Riello PRESS GV Series User manual

www.riello.com
PRESS GV Series
One Stage Light Oil Burners
PRESS G24 140 ÷ 237 kW
PRESS GV 178 ÷356 kW
LIGHT OIL
TECHNICAL DATA LEAFLET

PRESS GV SeriesOne Stage Light Oil Burners
The PRESS G series of burners covers a firing range from 140 to 356 kW and they have been designed for use in civil
installations of small dimensions or in industrial applications, like incinerators or dyer kilns.
Operation is “One stage”; the burners are fitted with a microprocessor-based burner safety control box which
supplies indication of operation and diagnosis of fault cause. The combustion head, that can be set on the basis
of required output, allows optimal performance ensuring good combustion and reducing fuel consumption.
The main feature of these burners is their reliability due to a simple and strong construction, which permits
operation without particular maintenance intervention.
Simplified maintenance is achieved by the slide bar system, which allows easy access to all of the essential
components of the combustion head. All electrical components are easily accessible only by dismounting a
protection panel, thus guaranteeing a quick and simple intervention on components.
A RIELLO burner (Heat Generator), where it is matched with a water-based boiler (Heater Housing) with a nominal
output ≤ 400 kW, providing heat for heating purposes and heat to deliver sanitary hot water, can be installed:
- With boilers (heater housings) already in service in the field, for replacement, in conformity to Article 1,
paragraph 2, point (G) of the EU Regulation No. 813/2013;
- With boilers (heater housings) on a new installation, put on the market after 26th of September 2015;
- With all new boilers (heater housings), where placed on the market before 26th of September 2015.
2

Technical Data
Model PRESS G24 PRESS GV
Burner operation mode One stage
Modulation ratio at max. output --
Servomotor type --
run time s--
Heat output
kW 140÷280 178÷356
Mcal/h 120÷241 153÷306
kg/h 14÷24 15÷30
Working temperature °C min./max. 0/40
FUEL/AIR DATA
Light oil
Net calorific
value
kWh/kg 11,86
kcal/kg 10200
Viscosity mm2/s (cSt) 4 ÷ 6 (at 20°C)
Pump type AS 47 AN 67 A
delivery kg/h 31 (12 bar) 67 (12 bar)
Atomised pressure bar 12
Fuel temperature max. °C 50
Fuel pre-heater NO
Fan type Centrifugal with forward curve blades
Air temperature max. °C 60
ELECTRICAL DATA
Electrical supply Ph/Hz/V 1/50/230~(±10%)
Auxiliary electrical supply Ph/Hz/V 1/50/230~(±10%)
Control box type RMO
Total electrical power kW 0,4 0,48
Auxiliary electrical power kW 0,15 0,23
Heaters electrical power kW --
Protection level IP 40
Pump motor electrical power kW --
Rated pump motor current A--
Pump motor start up current A--
Pump motor protection level IP --
Fan motor electrical power kW 0,25
Rated fan motor current A2,1
Fan motor start up current A10
Fan motor protection level IP 40
Ignition trasformer
type
V1 - V2 220V - 1x8 kV
I1 - I2 1,6A - 30 mA 1,8A - 30 mA
Operation Intermittent (at least one stop every 24 h)
EMISSIONS
Sound pressure dBA 73 75,5
Sound power dBA 84 86,5
CO emission mg/kWh < 40
Grade of smoke indicator NO Bacharach < 1
CxHy emission mg/kWh <10 (after the first 20 s.)
NOx emission mg/kWh < 200
APPROVAL
Directive 2009/142/EC - 2014/30/UE - 2014/35 UE
Conforming to EN 267
Certification --
Reference conditions:
Temperature: 20°C - Pressure: 1013,5 mbar - Altitude: 0 m a.s.l. - Noise measured at a distance of 1 meter.
Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum
rated output. The sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy:
Category 3” measuring accuracy, as set out in EN ISO 3746.
3

PRESS GV SeriesOne Stage Light Oil Burners
Firing Rates
Useful working field
for choosing the burner
Test conditions
conforming to EN267
Temperature: 20°C
Pressure: 1013,5 mbar
Altitude: 0 m a.s.l.
4

HYDRAULIC CIRCUIT
The burners are fitted with a self-priming pump and
one (for PRESS GV) or two (for PRESS G24) delivery valves
along the oil line from the pump to the nozzles.
The pump does not need calibrating, as it is set in
the factory at 12 bar; however, pressure level can be
changed if necessary, by adjusting the regulator fitted
on the pump.
The delivery valves control the passage from starting
to operating phase.
For PRESS G24, at the start, after pre-purging phase,
the first delivery valve opens and the fuel is sprayed
out through the first nozzle, igniting when it comes
into contact with the spark; then the second delivery
valve opens and the fuel is sprayed out through both
nozzles.
V2 V1
U1
U2
P
V P
Example of self-priming pump of
PRESS GV burners
PPump with oil filter and pressure
regulator
V1 1st delivery valve
V2 2nd delivery valve
U1 1st nozzle
U2 2nd nozzle
Hydraulic layout of PRESS G24 burner Hydraulic layout of PRESS GV burner
V1
U1
P
Fuel Supply
5

PRESS GV SeriesOne Stage Light Oil Burners
Dimensioning Of The Fuel Supply Lines
The fuel feed must be completed with the safety
devices required by the local norms.
The table shows the choice of piping diameter for
the various burners, depending on the difference in
height between the burner and the tank and their
distance.
MAXIMUM EQUIVALENT LENGTH FOR THE PIPING L[m]
Model PRESS G24-GV
Diameter piping Ø8mm Ø10mm
+H, -H (m) Lmax (m) Lmax (m)
+4,0 63 130
+3,0 55 115
+2,0 48 100
+ 1,5 44 92
+ 1,0 40 85
+0,5 36 78
032 70
-0,5 28 62
-1,0 24 55
-1,5 20 48
-2,0 16 40
-3,0 725
-4,0 -10
7
10
9 5 V
P
+H
-H
8
1
4
10 cm
2
5
73
9
6
6
HDifference in height pump-foot valve
0Internal pipe diameter
PMax. height 10 m
VHeight 4 m
1Burner
2Burner pump
3Filter
4Manual shut off valve
5Suction pipework
6Bottom valve
7Remote controlled rapid manual shut off valve
(compulsory in Italy)
8Type approved shut off solenoid valve
(compulsory in Italy)
9Return pipework
10 Check valve
With ring distribution oil systems, the feasible drawings and dimensioning are the responsibility of specialised engineering
studios, who must check compatibility with the requirements and features of each single installation.
6

Ventilation
The ventilation circuit produces low noise levels with high performance
pressure and air output, in spite of the compact dimensions.
The air damper is easy to set; when fitted, it makes no difference to air
delivery.
Combustion Head
For the PRESS G24 - GV series of burners a special kit for increasing combustion
head length is available.
The choice of using it depends on the thickness of the front panel and the
type of boiler.
Depending on the type of generator, check that the penetration of the head
into the combustion chamber is correct.
The internal position of the combustion head can easily be adjusted to the
maximum defined output by adjusting a screw fixed to the flange.
Example of fan air gate valve
indexed selector of PRESS G24
burner
Example of a PRESS GV burner
combustion head
L
D
Burner output (MW)
Flame lenght (m) Flame diameter (m)
0
1
1
2
00
0,5
1
0,5
Lmax
L
min
D
max
D
min
Example:
Burner thermal output = 500 kW;
L Combustion Chamber (m) = 1,3 m (medium value);
D Combustion Chamber (m) = 0,45 m (medium value)
SUGGESTED COMBUSTION CHAMBER DIMENSIONS
Length of the combustion chamber (m)
Diameter of the combustion chamber (m)
Burner output (MW)
7

All PRESS GV series burners are fitted with a new microprocessor control panel for the supervision during
intermittent operation.
For helping the commissioning and maintenance work, there are two main elements:
The lock-out reset button is the central operating element for resetting the burner control and for
activating / deactivating the diagnostic functions.
The multi-color LED is the central indication element for visual diagnosis and interface diagnosis.
Switch
Both elements are located under the transparent cover of lock-out reset button, as showed below.
There are two diagnostic choices, for indication of operation and diagnosis of fault cause:
- visual diagnosis :
PRESS GV SeriesOne Stage Light Oil Burners
Operation
BURNER OPERATION MODE
The burner of PRESS G24 - GV series is one stage
working.
On “one stage” operation, the burner adjusts output
to the requested level, by varying between on-off
phases (see picture A).
Picture A
Output
Checked Variable
bar
°C
ON
OFF
time
time
ON
OFF
“One stage” operation
8

COMPUTER
or
FLUE GAS
ANALYSER
INTERFACE ADAPTER
- interface diagnosis :
by the interface adapter and a PC with
dedicated software or by a predisposed
flue gas analyzer (see paragraph
accessories).
Color code table
Operation status Color code table
Stand-by
Pre-purging
Ignition phase
Flame OK
Poor flame
Undervoltage, built-in fuse
Fault, alarm
Extraneous light
LED off
Indication of operation:
In normal operation, the various status are indicated
in the form of colour codes according to the table
below.
The interface diagnosis (with adapter) can be activated
by pressing the lock-out button for > 3 seconds.
9

Diagnosis of fault causes:
After lock-out has occurred, the red signal lamp is steady on. In this status, the visual fault diagnosis according
to the error code table can be activated by pressing the lock-out reset button for > 3 seconds. The interface
diagnosis (with adapter) can be activated by pressing again the lock-out button for > 3 seconds.
The flashes of red LED are a signal with this sequence :
(e.g. signal with n° 3 flashes - faulty air pressure monitor)
LED off
3 sec. 3 sec. 3 sec.
Error code table
Possible cause of fault Flash code
No establishment of flame at the end of safety
time :
- faulty or soiled fuel valves
- faulty or soiled flame detector
- poor adjustment of burner, no fuel
- faulty ignition equipment
2 flashes
Faulty air pressure monitor 3 flashes
Extraneous light or simulation of flame on burner start up 4 flashes
Loss of flame during operation :
- faulty or soiled fuel valves
- faulty or soiled flame detector
- poor adjustment of burner
7 flashes
Wiring error or internal fault 10 flashes
START UP CYCLE
0s The burner begins the firing cycle;
The motor starts: pre-purge phase;
Ignition electrode sparks.
13s Delivery valve opens.
28s The spark goes out;
Start up cycle is concluded.
0s The burner begins the firing cycle.
2s The motor starts: pre-purge phase.
3s Ignition electrode sparks.
25s Delivery valve opens.
30s The spark goes out;
start up cycle is concluded.
PRESS GV
1°
0
TL
M
time (s)
1
0
25
25
30
2
2
3
PRESS G24
0
TL
M
1°
time (s)
28
13
30
PRESS GV SeriesOne Stage Light Oil Burners
10

Emissions
The emission data has been measured in the various models at maximum output, according to EN 267 standard.
NO2 EMISSIONS
0
mg/kWh
50
100
150
200
250
300
CO EMISSIONS
100
0
20
40
60
80
mg/kWh
PRESS G24
NOISE EMISSIONS
20
0
dB(A)
40
60
80
100
PRESS GV
PRESS G24
PRESS GV
PRESS G24 PRESS GV
11

Overall Dimensions (mm)
(1) Length with extended combustion head.
(1) Length with extended combustion head.
Z
X - X (1)
Y
PACKAGING
Model X - X (1) Y Z kg
PRESS G24 650 535 450 33
PRESS GV 680 535 450 33
BURNER - BOILER MOUNTING FLANGE
BURNER
Model A B C D E F - F (1) H I L O - O (1)
PRESS G24 425 222 203 397 485 118 - 253 125 290 -- - -
PRESS GV 439 234 205 397 473 185 - 320 140 292 59 690 - 825
PRESS G24 PRESS GV
PRESS G24 PRESS GV
Model D1 D2 D3 D4 D5 Ø
PRESS G24 213 198 160 190 11 -
PRESS GV 160 160 170 - - M10
PRESS GV SeriesOne Stage Light Oil Burners
12

Installation Description
Installation, start up and maintenance must be carried out by qualified and skilled personnel.
All operations must be performed in accordance with the technical handbook supplied with the burner.
BURNER SETTING
PRESS G24
XAfter drilling the boilerplate, using the supplied gasket as a template, fix the flange of burner to the boiler.
XDismantle the blast tube from the burner and install the nozzles, choosing these on the basis of the
maximum boiler output and following the diagrams included in the burner instruction handbook.
XCheck the position of the electrodes.
XAdjust the combustion head and refit the blast tube to the burner casing.
XInstall the burner to the flange.
PRESS GV
XThe PRESS GV model has slide bars, for easier installation and maintenance.
XAfter drilling the boilerplate, using the supplied gasket as a template, dismantle the blast tube from the
burner and fix it to the boiler.
XAdjust the combustion head.
XRefit the burner casing to the slide bars.
XInstall the nozzle, choosing this on the basis of the maximum boiler output and following the diagrams
included in the burner instruction handbook.
XCheck the position of the electrodes.
XClose the burner, sliding it up to the flange.
HYDRAULIC AND ELECTRICAL CONNECTIONS AND START-UP
XThe burners are supplied for connection to two pipes fuel supply system.
XConnect the ends of the flexible pipes to the suction and return pipework using the supplied nipples.
XMake the electrical connections to the burner following the wiring diagrams included in the instruction
handbook.
XPrime the pump by turning the motor.
XOn start up, check:
- Pressure pump (to max. and min.)
- Combustion quality, in terms of unburned substances and excess air.
13

Burner accessories
Nozzles
The nozzles must be ordered separately. The following table shows the features
and codes on the basis of the maximum required fuel output.
Burner Rated delivery [kg/h]
at 12 bar GPH Nozzle code
PRESS G24 6,3 1,50 3042107
PRESS G24 7,3 1,75 3042110
PRESS G24 8,5 2,00 3042126
PRESS G24 10,6 2,50 3042140
PRESS G24 12,7 3,00 3042158
PRESS G24 14,8 3,50 3042162
PRESS GV 17 4,00 3042172
PRESS GV 19,1 4,50 3042182
PRESS GV 21,2 5,00 3042192
PRESS GV 23,3 5,50 3042202
PRESS GV 25,5 6,00 3042212
PRESS GV 27,6 6,50 3042222
PRESS GV 29,7 7,00 3042232
PRESS GV 31,8 7,50 3042242
(*) Nozzle rated delivery is referred to atomised pressure
Extended head kit
“Standard head” burners can be transformed into “extended head” versions, by
using the special kit.
Burner Standard head
length (mm)
Extended head
length (mm)
Kit code
PRESS G24 118 253 3010051
PRESS GV 185 320 3000580
PRESS GV SeriesOne Stage Light Oil Burners
14

If burner head penetration into the combustion chamber needs reducing, varying
thickness spacers are available, as given in the following list.
Spacer kit
Burner Spacer thickness
S (mm)
Kit code
PRESS GV 142 3000755
If noise emission needs reducing even further, sound-proofing boxes are available.
In case of generator heights, where a lower dimension “B” is required, ask for the
Box Support Kit code 20065135. The useful dimensions are 40 mm less than the total
dimensions indicated in the table (A, D, E). Not suitable for outdoor use.
Sound proofing box
Burner Box
type
A
(mm)
B (mm)
min-max
C
(mm)
D
(mm)
E
(mm)
[dB(A)]
(*)
Box code
PRESS GV C1/3 650 372 - 980 110 690 770 10 3010403
(*) Average noise reduction according to EN 15036-1 standard
A
B
C
D E
BURNER KIT CODE
PRESS G24 - GV 3002719
To connect the control box to a personal computer for the transmission of opera-
tion, fault signals and detailed service information, an interface adapter with PC
software are available.
PC Interface kit
To solve problem of air in the oil sucked, two versions of degasing unit are available.
Degasing unit
Burner Filter Filtering degree
(µm)
Degasing unit
code
PRESS GV With filter 50 - 75 3010055
PRESS GV Without filter - 3010054
When the burner is installed in a room particularly subject to electromagnetic
interference (signals emitted over 10 V/m) due for example to INVERTER presence
or in systems where the lengths of the thermostat connections is over 20 meters,
this specific protection kit is available as an interface between the thermostatic
controls and the burner.
BURNER KIT CODE
All models 3010386
Protection kit (electromagnetic interferences)
15

DESIGNATION OF SERIES
Specification
AVAILABLE MODELS
PRESS G24 TC FS1 1/230/50 230/50
PRESS G24 TC FS1 1/220/60 220/60
PRESS GV TC FS1 1/200/50-60 200/50-60
PRESS GV TC FS1 1/230/50 230/50
PRESS GV TC FS1 1/220/60 220/60
PRESS G24 TC FS1 1/230/50 230/50
Series : PRESS
Operation : GV or G24 One stage
GW or 1-2-3-4G Two stage
Emission : ... Class 1 EN267
Head : TC Standard head
TL Extended head
Flame control system : FS1 Standard (1 stop every 24 h)
FS2 Continuous working (1 stop every 72 h)
Electrical supply to the system : 1/230/50 1/230V/50Hz
1/210/60 1/210V/60Hz
1/220/60 1/220V/60Hz
1/200/50-60 1/200V/50-60Hz
3/230-400/50 3/230V/50Hz - 3N/400V/50Hz
3/210/60 3/210V/60Hz
3/220-380/60 3/220V/60Hz - 3N/380V/60Hz
3/200/50-60 3/200V/50-60Hz
Auxiliary voltage : 230/50 230V/50Hz
120/60 120V/60Hz
220/60 220V/60Hz
200/50-60 200V/50-60Hz
BASIC DESIGNATION
EXTENDED DESIGNATION
PRESS GV SeriesOne Stage Light Oil Burners
16

STATE OF SUPPLY
Monoblock forced draught oil burner with one stage operation, fully automatic, made up of:
- Air suction circuit
- Fan with forward curve blades with high performance concerning pressure and air delivery
- Air damper for air setting
- Starting motor at 2850 rpm, single-phase, 230V, 50Hz
- Combustion head, that can be set on the basis of required output, fitted with:
- stainless steel end cone, resistant to corrosion and high temperatures
- ignition electrodes
- flame stability disk
- Gears pump for high pressure fuel supply, fitted with:
- filter
- pressure regulator
- connections for installing a pressure gauge and vacuometer
- internal by-pass for single pipe installation
- Oil valves on the output circuit
- Photocell for flame detection
- Microprocessor-based burner safety control box, with diagnostic function
- Slide bars for easier installation and maintenance (for GV model)
- Protection filter against radio interference
- IP 44 electric protection level.
Standard equipment:
- 2 flexible pipes for connection to the oil supply network
- 2 gaskets for the flexible pipes
- 2 nipples for connection to the pump
- 2 Pipe fittings (for GV model)
- 2 Pipe fittings gasket (for GV model)
- 1 burner flange (for G24 model)
- 4 screws for fixing the burner flange to the boiler
- 1 thermal screen
- Instruction handbook for installation, use and maintenance
- Spare parts catalogue.
17

PRESS GV SeriesOne Stage Light Oil Burners
NOTES
18

NOTES
19

06/2015
TS0036UK03
Since the Company is constantly engaged in the production improvement, the aesthetic
and dimensional features, the technical data, the equipment and the accessories can be
changed. This document contains confidential and proprietary information of RIELLO S.p.A.
Unless authorised, this information shall not be divulged, nor duplicated in whole or in part.
Riello Burners a world of experience in every burner we sell.
Across the world, Riello sets the standard in reliable and
high efficiency burner technology.
With burner capacity from 5 kW to 48 MW, Riello gas,
oil, dual fuel and Low Nox burners deliver unbeatable
performance across the full range of residential and
commercial heating applications, as well as in industrial
processes.
With headquarter in Legnago, Italy, Riello has been
manufacturing premium quality burners for over 90 year.
The manufacturing plant is equipped with the most
innovative systems of assembling lines and modern
manufacturing cells for a quick and flexible response to
the market.
Besides, the Riello Combustion Research Centre, located in
Angiari, Italy, represents one of the most modern facility
in Europe and one of the most advanced in the world for
the development of the combustion technology.
Today, the company’s presence on worldwide markets is
distinguished by a well-constructed and efficient sales
network, alongside many important Training Centres
located in various countries to meet its customers’ needs.
Riello has 13 operational branches abroad (in Europe,
America and Asia), with customers in over 60 countries.
[ 1 ]
[ 2 ]
BURNERS PRODUCTION PLANT
S. PIETRO, LEGNAGO (VERONA) - ITALIA
[ 1 ]
[ 2 ] HEADQUARTER BURNERS DIVISION
S. PIETRO, LEGNAGO (VERONA) - ITALIA
RIELLO S.p.A. - 37045 Legnago (VR) - Italy
tel. [phone] - fax: [phone]
www.riello.com