Riello PRESS GW Installation, Use And Maintenance Instructions
Gas oil burners, two-stage operation
Hide thumbs
Also See for PRESS GW:
- Installation, use and maintenance instructions (16 pages) ,
- Installation, use and maintenance instructions (44 pages)
Related Manuals for Riello PRESS GW
Summary of Contents for Riello PRESS GW
- Page 1 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 20140894 (1) - 11/2017...
-
Page 3: Table Of Contents
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... - Page 4 Contents Notes on safety for the first start-up ...........................31 Calibrations before firing ............................31 7.2.1 Combustion head setting ............................31 7.2.2 Pump adjustment ...............................31 7.2.3 Fan gate adjustment ..............................32 Burner calibration ...............................32 7.3.1 Firing ..................................32 7.3.2 Operation ...................................32 Combustion characteristics ............................33 Emissions into the atmosphere ..........................33 Flue gas temperature ..............................34 Combustion chamber pressure ..........................34 Loss of heat from the flue ............................34...
-
Page 5: Declaration
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 Research & Development Director RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department Mr. U. Ferretti Mr. F. Comencini... -
Page 6: Information And General Warnings
Information and general warnings Information and general warnings Information about the instruction manual 2.1.1 Introduction 2.1.3 Danger: live components The instruction manual supplied with the burner: This symbol indicates operations which, if not car- is an integral and essential part of the product and must not ried out correctly, lead to electric shocks with le- be separated from it;... -
Page 7: Guarantee And Responsibility
All components within the hydraulic circuit suitable for manual, operating negligence, incorrect installa- bio fuel use and supplied by Riello will be identified as Bio com- tion and carrying out of non authorised modifica- patible. No warranty is given in relation to the use of components... -
Page 8: Safety And Prevention
Safety and prevention Safety and prevention Introduction The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for rules of safety and envisaging all the potential danger situations. -
Page 9: Technical Description Of The Burner
Technical description of the burner Technical description of the burner Burner designation Series PRESS Operation : GV or G24 One stage GW or 1-2-3-4G Two stage Emission : ... Class 1 EN267 Head : Standard head Extended head Flame control system : Standard (1 stop every 24 h) Continuous working (1 stop every 72 h) Electrical supply of the system :... -
Page 10: Technical Data
Technical description of the burner Technical data MODEL PRESS GW PRESS 1G PRESS 2G PRESS 3G Type 605T85 606T85 607T85 608T85 Power 2nd stage 178 - 356 190 - 534 356 - 712 534 - 1168 kg/h 15 - 30... -
Page 11: Packaging - Weight
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. Fig. 1 PRESS GW PRESS 1G PRESS 2G PRESS 3G 1000 Tab. B Overall dimensions Approximate measurements. -
Page 12: Firing Rates
Technical description of the burner 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 PRESS 1G - MIN (1st stage) = 11 - 22,5 kg/h D392 (See the wiring diagram on page 26). -
Page 13: Burner Firing Rates According To Air Density
Technical description of the burner 4.6.1 Burner firing rates according to 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. The burner firing rate range provided in this Manual applies to op- It is therefore important to know if the maximum output required eration at a surrounding temperature of 20°C at an altitude of 100 of the burner at a given combustion chamber pressure remains... -
Page 14: Test Boiler
Technical description of the burner Example mbar mbar D389 21,1 22,3 kg/h kg/h Fig. 5 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) = 4,5 mbar air 20 °C - altitude 1000 m a.s.l. -
Page 15: Burner Description
Slide bars for opening the burner and inspecting the combustion head Combustion head Air inlet to fan Motor capacitor (PRESS GW) Motor contact-maker and thermal cut out with reset button (PRESS 1G-2G-3G) Terminal strip Fairleads for wiring carried out by the installer... -
Page 16: Installation
Installation Installation Notes on safety for the installation After carefully cleaning all around the area where the burner will The installation of the burner must be carried out be installed, and arranging the correct lighting of the environ- by qualified personnel, as indicated in this manual ment, proceed with the installation operations. -
Page 17: Operating Position
Drill the combustion chamber locking plate as shown in Fig. 10. D329 The position of the threaded holes can be marked using the ther- mal screen supplied with the burner. PRESS GW PRESS 1G PRESS 2G PRESS 3G Tab. E Fig. -
Page 18: Blast Tube Length
Installation Blast tube length The length of the blast tube must be selected according to the in- For boilers with front flue passes 9) or flame inversion chambers, dications provided by the manufacturer of the boiler, and in any protective fettling in refractory material 7) must be inserted be- case it must be greater than the thickness of the boiler door com- tween the boiler's fettling 8) and the blast tube 6). -
Page 19: Nozzle Installation
10 bar 12 bar 14 bar D339 In order to guarantee that emissions do not vary, recommended 2.00 100.8 and/or alternative nozzles specified by Riello in the Instruction 2.25 10.4 112.7 and warning booklet should be used. 2.50 10.6 11.5 125.7... -
Page 20: Nozzle
Installation 5.8.2 Nozzle Monarc The spray patterns in relation to the leading brands of nozzle on Spray Delevan Danfoss Steinen sale are shown in (Tab. G). The nozzle deliveries indicated in the Tab. F are the rated values. hollow H - PH In reality, the delivery may differ by +/- 10% due to the reasons below: •... -
Page 21: Nozzle Assembly
Installation 5.8.3 Nozzle assembly Lastly, close the burner by screwing in the two screws 1)(Fig. 15). The nozzle for the 1st stage of operation is the one lying beneath the firing electrodes (Fig. 14). D333 With the burner open on the slide bars as shown in (Fig. 11 on page 16), unscrew and remove the plastic plug 1) (Fig. -
Page 22: Hydraulic Connections
4 meters in order to permit pump self-priming supply line. even when the tank is almost completely empty. Riello recommends a good quality fuel filter at the CAUTION tank (Fig. 17 - Fig. 18) and a secondary filter The tank lower than the burner B (Fig. - Page 23 • max altitude = 200 m (a.s.l.) ø Inside pipe diameter Burner Pump Filter Manual on/off valve Suction line Foot valve Return line PRESS GW PRESS 1G - 2G PRESS 3G Ø mm Ø mm Ø mm +0,5 -0,5 Tab. H...
-
Page 24: 5.10.2 Single-Pipe Circuit
Installation 5.10.2 Single-pipe circuit Key (Fig. 18) H Pump/Foot valve height difference There are two solutions possible: L Piping length • Pump external bypass (A, Fig. 19) (recommended) • values calculated for gas oil: The two flexible hoses are connected to an automatic degassing •... -
Page 25: 5.10.3 The Loop Circuit
(equivalent) He = (real) H - F where: F = (real altitude) (m - 200) / 1000 5.11 Pump PRESS 3G PRESS GW SUNTEC J6 SUNTEC ANV67 D378 D376 Fig. 22 Fig. 20 Pump... -
Page 26: 5.11.1 Technical Data
Installation 5.11.1 Technical data 5.11.2 Pump priming Before starting the burner, make sure that the AN 67 AN 77 tank return line is not clogged. kg/h Obstructions in the line could cause the seal- 10 - 18 10 - 18 10 - 21 WARNING ing organ located on the pump shaft to break. -
Page 27: Electrical System
Electrical system Electrical system Notes on safety for the electrical wiring The electrical wiring must be carried out with the electrical supply disconnected. Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. -
Page 28: Electrical Connection
Electrical system Electrical connection 6.2.1 PRESS GW electrical equipment factory-set (single-phase model) (as set up by the manufacturer) 20141029 Fig. 23 Key (Fig. 25) C - Capacitor CMV- Motor contact-maker RMO- Control box FR- Sensor flame MB- Burner terminal strip... -
Page 29: Press 1G - 2G - 3G Electrical Equipment Factory-Set (Three-Phase Model)
Electrical wiring must be made in accordance with the regulations currently in force in the country of destination and by qualified personnel. WARNING Riello S.p.A. declines all liability for modifications or connections other than those shown on these diagrams. 20140894... -
Page 30: Press Gw Electrical Connection Of Burner (Single-Phase Model)
Electrical system 6.2.3 PRESS GW electrical connection of burner (single-phase model) (by installer) 20141015 Fig. 25 Key (Fig. 25): IN - Manual burner stop switch MB- Burner terminal strip PS- Lock-out reset button S - Remote lock-out signal TB- Burner ground (earth) connection... -
Page 31: Press 1G - 2G - 3G Electrical Connection Of Burner (Three-Phase Model)
Electrical system 6.2.4 PRESS 1G - 2G - 3G electrical connection of burner (three-phase model) (by installer) 20141016 Fig. 26 Key (Fig. 25): IN - Manual burner stop switch MB- Burner terminal strip PS- Lock-out reset button S - Remote lock-out signal TB- Burner ground (earth) connection TL- Limit control device system: This shuts down the burner when the boiler temperature or... -
Page 32: Calibration Of Thermal Cutout
The fairleads and precut holes can be used in various ways. One example is given below: Fig. 28 The PRESS GW Model (Fig. 29) 1 - Single-phase power supply........Pg 13.5 2 - Control devices TL ............ Pg 13.5 PRESS GW PRESS 1-2-3 3 - Control devices TR ........... -
Page 33: Start-Up, Calibration And Operation Of The Burner
Start-up, calibration and operation of the burner Start-up, calibration and operation of the burner Notes on safety for the first start-up The first start-up of the burner must be carried out Check the correct working of the adjustment, com- by qualified personnel, as indicated in this manual mand and safety devices. -
Page 34: Fan Gate Adjustment
Fig. 33 D338 2nd stage: The air gate valve 1) (Fig. 33) must be set using the cylinder 6) PRESS GW PRESS 1G PRESS 2G PRESS 3G (Fig. 33). This setting must be adapted case by case to the burn- N°... -
Page 35: Combustion Characteristics
Start-up, calibration and operation of the burner Combustion characteristics The burner delivery in the 2nd stage must not exceed the rated The burner's delivery in the 1st stage is usually 50% of the de- delivery for the boiler, and should be adjusted in relation to the livery in the 2nd stage and must be contained in the MIN. -
Page 36: Flue Gas Temperature
Start-up, calibration and operation of the burner Flue gas temperature This temperature varies in relation to the delivery generated: the Bear in mind that excessive temperature reduction, however, lower the delivery, the lower the temperature and the higher the gives rise to the formation of condensate. fuel saving. -
Page 37: Burner Operation
Start-up, calibration and operation of the burner Burner operation 7.9.1 Burner starting D380 - When the control device TL closes, the control box programmes the starting phase. - 0 sec. time: The control device TL closes. - After 27 sec.: The motor starts and the ignition transformer is connected. -
Page 38: Firing Failure
Start-up, calibration and operation of the burner 7.9.3 Firing failure If the burner does not fire, it goes into lock-out within 5 seconds of the opening of the 1st stage solenoid valve and 30 seconds af- ter the closing of control device TL. The control box pilot light will light up. -
Page 39: Maintenance
Maintenance Maintenance Notes on safety for the maintenance The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper- safety, yield and duration of the burner. ations: It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time. - Page 40 Maintenance Nozzles Gas oil fuel supply line (Fig. 40) Do not clean the nozzle opening; do not even open it. The nozzle If the previous checks have suggested that air may be entering filter however may be cleaned or replaced as required. Replace the circuit somewhere, pressurize the circuit piping.
-
Page 41: Opening The Burner
Maintenance 8.2.3 Opening the burner Disconnect the electrical supply from the burner. DANGER Unscrew the screws 1) Pull back part A while keeping it slightly lifted. D397 Fig. 41 Other control measurements Check the parameters listed in the data sheet on page 41. Significant differences with respect to the previous measure- ments indicate the points where more care should be exercised during maintenance. -
Page 42: Faults - Possible Causes - Solutions
- Light is entering or flame is simulated Eliminate light or replace control box The burner starts but stops almost immediately - Missing phase (NO PRESS GW) thermal cutout triggers Reset thermal cutout when third phase returns After pre-purge the burner goes to lock out and - No fuel in tank;... -
Page 43: Burner Start-Up Cycle Diagnostics
Faults - Possible causes - Solutions FAULT PROBABLE CAUSE SUGGESTED REMEDY Smoke in flame - dark Bacharach - Not enough air Adjust head and fan gate according to Manual - Nozzle worn or dirty Replace - Nozzle filter clogged Clean or replace - Erroneous pump pressure Adjust to between 10 - 14 bar - Dirty fan... -
Page 44: Operating Fault Diagnostics
Faults - Possible causes - Solutions Operating fault diagnostics The control box has a self-diagnostic system, which easily allows After releasing the button, the RED LED starts flashing as shown identifying the operating faults (RED LED signal). in the diagram below. To use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a minimum of 3 seconds. -
Page 45: Control Card
Faults - Possible causes - Solutions Control card BURNER MODEL TYPE CODE BOILER COMPANY MODEL D390 Fig. 42 Q = Delivery T2= Temperature °-T= Angle and type of spray (Tab. G on page 18) PF= +/- pressure at stack PP= Pump delivery pressure T1= Temperature VP= Pump suction pressure or depressure PV= Fan pressure... - Page 46 INVERTER, or in applications where the length of Burner Code the thermostat connections exceeds 20 metres, a protection kit is PRESS GW 3000581 320 mm available as an interface between the control box and the burner. PRESS 1G...
- Page 47 This is achieved by hydraulic cylinder M, which closes the fan gate valve completely when the burner shuts down. The casing is wheel-mounted so that it can be easily removed for burner inspection. Burner Code PRESS GW 3000853 PRESS 1G 3000854 PRESS 2G 3000855...
- Page 48 RIELLO S.p.A. I-37045 Legnago (VR) Tel.: +39.0442.630111 http:// www.riello.it http:// www.riello.com Subject to modifications...
Need help?
Do you have a question about the PRESS GW and is the answer not in the manual?
Questions and answers