Riello PRESS GV INCINERATOR Quick start guide

Installation, use and maintenance instructions
20098582 (1) - 02/2015
Oil burner
One stage operation
CODE MODEL
20096753 PRESS GV INCINERATOR
GB

Original instructions

1
20098582
GB
Contents
1 Declarations................................................................................................................................................................................ 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 Other symbols............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Burner designation...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Technical data............................................................................................................................................................. 7
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Maximum dimensions.................................................................................................................................................. 8
4.6 Firing rate .................................................................................................................................................................... 9
4.6.1 Burner firing rate according to air density.................................................................................................................... 9
4.7 Test boiler.................................................................................................................................................................. 10
4.8 Burner description..................................................................................................................................................... 11
4.9 Burner equipment...................................................................................................................................................... 11
5 Installation ................................................................................................................................................................................ 12
5.1 Notes on safety for the installation............................................................................................................................ 12
5.2 Handling.................................................................................................................................................................... 12
5.3 Preliminary checks.................................................................................................................................................... 12
5.4 Operating position ..................................................................................................................................................... 13
5.5 Preparing the boiler................................................................................................................................................... 13
5.5.1 Boring the boiler plate ............................................................................................................................................... 13
5.5.2 Blast tube length........................................................................................................................................................ 13
5.6 Securing the burner to the boiler............................................................................................................................... 14
5.7 Nozzle ....................................................................................................................................................................... 14
5.7.1 Choice of nozzle........................................................................................................................................................ 15
5.7.2 Nozzle assembly....................................................................................................................................................... 15
5.8 Electrode position...................................................................................................................................................... 16
5.9 Combustion head adjustment.................................................................................................................................... 16
5.10 Fan gate adjustment.................................................................................................................................................. 16
5.11 Fuel supply................................................................................................................................................................ 17
5.11.1 Double-pipe siphon-type systems A)(Fig. 18) ........................................................................................................... 17
5.11.2 Double-pipe suction-type systems B)(Fig. 18) .......................................................................................................... 17
5.11.3 Single-pipe systems .................................................................................................................................................. 18
5.11.4 Loop circuit................................................................................................................................................................ 18
5.11.5 Hydraulic connections............................................................................................................................................... 19
5.12 Pump......................................................................................................................................................................... 19
5.12.1 Priming pump............................................................................................................................................................ 20
5.13 Electrical wiring ......................................................................................................................................................... 21
5.13.1 Electrical cable fastening........................................................................................................................................... 21
5.13.2 Electrical system ....................................................................................................................................................... 22
6 Start-up, calibration and operation of the burner ................................................................................................................. 23
6.1 Notes on safety for the first start-up.......................................................................................................................... 23
6.2 Calibrations before firing ........................................................................................................................................... 23
6.3 Burner calibration...................................................................................................................................................... 23

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Contents
6.3.1 Firing..........................................................................................................................................................................23
6.3.2 Operation...................................................................................................................................................................23
6.4 Combustion characteristics........................................................................................................................................23
6.4.1 Emissions into the atmosphere..................................................................................................................................23
6.4.2 Flue gas temperature.................................................................................................................................................24
6.4.3 Combustion chamber pressure..................................................................................................................................24
6.5 Burner operation........................................................................................................................................................24
6.5.1 Burner starting ...........................................................................................................................................................24
6.5.2 Steady state operation...............................................................................................................................................24
6.5.3 Firing failure ...............................................................................................................................................................24
6.5.4 Undesired shut-down during operation......................................................................................................................24
6.6 Burner start-up cycle diagnostics...............................................................................................................................25
6.7 Operating fault diagnostics ........................................................................................................................................25
6.8 Final checks (with burner operating)..........................................................................................................................26
7 Maintenance ..............................................................................................................................................................................27
7.1 Notes on safety for the maintenance.........................................................................................................................27
7.2 Maintenance programme...........................................................................................................................................27
7.2.1 Maintenance frequency..............................................................................................................................................27
7.2.2 Checking and cleaning...............................................................................................................................................27
7.3 Opening the burner....................................................................................................................................................29
7.4 Closing the burner......................................................................................................................................................29
8 Faults - Probable causes - Solutions......................................................................................................................................30

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20098582
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Oil burner
Model: PRESS GV INCINERATOR
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 03.09.2014 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. R. Cattaneo

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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 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
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
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤This symbol indicates a list.

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20098582
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Information and general warnings
2.1.4 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.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, 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 occurred;
➤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;
➤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.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
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.

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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 other items. Inattention, thoughtlessness and excessive confi-
dence often 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 dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
the type and pressureof 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 envisaged by the manufacturer can be
replaced.
3.2 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;
➤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;
➤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.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
➤must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
➤the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
➤personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

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20098582
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4.3 Technical data
Tab. B
(1)
Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
4 Technical description of the burner
Series: PRESS
Operation: One stage
Gas oil
Flame control system: FS1
FS2 Standard (1 stop every 24 h) Continuous working (1 stop every 72 h)
Electrical supply of the system: 1/230/50
1/220/60
Voltage of auxiliaries: 230/50
220/60
PRESS GV TC 1/230/50
Emission: ... Class 1 EN267
230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
FS1
1/230V/50Hz
1/220V/60Hz
230V/50Hz
220V/60Hz
GV or G24
GW or 1-2-3-4G
Head: TC Standard head
TL Long head
3/230-400/50
3/220-380/60 3/230V/50Hz - 3N/400V/50Hz 3/220V/60Hz - 3N/380V/60Hz
Designation Voltage Start-up Code
PRESS GV INCINERATOR TC 1/230/50 Direct 20096753
Model PRESS GV
Output
(1)
Delivery
(1)
kW
Mcal/h
kg/h
178 - 356
153 - 306
15 - 30
Fuel Light oil, viscosity max. at 20 °C: 6 mm
2
/s (1.5 °E - 6 cSt)
Operation Intermittent (min. 1 stop in 24 hours)
Single stage (all - nothing)
Pump delivery (at 12 bar)
pressure range
fuel temperature
kg/h
bar
°C max
65
10 - 20
60
Nozzle number 1
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Weight kg 33

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Technical description of the burner
4.4 Electrical data
Tab. C
4.5 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
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 dimensions of the burner when open are given by
measurement O.
Tab. D
Model PRESS GV
Electrical supply 1 ~ 230V 50Hz
Fan motor rpm
W
V
A
2810
250
230
1.68
Motor capacitor µF/V 8/450
Ignition Transformer V1 - V2
I1 - I2 230v - 8kV 1.8A - 30mA
Electrical power consumption W max 0,43
Electrical protection IP 40
S9269
Fig. 1
mm A B C D E F - F(1) H I L O - O(1)
PRESS GV 439 234 205 397 473 185 - 320 140 292 59 690 - 825

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Technical description of the burner
4.6 Firing rate
The burner delivery must be selected within the range of the
Fig. 2. This area is known as the firing rate and provides the max-
imum delivery of the burner according to the combustion cham-
ber pressure.
This area is delimited by:
– the 15 - 30 kg/h delivery line
– the 0 + 2.5 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.
Consult paragraph "Burner firing rate according to air density", for
operation at different surrounding temperatures and/or altitudes.
The burner can also operate in depression combustion cham-
bers.
4.6.1 Burner firing rate according to air density
The firing rate of the burner shown in the manual is valid for a
room temperature of 20°C and an altitude of 0m above sea level
(barometric pressure around 1013 mbar).
It may be that a burner has to operate with combustive air at a
higher temperature and/or higher altitudes.
The heating of the air and the increase in altitude produce the
same effect: the expansion of the air volume (i.e. the reduction of
its density).
The delivery of the burner fan remains essentially the same, but
the oxygen per m
3
of air, and the thrust (discharge head) of the
fan are reduced.
It is therefore important to know if the maximum output requested
from the burner at a determinate combustion chamber pressure
remains within the firing rate of the burner even with the changed
temperature and altitude conditions.
To check it, proceed as follows:
1 find the corrective factor F (relating to the air temperature
and altitude of the system) in the Tab. E.
2 Divide the output Q required from the burner by F to obtain
the equivalent output Qe:
3 In the firing rate of the burner, mark the work point identified
by:
Qe = equivalent output
H1 = pressure in combustion chamber
point A that must remain within the firing rate.
4 Trace a vertical line from point A)(Fig. 3), and find the maxi-
mum pressure H2 of the firing rate.
5 Multiply H2 by F to obtain the maximum lowered pressure
H3 of the firing rate:
If H3 is greater than H1)(Fig. 3), the burner can produce the de-
livery requested.
If H3 is less than H1, it is necessary to reduce the output of the
burner. The reduction in output is accompanied by a reduction in
the combustion chamber pressure:
Qr = reduced output
H1r = reduced pressure
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20°C, an
atmospheric pressure of 1013 mbar (approx. 0m
above sea level), and with the combustion head
adjusted as shown on page 16.
S9270
Combustion chamber
pressure - mbar
Thermal power Fig. 2
Qe = Q : F (kW)
H3 = H2 x F (mbar)
H1r = H1 x ( )
Qr
Q
2

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Technical description of the burner
Example, 5% reduction in output:
Qr = Q x 0,95
H1r = H1 x (0,95)
2
With the new values - Qr and H1r - repeat steps 2 - 5.
Tab. E
4.7 Test boiler
The firing rates were obtained in special test boilers, according to
EN 267 regulations.
Fig. 4 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.
WARNING
The combustion head should be adjusted in rela-
tion to the equivalent output Qe.
Qe kg/h
mbar
Qe kW
mbar
A
H1
H2
H3
D388
Fig. 3
Altitude Average baro-
metric pressure F
a.s.l. Air temperature °C
m mbar 0 5 10 15 20 25 30 40
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
1.087
1.073
1.061
1.050
1.037
1.025
1.013
1.000
0.988
0.977
0.964
0.942
0.919
0.897
0.875
0.852
1.068
1.054
1.042
1.031
1.018
1.007
0.995
0.982
0.971
0.959
0.946
0.925
0.902
0.881
0.859
0.837
1.049
1.035
1.024
1.013
1.000
0.989
0.977
0.965
0.954
0.942
0.930
0.909
0.886
0.866
0.844
0.822
1.031
1.017
1.006
0.995
0.983
0.972
0.960
0.948
0.937
0.926
0.914
0.893
0.871
0.851
0.829
0.808
1.013
1.000
0.989
0.978
0.966
0.955
0.944
0.932
0.921
0.910
0.898
0.878
0.856
0.836
0.815
0.794
0.996
0.983
0.972
0.962
0.950
0.939
0.928
0.916
0.906
0.895
0.883
0.863
0.842
0.822
0.801
0.781
0.980
0.967
0.956
0.946
0.934
0.923
0.913
0.901
0.891
0.880
0.868
0.849
0.828
0.808
0.788
0.768
0.948
0.936
0.926
0.916
0.904
0.894
0.884
0.872
0.862
0.852
0.841
0.822
0.801
0.783
0.763
0.743
Fig. 4
Combustion chamber
length - m
D449

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Technical description of the burner
4.8 Burner description
1 Slide bars for opening the burner and inspecting the com-
bustion head
2 Combustion head
3 Air inlet to fan
4 Motor capacitor
5 Ignition transformer
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
11 Fan
12 Electrical motor
13 Screw for combustion head adjustment
14 Photocell for flame presence control
15 Fan rotation direction
16 Indexed selector. Opens the fan gate to the value necessary
at the burner delivery.
NOTE:
if the control box 8)(Fig. 5) push-button lights up, it indicates that
the burner is in lock-out. To reset, press the push-button for a
minimum of three seconds.
4.9 Burner equipment
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Gaskets for flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Nipples for flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Reducers with gasket for connection of flexible hoses. . . . No. 2
Screws M10 x 25 to secure the burner flange to the boiler No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 5
D423
D402

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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 burner packaging includes a wooden platform, it is therefore
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. 6) 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 data of the burner's minimum and maximum output pos-
sibilities (G) (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
➤light oil maximum viscosity (H).
5 Installation
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.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
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
20-25cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
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.
A
B C
D F
G
G
H
Fig. 6
S9271

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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in Fig. 8.
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
Tab. F
5.5.2 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:
Tab. G
For boilers with front flue passes 9)(Fig. 9) or flame inversion
chambers, protective fettling in refractory material 7) must be in-
serted between the boiler's fettling 8) and the blast tube 6).
WARNING
➤The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 7).
➤Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
➤Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
➤Any other position could compromise the cor-
rect operation of the appliance.
➤Installation 5is prohibited for safety reasons.
Fig. 7
2 3 4 51
S9272
mm A B C C
PRESS GV 155 160 160 M10
Fig. 8
D329
mm Shortened Standard Lengthened
PRESS GV 43 185 320
WARNING
This protective fettling must not compromise the
extraction of the blast tube.

20098582
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Installation
5.6 Securing the burner to the boiler
Disassemble the blast tube 6)(Fig. 9) from the burner by proceed-
ing 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. 8), inserting
the gasket provided 5).
➤Use the 4 screws provided after having protected the thread
with antiscruffing products (high-temperature grease, com-
pounds, graphite).
➤Re-assemble the burner 4) on the slide bars 3) and re-insert
the screws 2).
➤Leave the burner open as shown in Fig. 9.
5.7 Nozzle
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 spray patterns in relation to the leading brands of nozzle on
sale are shown in Tab. H.
The nozzle deliveries indicated in the Tab. I on page 15 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.
Tab. H
WARNING
The seal between burner and boiler must be
airtight.
Fig. 9
D405
WARNING
It is advisable to replace the nozzle once a year
during periodical maintenance.
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.
Spray Delevan Monarch Danfoss Steinen
Hollow
A PL H H - PH
Solid
B AR S Q
Universal
W NS - PLP B SS
Semi-solid
E R - S

15
20098582
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Installation
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 required. Grip the
nozzle on its hexagonal part when handling.
5.7.1 Choice of nozzle
The nozzle must be chosen from among those listed in Tab. I.
Use nozzles with atomization angles of 60° and, if possible, at a
pressure of 12 bar.
Tab. I
(1)
Light oil: density 0,84 kg/dm
3
- viscosity 4,2 cSt/20°C - temperature
10°C.
Example:
Boiler output = 230 kW - efficiency 90%
Output required by the burner = 230 : 0.9 = 255 kW (21.5 kg/h);
therefore 1 nozzle - 5,00 GPH - 60° - 12 bar is required.
NOTE:
other information regarding nozzles may be found in Tab. H on
page 14.
5.7.2 Nozzle assembly
With the burner open on the slide bars as shown in Fig. 9 on
page 14, unscrew and remove the plastic plug 1)(Fig. 10).
Screw the nozzle 1)(Fig. 11) into the same place using a 16 mm
wrench.
Lastly, close the burner by screwingin the two screws 1)(Fig. 12).
GHP kg/h
(1)
kW
12 bar
10 bar 12 bar 14 bar
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
15.4
17.3
19.2
21.1
23.1
25.0
26.9
28.8
17.0
19.1
21.2
23.3
25.5
27.6
29.7
31.8
18.4
20.7
23.0
25.3
27.7
30.0
32.3
34.6
201.6
226.5
251.4
276.3
302.4
327.3
352.3
377.2
WARNING
➤Do not use any sealing products such as gas-
kets, sealing compound, or tape.
➤Be careful to avoid damaging the nozzle seal-
ing seat.
➤The nozzle must be screwed into place tightly
but not to the maximum torque value pro-
vided by the wrench.
Fig. 10
D406
Fig. 11
D407
Fig. 12
D409

20098582
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Installation
5.8 Electrode position
5.9 Combustion head adjustment
The setting of the combustion head depends exclusively on the
delivery of the burner - in other words, the combined delivery of
the two nozzles selected on page 14.
Set the screw 1)(Fig. 15) in such way that its rear surface corre-
sponds to the notch number shown in diagram (Fig. 14).
Example:
The burner with two 5.00 GPH nozzles and 12 bar pump pres-
sure.
Find the delivery of the 5.00 GPH nozzle in Tab. I on page 15 =
21.2 kg/h.
Diagram (Fig. 14) indicates that for a delivery of 21.2 kg/h the
burner requires the combustion head to be set to approx.
3.1 notches, as shown in Fig. 16.
5.10 Fan gate adjustment
The fan gate is set using the indexed selector 1)(Fig. 17), after
having loosened the nut 2).
This setting must be adapted case by case to the burner's deliv-
ery and combustion chamber pressure.
The first time the burner is fired, this setting should be left as orig-
inally set by the manufacturer: notch 2.
WARNING
Make sure that the electrodes are positioned as
shown in Fig. 13.
Fig. 13
D408
0
1
2
3
4
5
6
7
8
15 20 25 30
Fig. 14
S9273
Light oil delivery - kg/h
Notches
Fig. 15
D2560
Fig. 16
D336
Fig. 17
D412

17
20098582
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Installation
5.11 Fuel supply
The burner is equipped with aself-priming pump which is capable
of feeding itself within the limits listed in the table at the side.
There are three types of fuel hydraulic circuits:
– Double-pipe circuits (the most common)
– Single-pipe circuits
– Loop circuits
According to the burner/tank layout, either of two fuel supply sys-
tems can be used:
– Siphon-type (with the tank higher than the burner)
– Suction-type (with the tank lower than the burner)
5.11.1 Double-pipe siphon-type systems A)(Fig. 18)
The distance “P” must not exceed 10 meters in order to avoid
subjecting the pump's seal to excessive strain; the distance “V”
must not exceed 4 meters in order to permit pump self-priming
even when the tank is almost completely empty.
5.11.2 Double-pipe suction-type systems B)(Fig. 18)
Pump depression values higher than 0.45 bar (35 cm Hg) must
not be exceeded because at higher levels gas is released from
the fuel, the pump starts making noise and its working lifespan
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.
Tab. J
Key (Fig. 18)
H Pump/Foot valve height difference
L Piping length values calculated for light oil:
• viscosity = 6 cSt / 20 °C
• density = 0,84 kg/dm
3
• 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 Foot valve
7 Return line
Useful suggestions for both systems (A) and (B)
– Use copper pipes whenever possible.
– Any curves used in the system should be made with the wid-
est possible radius.
– Use biconic connectors at both ends of the pipe.
– Whenever the burner is installed in areas with extremely cold
winter climates (temperatures lower than -10°C), we recom-
mend insulating both the tankand the piping. Avoid the small-
est of the three pipe diameters provided in the Table and lay
the piping along the most sheltered route possible. The par-
affin in the fuel begins to solidify below 0°C, and the filters
and nozzle begin to clog accordingly.
– Install a filter on the suction lines with a transparent plastic
bowl if possible in order to permit the regular flow of fuel and
quick checking of the state of the filter.
– The return pipe does not require an on/off valve, but if the
user desires to insert one, a lever-type valve should be se-
lected which clearly indicates when the valve is open or
closed (if the burner starts with the return pipe closed, the
sealing organ located on the pump shaft will break).
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
+/- H
mL (m)
Ø 8 mm Ø 10 mm Ø 12 mm
+4
+3
+2
+1
+0,5
35
30
26
21
19
90
80
69
59
53
152
152
152
130
119
0 17 48 108
-0,5
-1
-2
-3
-4
15
13
9
4
-
43
37
27
16
6
97
86
64
42
20
Fig. 18
D396
A
B

20098582
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Installation
– The opening of the burner or 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
vacuum meter attachment. On one branch of this T install a
pressure gauge and on the other branch inject air at a pres-
sure of 1 bar. After the air injection, the gauge must remain at
a constant pressure.
5.11.3 Single-pipe systems
There are two solutions possible:
– Pump external by-pass A)(Fig. 19) (recommended)
Connect the two flexible hoses to an automatic degassing
unit. The pump by-pass screw must not be removed.
– Pump internal by-pass B)(Fig. 19)
The pumps are equipped with a screw 6)(Fig. 26 on
page 24), which is accessible through the return line connec-
tor, which when removed opens the return pipe to the suction
line.
The pump return line connector must be plugged.
This solution is possible only with low pump depression values
(max. 0.2 bar) and perfectly-sealed piping.
5.11.4 Loop circuit
This is composed by piping that leaves from the tank and returns
to the same with an auxiliary pump that circulates the fuel under
pressure.
A branch connection from the loop goes to feed the burner. This
circuit is extremely useful whenever the burner pump does not
succeed in self-priming because the tank distance and/or height
difference are higher than the values listed in the Tab. K.
Contact our Engineering Department for further information re-
garding single-pipe systems and the loop circuit.
Altitude
Altitude has a determined effect on pump suction power.
At altitudes of more than 200 meters above sea level, the level
difference, in metres, between the pump and the foot valve must
be corrected by the factor “F”, see Tab. E on page 10, in order to
obtain the equivalent height difference with which to determine
the maximum 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
Tab. K
Key (Tab. K)
m= Altitude in m a.s.l.
F= correction factor
Example:
Suction type system - H = 2 m
Piping diameter Ø = 10 mm
Tab. L
m200 300 600 900 1200 1500 1800 2100
F0 0.1 0.4 0.7 1.0 1.3 1.6 1.9
Altitude m 200 1200
F 0 1
- H m 2 2 + 1 = 3
Piping length m 27 16
Fig. 19
D349
A B