Riello PRESS GW Quick start guide

20140894 (1) - 11/2017
Installation, use and maintenance instructions
Gas oil burners
Two-stage operation
CODE MODEL TYPE
3473787 PRESS GW 605 T85
3474587 PRESS 1G 606 T85
3474987 PRESS 2G 607 T85
3475987 PRESS 3G 608 T85
GB

1 20140894
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Contents
1 Declaration.................................................................................................................................................................................. 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 Danger: live components............................................................................................................................................. 4
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Safety warnings........................................................................................................................................................... 6
3.3 Basic safety rules........................................................................................................................................................ 6
3.4 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation...................................................................................................................................................... 7
4.2 Technical data............................................................................................................................................................. 8
4.3 Electrical data.............................................................................................................................................................. 8
4.4 Packaging - Weight..................................................................................................................................................... 9
4.5 Overall dimensions...................................................................................................................................................... 9
4.6 Firing rates ................................................................................................................................................................ 10
4.6.1 Burner firing rates according to air density................................................................................................................ 11
4.7 Test boiler.................................................................................................................................................................. 12
4.8 Burner description..................................................................................................................................................... 13
4.9 Standard equipment.................................................................................................................................................. 13
5 Installation ................................................................................................................................................................................ 14
5.1 Notes on safety for the installation............................................................................................................................ 14
5.2 Handling.................................................................................................................................................................... 14
5.3 Preliminary checks.................................................................................................................................................... 14
5.4 Operating position..................................................................................................................................................... 15
5.5 Boiler plate ................................................................................................................................................................ 15
5.6 Blast tube length........................................................................................................................................................ 16
5.7 Securing the burner to the boiler............................................................................................................................... 16
5.8 Nozzle installation ..................................................................................................................................................... 17
5.8.1 Choice of nozzles for 1st and 2nd stage................................................................................................................... 17
5.8.2 Nozzle ....................................................................................................................................................................... 18
5.8.3 Nozzle assembly....................................................................................................................................................... 19
5.9 Hydraulic connections............................................................................................................................................... 20
5.10 Gas oil supply............................................................................................................................................................ 20
5.10.1 Double-pipe circuit..................................................................................................................................................... 20
5.10.2 Single-pipe circuit...................................................................................................................................................... 22
5.10.3 The loop circuit.......................................................................................................................................................... 23
5.11 Pump......................................................................................................................................................................... 23
5.11.1 Technical data........................................................................................................................................................... 24
5.11.2 Pump priming............................................................................................................................................................ 24
6 Electrical system...................................................................................................................................................................... 25
6.1 Notes on safety for the electrical wiring..................................................................................................................... 25
6.2 Electrical connection ................................................................................................................................................. 26
6.2.1 PRESS GW electrical equipment factory-set (single-phase model).......................................................................... 26
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 Calibration of thermal cutout ..................................................................................................................................... 30
6.2.6 Electrical cable fastening........................................................................................................................................... 30
7 Start-up, calibration and operation of the burner ................................................................................................................. 31

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Contents
7.1 Notes on safety for the first start-up...........................................................................................................................31
7.2 Calibrations before firing............................................................................................................................................31
7.2.1 Combustion head setting ...........................................................................................................................................31
7.2.2 Pump adjustment.......................................................................................................................................................31
7.2.3 Fan gate adjustment..................................................................................................................................................32
7.3 Burner calibration.......................................................................................................................................................32
7.3.1 Firing..........................................................................................................................................................................32
7.3.2 Operation ...................................................................................................................................................................32
7.4 Combustion characteristics........................................................................................................................................33
7.5 Emissions into the atmosphere..................................................................................................................................33
7.6 Flue gas temperature.................................................................................................................................................34
7.7 Combustion chamber pressure..................................................................................................................................34
7.8 Loss of heat from the flue ..........................................................................................................................................34
7.9 Burner operation ........................................................................................................................................................35
7.9.1 Burner starting ...........................................................................................................................................................35
7.9.2 Steady State Operation..............................................................................................................................................35
7.9.3 Firing failure...............................................................................................................................................................36
7.9.4 Undesired shutdown during operation .......................................................................................................................36
7.9.5 Final checks...............................................................................................................................................................36
8 Maintenance ..............................................................................................................................................................................37
8.1 Notes on safety for the maintenance.........................................................................................................................37
8.2 Maintenance programme...........................................................................................................................................37
8.2.1 Maintenance frequency..............................................................................................................................................37
8.2.2 Checking and cleaning...............................................................................................................................................37
8.2.3 Opening the burner....................................................................................................................................................39
9 Faults - Possible causes - Solutions.......................................................................................................................................40
9.1 Burner start-up cycle diagnostics...............................................................................................................................41
9.2 Operating fault diagnostics ........................................................................................................................................42
9.3 Control card ...............................................................................................................................................................43

3 20140894
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Declaration
1 Declaration
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Gas oil burners
Model: PRESS GW
PRESS 1G
PRESS 2G
PRESS 3G
These products are in compliance with the following Technical Standards:
EN 267
EN 292
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 01.12.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

20140894 4
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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 Danger: live components
Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
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 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
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
This symbol indicates a list.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................

5 20140894
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Information and general warnings
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, 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 occured
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;
the 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.
Riello warranty is subject to correct burner, appliance and appli-
cation matching, and set up in line with Riello's instructions and
guidelines. All components within the hydraulic circuit suitable for
bio fuel use and supplied by Riello will be identified as Bio com-
patible. No warranty is given in relation to the use of components
which are not so identified with bio fuel blends. If in any doubt
please contact Riello for further advice.
If any Riello burners are used with fuel with a bio content >10%
then the components within the hydraulic circuit maybe affected
and are not covered under warranty. The hydraulic circuit con-
sists of;
–Pump
– Hydraulic ram (where applicable)
– Valve block
– Flexible oil lines (considered as a consumable component)
1. Irrespective of any warranty given by Riello in relation to
normal use and manufacturing defects, when fuels not
meeting the relevant standards are used, or where fuel stor-
age issues have not been addressed correctly, or the equip-
ment used is not compatible, if failures occur which are
directly or indirectly attributed to such issues and/or to the
non-observance of this guidance, then no warranty or liabil-
ity is implied or accepted by Riello.
2. Riello have carefully chosen the specification of the bio
compatible components including the flexible oil lines to pro-
tect the pump, safety value and nozzle. The Riello warranty
is dependent upon the use of Riello genuine components
including the oil lines, being used.
3. Riello warranty does not cover defects arising from incorrect
commissioning or servicing by non Riello employed service
engineers, and any issues impacting the burner arising from
external site related issues.
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.

20140894 6
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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
theuserorthirdparties,aswell asthe damagingof the burneror oth-
er items. Inattention, thoughtlessness and excessive confidence of-
ten 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 dangerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly named by the manufacturer;
the type and pressure of 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 detailed as available as spare parts by the
Manufacturer can be replaced.
3.2 Safety warnings
The dimension of the boiler’s combustion chamber must respond
to specific values, in order to guarantee a combustion with the
lowest polluting emissions rate.
The Technical Service Personnel will be glad to give you all the
information for a correct matching of this burner to the boiler.
This burner must only be used for the application it was designed
for.
The manufacturer accepts no liability within or without the con-
tract for any damage caused to people, animals and property due
to installation, adjustment and maintenance errors or to improper
use.
3.3 Basic safety rules
Children or inexpert persons must not use the appliance.
Under no circumstances must the intake grids, dissipation
grids and ventilation vents in the installation room be cov-
ered up with cloths, paper or any other material.
Unauthorised persons must not attempt to repair the appli-
ance.
It is dangerous to pull or twist the electric leads.
Cleaning operations must not be performed if the appliance
is not disconnected from the main power supply.
Do not clean the burner or its parts with inflammable sub-
stances (e.g. petrol, alcohol, etc.). The cover must be
cleaned with soapy water.
Do not place anything on the burner.
Do not block or reduce the size of the ventilation vents in the
installation room.
Do not leave containers and inflammable products or com-
bustible materials in the installation room.
3.4 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;
must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
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;
must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
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.
3 Safety and prevention

7 20140894
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Technical description of the burner
4.1 Burner designation
4 Technical description of the burner
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 of the system : 1/230/50 1/230V/50Hz
1/210/60 1/210V/60Hz
1/220/60 1/220V/60Hz
1/200/50-60 1/200V/50-60Hz
3/230-400/50 3/230V/50Hz-3N/400V/50Hz
3/210/60 3/210V/60Hz
3/220-380/60 3/220V/60Hz-3N/380V/60Hz
3/200/50-60 3/200V/50-60Hz
Auxiliary voltage : 230/50 230V/50Hz
120/60 120V/60Hz
220/60 220V/60Hz
200/50-60 200V/50-60Hz
PRESS 1G TC FS1 1/200/50-60 200/50-60

20140894 8
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Technical description of the burner
4.2 Technical data
Tab. A
(1) Reference conditions: ambient temperature 20 °C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point with zero pressure in the combustion chamber and maximum burner output.
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated
output.
4.3 Electrical data
MODEL PRESS GW PRESS 1G PRESS 2G PRESS 3G
Type 605T85 606T85 607T85 608T85
Power (1)
Output (1)
2nd stage kW
kg/h 178 - 356 15 - 30 190 - 534 16 - 45 356 - 712 30 - 60 534 - 1168 45 - 100
1st stage kW
kg/h 107 - 178 9 - 15 130 - 267 11 - 22.5 214 - 356 18 - 30 273 - 593 23 - 50
Fuel Light oil
Gas oil net calorific
value density
viscosity at 20 °C
kWh/kg
kg/dm3
mm2/s max
11.8
0.82 - 0.85
6 (1.5 °E - 6 cSt)
Operation • Intermittent (min. 1 stop in 24 hours).
• Two-stage (high and low flame) and single-stage (all - nothing).
Pump output (at 12 bar)
pressure range fuel
temperature
kg/h
bar
°C max
73
20
60
95
20
60
195
10 - 21
90
Nozzles number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
MODEL PRESS GW PRESS 1G PRESS 2G PRESS 3G
Electrical supply V
Hz 200 +/- 10% 60 (changing fan)
50 - single-phase
200 +/- 10%
60 (changing fan)
50 - triple-phase
Electric motor kW
V
A
0.37
200
2.9
0.45
230-260
1.8-1.6
0.74
230-260
2.6-2.3
1.5
200-220
7.1-7.4
Ignition transformer V1 - V2
I1 - I2 230 V - 8 kV 1.8 A - 30 mA
Electrical power consumption kW max 0.55 0.61 1.07 2.05
Protection level IP40

9 20140894
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Technical description of the burner
4.4 Packaging - Weight
Approximate measurements.
• 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.
Tab. B
4.5 Overall dimensions
Approximate measurements.
The maximum dimensions of the burner are given in (Fig. 2).
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part withdrawn on the slide
bars.
The maximum dimension of the burner when open is give by
measurement I.
Tab. C
mm ABCkg
PRESS GW 800 535 500 37
PRESS 1G 800 535 500 44
PRESS 2G 800 535 500 44
PRESS 3G 1000 790 550 55
Fig. 1
D88
Fig. 2
D320
mmABCDEFGH I
PRESS GW 234 205 292 140 185 473 59 397 688
PRESS 1G 270 205 292 150 236 473 59 307 688
PRESS 2G 270 205 332 155 237 506 89 437 721
PRESS 3G 406 205 370 175 227 570 88 485 761

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Technical description of the burner
4.6 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
(See the wiring diagram on page 26).
The burner fires in the 1st stage, where it remains for 7 seconds
before passing to the 2nd stage when commanded by the control
box 8) (Fig. 7 on page 13).
When the boiler temperature or pressure exceeds the values set
on the control device TL, the burner shuts down.
In two-stage operation, two control devices are provided: TL and
TR.
The burner fires in the 1st stage but passes to the 2nd stage only
if control device TR is closed. Once the temperature or pressure
value set on control device TR has been reached, the burner re-
turns to the 1st stage.
The burner shuts down only when the boiler temperature or pres-
sure exceeds the value set on control device TL, even if the burn-
er is still operating in the 1st stage.
Two-stage operation ensures reduced boiler temperature or
pressure fluctuation and consequently lower operating costs.
MINIMUM 1ST STAGE DELIVERY (MIN) must be selected with-
in the range of the values listed above the adjacent diagrams.
Example:
for the PRESS 1G Model, the selection may range from 11 - 22.5
kg/h.
It is not necessary to know the pressure in the combustion cham-
ber in the 1st stage.
MAXIMUM 2ND STAGE DELIVERY (MAX) must be selected
within the range of the adjacent diagrams. This area is known as
the FIRING RATE and provides the maximum delivery of the
burner according to the combustion chamber pressure.
Example:
for the PRESS 1G Model, this area is delimited by:
– the 16 - 45 kg/h delivery line
– the 0 +6,5 mbar combustion chamber pressure line
– the combustion chamber maximum pressure curve.
The work point may be found by plotting a 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.
Example:
if the PRESS 1G Model has a delivery of 30 kg/h at a combustion
chamber pressure of 4 mbar, the work point will be found on the
maximum pressure curve.
Consult page 11, for operation at different surrounding tempera-
tures and/or altitudes.
The delivery of the burner to be coupled to the boiler must be se-
lected in the MAX. area - in other words, within the FIRING
RATE.
The burner can also operate in depression combustion cham-
bers.
WARNING
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
above sea level), and with the combustion head
adjusted as shown on page 31.
Fig. 3
kg/h
PRESS 1G - MIN (1st stage) = 11 - 22,5 kg/h D392
MAX
PRESS 2G - MIN (1st stage) = 18 - 30 kg/h
kg/h
D393
MAX
PRESS 3G - MIN (1st stage) = 23 - 50 kg/h D394
kg/h
MAX
D395
PRESS 4G - MIN (1st stage) = 35 - 70 kg/h
kg/h
MAX
Combustion chamber pressure mbar Combustion chamber pressure mbar
Combustion chamber pressure mbarCombustion chamber pressure mbar

11 20140894
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Technical description of the burner
4.6.1 Burner firing rates according to air density
The burner firing rate range provided in this Manual applies to op-
eration at a surrounding temperature of 20°C at an altitude of 100
meters above sea level (atmospheric pressure approx. 1000
mbar).
The burner may be required to operate with comburent air at a
higher temperature and/or at higher altitudes.
Heating of air and increase in altitude produce the same effect:
the expansion of the air volume, i.e. the reduction of 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.
It is therefore important to know if the maximum output required
of the burner at a given combustion chamber pressure remains
within the burner's firing rate range even at different temperature
and altitude conditions. Proceed as follows to check the above:
1 -Find the correction factor F in the Tab. D for the plant's air tem-
perature and altitude.
(1)AVERAGE BAROM. PRESS.
Tab. D
2 -Divide the burner's delivery Q by F in order to obtain the equiv-
alent delivery Qe:
3 -In the firing rate range of the burner (Fig. 4), indicate the work
point defined by:
Qe = equivalent delivery
H1 = combustion chamber pressure
The resulting point A must remain within the firing rate
range.
4 -Plot a vertical line from Point A as shown in (Fig. 4) and find
the maximum pressure H2 of the firing rate.
5 -Multiply H2 by F to obtain the maximum reduced pressure H3
of the firing rate.
If H3 is greater than “H1”, as shown in (Fig. 4), the burner deliver
the output required.
If H3 is lower than H1, the burner's delivery must be reduced.
A reduction in delivery is accompanied by a reduction of the pres-
sure in the combustion chamber:
Qr = reduced delivery
H1r = reduced pressure
H1r = H1x (Qr/Q)2
Example, a 5% delivery reduction:
Qr = Q x 0,95
H1r = H1x (0,95)2
Steps 2-5 must now be repeated using the new Qr and H1r val-
ues.
Altitude
a.s.l. (1) Correction factor F
Air temperature °C
mmbar 0 5 10 15 20 25 30 40
01013 1,087 1,068 1,049 1,031 1,013 0,996 0,980 0,948
100 1000 1,073 1,054 1,035 1,017 1,000 0,983 0,967 0,936
200 989 1,061 1,042 1,024 1,006 0,989 0,972 0,956 0,926
300 978 1,050 1,031 1,013 0,995 0,978 0,962 0,946 0,916
400 966 1,037 1,018 1,000 0,983 0,966 0,950 0,934 0,904
500 955 1,025 1,007 0,989 0,972 0,955 0,939 0,923 0,894
600 944 1,013 0,995 0,977 0,960 0,944 0,928 0,913 0,884
700 932 1,000 0,982 0,965 0,948 0,932 0,916 0,901 0,872
800 921 0,988 0,971 0,954 0,937 0,921 0,906 0,891 0,862
900 910 0,977 0,959 0,942 0,926 0,910 0,895 0,880 0,852
1000 898 0,964 0,946 0,930 0,914 0,898 0,883 0,868 0,841
1200 878 0,942 0,925 0,909 0,893 0,878 0,863 0,849 0,822
1400 856 0,919 0,902 0,886 0,871 0,856 0,842 0,828 0,801
1600 836 0,897 0,881 0,866 0,851 0,836 0,822 0,808 0,783
1800 815 0,875 0,859 0,844 0,829 0,815 0,801 0,788 0,763
2000 794 0,852 0,837 0,822 0,808 0,794 0,781 0,768 0,743
Qe = Q : F (kg/h)
H3 = H2 x F (mbar)
CAUTION
The combustion head must be adjusted in respect
to the equivalent delivery Qe.
Qe kg/h
mbar
Fig. 4
D388

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Technical description of the burner
Example
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)2= 4,5 mbar
4.7 Test boiler
The firing rates were set in relation to special test boilers in ac-
cordance with the methods defined in EN 267 standards.
Fig. 6 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.
kg/h
B
mbar
4,6
5,7
23
21,1
5
5,5
6,1
A
mbar
kg/h
C
4,5
22,3
4,7
5,8
Fig. 5
D389
***
air 20 °C - altitude 1000 m a.s.l. - F = 0.898 *
Qe = Q : F = 19 : 0.898 = 21,1 kg/h 5 mbar A
H2 = 6.1 mbar
H3 = H2 x F = 6.1 x 0.898 = 5.5 mbar
H3 > H1 (5.5 > 5) OK
air 30 °C - altitude 1600 m a.s.l. - F = 0.808 *
Qe = Q : F = 19 : 0.808 = 23 kg/h 5 mbar B
H2 = 5,7 mbar
H3 = H2 x F = 5.7 x 0.808 = 4.6 mbar
H3 < H1 (4.6 < 5) IMPOSSIBLE
Qe = Q : F = 18 : 0.808 = 22.3 kg/h 4.5 mbar C **
H2 = 5.8 mbar
H3 = H2 x F = 5.8 x 0.808 = 4.7 mbar
H3 > H1 (4.7 > 4.5) OK
Fig. 6
D449
Combustion chamber length m

13 20140894
GB
Technical description of the burner
4.8 Burner description
1 Slide bars for opening the burner and inspecting the
combustion head
2 Combustion head
3 Air inlet to fan
4 Motor capacitor
(PRESS GW)
5 Motor contact-maker and thermal cut out with reset button
(PRESS 1G-2G-3G)
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 (see ‘Pump” on page 23)
12 Electrical motor
13 Screw for combustion head adjustment
14 Sensor for flame presence control
15 Fan rotation direction
16 Variable stroke hydraulic cylinder.
Opens the fan gate valve to the value necessary at the
2nd stage of operation.
17 Indexed selector.
This selector adjusts the opening of the fan gate to the
value necessary at the 1st stage of functioning.
Two types of burner failure may occur:
- CONTROL BOX LOCK-OUT:
if the control box 8) (Fig. 7) pushbutton lights up, it indicates that
the burner is in lock-out.
To reset, press the pushbutton for a minimum of three seconds.
- MOTOR TRIP (PRESS 1-2-3 G):
release by pressing the pushbutton on thermal relay 5)(Fig. 7).
4.9 Standard equipment
2 - Hoses
2 - Gaskets for hoses
2 - Nipples for hoses
1 - Reducer with gasket for connection of flexible suction hose
to pump (PRESS 1G-2G)
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the boiler:
M10 x 25 for GW - 1G - 2G
M12 x 40 for 3G
1 - Instruction booklet
1 - Fan for 60Hz use
S8281
S9704
Fig. 7
WARNING
You must replace burner fan in application with 60
Hz power supply.

20140894 14
GB
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 packaging of the burner includes a wooden platform, so it is
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. 8) 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 types of fuel used and the relative supply pressures (G);
the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate).
5Installation
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.
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
20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Beforeproceedingwiththeinstallationoperations,
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.
Fig. 8
S8268

15 20140894
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Installation
5.4 Operating position
The burner is designed to work only in the positions 1, 2, 3 and 4.
Installation 1is preferable, as it is the only one that allows per-
forming maintenance operations as described in this manual.
Installations 2, 3 and 4 permit operation but make maintenance
and inspection of the combustion head difficult, page 37.
5.5 Boiler plate
Drill the combustion chamber locking plate as shown in Fig. 10.
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
Tab. E
WARNING
Any other position could compromise the correct
working of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 9
2 3 4 51
S8269
mm A B C D
PRESS GW 155 160 160 M10
PRESS 1G 165 160 160 M10
PRESS 2G 165 160 160 M10
PRESS 3G 185 195 195 M12
D329
Fig. 10

20140894 16
GB
Installation
5.6 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 doorcom-
plete with its fettling.
The range of lengths available, L (mm), is as follows:
For boilers with front flue passes 9) or flame inversion chambers,
protective fettling in refractory material 7) must be inserted be-
tween the boiler's fettling 8) and the blast tube 6).
This protective fettling must not compromise the extraction of the
blast tube.
5.7 Securing the burner to the boiler
Disassemble the blast tube 6) from the burner by proceeding as
follows:
– Remove the screws 2) from the two slide bars 3).
– Remove the screws 1) that secure the blast tube 6) to the
burner 4).
– Now disassemble the blast tube complete with the slide bars.
Fasten the blast tube 6) to the boiler plate (Fig. 10 on page 15),
inserting the gasket provided 5). Use the 4 screws provided after
having protected the thread with antiscruffing products (high-tem-
perature grease, compounds, graphite). The burner-boiler seal
must be airtight.
Reassemble the burner 4) on the slide bars 3) and re-insert the
screws 2).
Leave the burner open as shown in (Fig. 11).
Blast tube GW 1G 2G 3G
shortened 43 mm 94 mm 95 mm 85 mm
standard 185 mm 236 mm 237 mm 237 mm
lengthened 320 mm 369 mm 395 mm 384 mm
Fig. 11
D330

17 20140894
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Installation
5.8 Nozzle installation
5.8.1 Choice of nozzles for 1st and 2nd stage
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 nozzle must be chosen from among those listed in (Tab. F).
Use nozzle with atomization angle of 60° and, if possible, at a
pressure of 12 bar.
Example with the Press 1G Model:
Boiler output = 270 kW - efficiency 90 %
Output required by the burner =
270 : 0.9 = 300 kW;
300 : 2 = 150 kW per nozzle;
therefore, two equal, 60°, 12 bar nozzles are required:
1° = 3.00 GPH - 2° = 3.00 GPH,
or the following two different nozzles:
1° = 2.50 GPH - 2° = 3.50 GPH, or
1° = 3.50 GPH - 2° = 2.50 GPH.
NOTE:
Other information regarding nozzles may be found on ‘Noz-
zle” on page 18.
(1) We get the indicated delivery when both nozzles are working
and gas oil has the following characteristics:
density 0.84 kg/dm3- viscosity 4.2 cSt/20 °C - temperature
10 °C
Tab. F
WARNING
It is advisable to replace nozzles every year
during regular maintenance operations.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards
to people and objects.
The manufacturing company shall not be liable for
any such damage arising from non-observance of
the requirements contained in this manual.
GPH Delivery kg/h (1) kW
12 bar
10 bar 12 bar 14 bar
PRESS GW
2.00 7.7 8.5 9.2 100.8
2.25 8.6 9.5 10.4 112.7
2.50 9.6 10.6 11.5 125.7
3.00 11.5 12.7 13.8 150.6
3.50 13.5 14.8 16.1 175.5
4.00 15.4 17.0 18.4 201.6
PRESS 1G
2.00 7.7 8.5 9.2 100.8
2.25 8.6 9.5 10.4 112.7
2.50 9.6 10.6 11.5 125.7
3.00 11.5 12.7 13.8 150.6
3.50 13.5 14.8 16.1 175.5
4.00 15.4 17.0 18.4 201.6
4.50 17.3 19.1 20.7 226.5
5.00 19.2 21.2 23.0 251.4
5.50 21.1 23.3 25.3 276.3
PRESS 2G
4.00 15.4 17.0 18.4 201.6
4.50 17.3 19.1 20.7 226.5
5.00 19.2 21.2 23.0 251.4
5.50 21.1 23.3 25.3 276.3
6.00 23.1 25.5 27.7 302.4
6.50 25.0 27.6 30.0 327.3
7.00 26.9 29.7 32.3 352.3
PRESS 3G
6.00 23.1 25.5 27.7 302.4
6.50 25.0 27.6 30.0 327.3
7.00 26.9 29.7 32.3 352.3
7.50 28.8 31.8 34.6 377.2
8.30 31.9 35.2 38.3 417.5
9.50 36.5 40.3 43.8 478.0
10.50 40.4 44.5 48.4 527.8
12.00 46.1 50.9 55.3 603.7
60
D339

20140894 18
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Installation
5.8.2 Nozzle
The spray patterns in relation to the leading brands of nozzle on
sale are shown in (Tab. G).
The nozzle deliveries indicated in the Tab. F 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.
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 re-
quired. Grip the nozzle on its hexagonal part when handling.
Tab. G
Spray Delevan Monarc
hDanfoss Steinen
hollow APLHH-PH
solid BARS Q
universal W NS - PLP B SS
semi-
solid ER-S