Riello Burners PRESS 60 N/ECO User manual

2916202 (1) - 01/2009
Instrucciones de instalación, uso y mantenimiento
Instruções para instalação, uso e manutenção
Instruction for installation, use and maintenance
Fuel-oil-fired burner
Quemador de aceite pesado
Queimador de nafta
CODE
CÓDIGO MODEL MODELO TYPE
TIPO
3435081 PRESS 60 N/ECO 628 T80
3435082 PRESS 60 N/ECO 628 T80
GB
E
P
Two-stage operation
Funcionamiento biestadio
Funcionamento bifásico

6202 1GB
INDEX
1. BURNER DESCRIPTION
Two stage heavy oil burner.
1.1 EQUIPMENT
Flexible tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples . . . . . . . . . . . . . . . . . . . . . . . No. 2
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 2 Screws . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1 Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Guide extensions (for the lengthened head version) No. 2 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fitting for operation with emulsified fuel
oil (see page 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Field of operation. . . . . . . . . . . . . . . . . . . . 2
3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . 3
3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 3
3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 4
3.3 Electrical connections . . . . . . . . . . . . . . . . 5
4. OPERATION. . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 6
4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6
4.3 Combustion head setting. . . . . . . . . . . . . . . . 6
4.4 Adjustment of the air damper motor . . . . . . . 6
4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . 7
4.6 Atomisation temperature adjustment . . . . . . . 7
4.7 Start-up programme . . . . . . . . . . . . . . . . . . . 9
4.8 Ecological oil burners . . . . . . . . . . . . . . . . . . 9
4.9 Emulsified fuel oil functioning . . . . . . . . . . . . 9
4.10 Start-up programme diagnostics . . . . . . . . . 10
4.11 Operating fault diagnostics . . . . . . . . . . . . . 10
2893
OThe burner meets protection level of IP 40, EN 60529
OBurner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage
73/23/EEC and Machines 98/37/EEC .
1 - Suction line
2 - Return fitting
3 - Pump pressure regulator
4 - Manometer fitting(G1/8)
5 - Vacuometer fitting (G1/2)
6 - Air damper opening motor
7 - Control box reset push-button
and lock-out light
8 - Fan overload cutout reset
9 - Regulating screw for combustion head
10 - Double filter
11 - Valve group
12 - Manometer with protection valve
13 - Adjustment thermostat
14 - Pre-heater contact maker
15 - Ignition transformer
16 - Terminal board
17 - Cable glands
18 - Antigas valve
19 - Thermometer
20 - Pump motor starter with reset
21 - Air pressure switch
Fig. 1

6202 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 DIMENSIONS
2.3 FIELD OF OPERATION (2 nozzles in operation)
TYPE 628 T80
Thermal power - Capacity 171/342 - 684 kW – 15/30 - 60 kg/h
Fuel Oil with max. viscosity at 50° C 115 sq.mm/s (15° E)
Electrical supply Three-phase, 230V ±10% ~60Hz without neutral
400V ±10% ~60Hz with neutral
Motor 230V - 400V Fan: 3.4A - 2A
Pump: 2.5A - 1.4A
Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA
Heaters 4.2 kW
Electrical intake power 5.9 kW
Pump 100 kg/h at 20 bar
D2715
D2686
BurnerBoiler plate
NOTE
The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised
to hold the burner while it is being extracted so as not damage the flame disc and the said guides.
For long - head version.
Use the pin extensions provided to move the burner back.
*
834 245
400 625 290
*
79
Diam. 172
335
Thermal power
Pressure in combustion
chamber – mbar
D2723
When the burner operates with only one nozzle, the pressurization conditions are better and no problems
arise. Minimal fuel capacity with one only nozzle: 15 kg/h - 171 kW.
kg/h
kW

6202 3GB
3. INSTALLATION
3.1 FUEL OIL SUPPLY SYSTEMS
GRAVITY SYSTEM
SUCTION SYSTEM
LOOP SYSTEM (max loop system 3 bar)
Pump priming:
loosen the cap of the vacuometer fitting
(5, fig. 1) and wait for the fuel flow.
H: Difference in height
L: Length of the suction tube
For fuel oil with viscosity max. 7°E at 50°C.
D2720
max. 30m
H
H
metres
L metres
diam.
1” gas diam. 1 1/4” gas
0610
0,5 11 17
11624
1,5 21 31
22638
Not advised, to be used only if there is a
previously existing system.
Never exceed the max. vacuum of 0.5 bar
(38 cm Hg) measured at the vacuometer
fitting (5, fig. 1).
The pipes should be perfectly airtight.
When the tank is placed below of the burn-
er level, the return pipe should arrive at the
same level of the suction pipe.
In this case the foot valve is not required.
For light fuel oil with viscosity max. 7°E at 50°C.
D2721
max. 30m
HH
H
metres
L metres
diam. 1
1/4” gas diam. 1
1/2”
02245
0.5 19 39
11633
1,5 13 27
21021
2.5 7 15
308
1- Tank (properly heated for heavy oil) 5- Transfer pump
2- Filter (with resistor for oil > 7°E / 50°C) 6- Manometer
3- Burner 7- Burner pump
4- Air dampers for excluding burner (coupled) 8- Pressure adjuster
For heavy oil with viscosity up to 50°E/50°C.
Notice: to ensure proper fuel flow all the pipes have to be properly sized, insulated and heated. (elec. re-
sistor or steam or hot water).
Warning: before starting up the burner make sure that there is no obstruction in the pipes,
any obstruction may damage the sealing of the pump.
D2631

6202 4GB
3.2 BURNER ELECTRICAL SYSTEM (made in the factory)
531
624
A1
A2
CR
S
789123456
TM
TB
M
R3
R2
R1
A1
13
14
3
M
531
A2
96
95
642
MV
RT
TE
V2
7
8
6
11
2
5
3
4
1
+
-
MV2HS1ST0
ST1
ST2
R1
R2
M
SM
FR
V1
411 85918 13 17 10
TB
1612 15
TA
Tm
1
RT1
TB
A1
13
14
3
M
531
A2
95
96
642
MP
P
PA
TAV
TB
RMO88. 53A2
MB
A
12
P
F
L1R L2R L3R
N L1L2L3 LN S3 T130 T2T6T8
V2 1 V2 2
L1P L2P L3P
CMP
CMV
CMP Pump motor contact maker
CR Pre-heater contact maker
FSuppressor
FR photocell
MB Burner terminal strip
MP Pump motor
MV Fan motor
PA Air pressure switch
R1 Atomiser holder resistor
R2 Pump resistor
R3 Valve assembly resistor
RMO Electrical control box
RT Fan motor thermal relay
RT1 Pump motor thermal relay
SPre-heater tank
SM Servomotor
TA Ignition transformer
TB Burner earth
TE Regulation thermostat and start-up enabling
signal
Tm Minimum contact thermostat
Tm Maximum contact thermostat
V1 Oil valve for 1st stage
V2 Oil valve for 2nd stage
2615

6202 5GB
3.3 ELECTRICAL CONNECTIONS TO THE BURNER TERMINAL STRIP (to be made by the installer)
FASTENING OF THE ELECTRICAL WIRES
All the wires, to be connected to the burner terminal strip (16, fig. 1) shall pass through the cable entries
(17, fig. 1), see the figure below.
Further prospective signals or controls can be connected to the burner terminal strip by presheared disk inserting
a common cable gland for the passage and the clamping of the leads. To ensure the IP 40 degree of protection
in compliance with EN 60529 close the passage holes of the cables and any unused entry leads with appropriate
disks.
NOTES
- Make a safe earth connection.
- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.
PREHEATER
CONNECTIONS
230V 400V
A Ampere 10 6
B Ampere 6 4
C Ampere 16 10
D sq. mm 1.5 1.5
E sq.mm 2.5 1.5
F sq. mm 4 2.5
D2692
RESISTORS
NOTE
yWire section: min. 1 sq. mm.
(Unless required otherwise by local standards and legis-
lation).
yFor supply at 230V make the triangle connection on
the pre-heater and on the motor (the original connec-
tion is “star” for 400V).
TWO STAGE OPERATION
This is achieved by the remote control device connected to
terminals 5-6 (removing the jumper), that controls 2nd
valve.
IN Manual stop switch
MB Burner terminal strip
HLock-out signal
TL Limit remote control
TR Regulation remote control
TS Safety control device system
D3742
D2635
1- Single phase pre-heated resistor
power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21
2 - Motor three phase supply:. . . . . . . . . . . . .cable entry Pg 16
3 - Single phase power supply and
safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
4- Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5
5- 2nd stage thermostat: . . . . . . . . . . . . . . . .cable entry Pg 13.5

6202 6GB
4. OPERATION
4.1 CHOICE OF NOZZLES
Recommended nozzle:
- Monarch F 80 H0.
4.2 PUMP PRESSURE
Recommended pressure:
- Light oil: 20 bar
- Heavy oil: 25 bar
The flow rate of the nozzes indicated in the table are
nominal, obtained for a light oil having viscosity from 3 to 5°E
at 50° C pre-heated at 100°C. The actual flow rate may vary
by ± 5% against the rated flow rate.
if flow rate values between those indicated in the table are
required, it is possible to vary the pump pressure or arrange
the nozzles differently.
The pump leaves the factory set at 20 bar.
4.3 COMBUSTION HEAD ADJUSTMENT
Turn the screw A, fig. 2 to the set-point, shown in the diagram,
lines up with sleeve B, fig. 2.
4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR
STOP - Blue lever
This lever leaves the factory vertically positioned and corre-
sponds to the complete closure of the air damper.
A partial opening of the air damper might be obtained by
moving this lever leftwards (+on the plate).
The new position of the air damper is detectable when the
burner is off.
Do not exceed the position of the orange lever for the 1st
stage.
1st STAGE - Orange lever
The orange lever controls the air damper position for the first
flame, it is adjustable both for opening and closing.
2nd 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.
D2638
Black lever
Red lever
Orange lever
Blue lever
Opening +–Closure
Nozzle
GPH (45° - 60°) 20 bar kg/h 25 bar kg/h
2.50 + 2.50 30.00 34.00
3.00 + 3.00 36.00 40,60
3.50 + 3.50 42.00 47,40
4.00 + 4.00 48.00 54,20
4.50 + 4.50 54.00 61.00
5.00 + 5.00 60.00 –
kg/h
Set-point
D2693
D2637
B
Set-point 4
A
Fig. 2

6202 7GB
4.5 AIR PRESSURE SWITCH
4.6 ATOMISATION TEMPERATURE ADJUSTMENT
Adjustment thermostat - maximum value - minimum value
Adjustment thermostat prevents the burner start up if the fuel temperature has not reached the required value
for a better atomisation as indicated in the diagram below.
Example
Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.
The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob
to get approximately 100°C at the nozzles).
The value has to be read after some minutes of operation and later the necessary adjustments might be carried
out.
Minimum value contact thermostat intervenes by stopping the burner if the fuel temperature decreases
under the value necessary for better combustion.
Maximum value contact thermostat switches off the resistors when in case of failure of the adjustment
thermostat, the temperature increases inside the pre-heater. In case of abnormal temperature, make sure
of the regular functioning of control thermostat and of the resistor in contact with the probe of the thermostat.
The thermostat is calibrated by the factory at 180 °C.
Regulate the air pressure switch after carrying out all
the other regulations of the burner with the air pres-
sure switch adjusted at the beginning of the scale.
With the burner operating at MIN power, increase the
pressure of the adjustment by slowly turning the
appropriate knob clockwise until the burner locks out.
Then turn the knob counterclockwise to a value equal
to about 20% of the regulated value and then check
the correct burner start up. If the burner locks out
again turn the knob a bit further in a counterclockwise
direction.
D521
D2719
Adjusting knob
of thermostat
Pre-heater
Purge
Atomisation temperature
Viscosity at 50° C
sq.mm/s °E D2694

6202 8GB
IMPORTANT NOTES
Pre-heater thermostat replacement.
Replace the probe of the new thermostat, after loosen-
ing the fixing screws of the plates pack, taking care of
better contact between the probe and the pipes and the
resistor, see drawing. The same precautions should be
taken when renewing the resistors in contact with the
thermostat probes.
If during operation exceptional changes or excessive
temperatures should be detected, verify the continuity
of the resistor, using and ohmmeter, in contact with the temperature probe (approximately 35 Ohm).
Use only filters with a groove on the tightening hexagon.
NOTE
yThe pre-heater might be provided with a second thermostat in contact of maximum value.
This thermostat can be used to act as a switch on an external contact maker to cut off the current to the pre-
heater if there is excess temperature (kit code no. 3000800).
yBefore burner start-up, verify that the pump is filled with fuel to prevent it running empty for too long.
yFilter cleaning:
periodically clean the filters in order to avoid any burner operation problems.
ySupply line filter:
positioned on the suction line, it causes the increase of the vacuum in the pump with the consequent flow of
gas and noise. Do not exceed the vacuum of 38 cm Hg (5 m W.c.), measured at the vacuometer fitting
(5,fig.1).
yPre-heater filter (10, fig. 1):
positioned on the suction line, it causes a decrease of the atomising pressure which is detectable by use
of a manometer (12, fig. 1).
MANOMETER PROTECTION VALVE
After atomisation pressure has been checked during opportunity, the manometer should be turned off (12, fig. 1)
to avoid the pressure shocks that it might be subjected to each time the burner is turned on.
Close the protection valve when the burner is not in operation and the manometer indicates 0 bar.
Thermostat probe
Resistor
Aluminium plate pipes
Plate
D2751

6202 9GB
4.7 BURNER START-UP PROGRAMME
Motor lock-out
It is caused by the thermal motor overload relay if overload or no phase occurs
4.8 ECOLOGICAL OIL BURNERS
WARNING
In all cases the transition from normal fuel oil to ecological fuel oil requires:
yThe tank to be emptied of normal fuel oil.
yCleaning of the cistern and the pipes that carry the fuel oil to the burner.
yApplication of a filter if there is not one already on the burner fuel line with a filtering grade of 0,3 mm maxi-
mum.
If this is not done, Riello S.p.A. declines all liability if the burner fails to work properly or wears out prematurely.
NOTES
These burners are the result of careful study that allows them to be used with ecological fuels as well; oils, that
in certain temperature and speed conditions, are particularly aggressive for the vital parts of the burner.
The objective has been achieved with the reduction of the transiting speed in some of the parts and an appropri-
ate choice of materials (in particular surface treatments) as well as a redefinition of the backlashes and coupling
tolerances.
The burners for ecological oils are very different from normal fuel oil burners because they have a separate
pump (worked by its own motor at 1400 rpm) and for the presence of double filtration between pump and nozzle.
4.9 EMULSIFIED FUEL OIL OPERATION
Lock-out because of no ignitionNormal
Thermostat
Motors
Ignition transformer
1st flame valve
2nd flame valve
Lock-out indicator
2894
D3745
WARNING
In the case of functioning with emul-
sified fuel oil it is necessary to
change the fitting on the burner (*)
with the one supplied with it.