Page 47: ... for burner inspection Complete closure of the air gate valve during pauses in burner operation Serves to minimize thermal dispersion caused by the stack draught sucking air from the fan s suction opening This is achieved by hydraulic cylinder M which closes the fan gate valve completely when the burner shuts down mm A B C H kg MIN MAX D1 770 650 690 482 1090 52 Fig 3 D322 Burner Code PRESS GW 300...

Page 48: ...Subject to modifications RIELLO S p A I 37045 Legnago VR Tel 39 0442 630111 http www riello it http www riello com ...

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