Riello Burners PRESS 45 N/ECO Guide de démarrage rapide

2916193 (0)

Montage und Bedienungs Anleitung

Manuel d’entretien

Installation, use and maintenance instructions

Istruzioni per installazione, uso e manutenzione

Bruciatore di nafta

Heizölbrenner

Heavy oil burner

Brûleur à fioul lourd

CODICE

CODE

MODELLO - MODELL

MODELE - MODEL

TIPO - TYP

TYPE

3434623 PRESS 45 N/ECO 627 T

3434624 PRESS 45 N/ECO 627 T

Funzionamento bistadio

Zweistufiger Betrieb

Two-stage operation

Fonctionnement à deux allures

6193 1GB

INDEX

1. BURNER DESCRIPTION

Two stage heavy oil burner.

1.1 EQUIPMENT

Flexible tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Nipples. . . . . . . . . . . . . . . . . . . . . . . . No. 2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 2 Screws . . . . . . . . . . . . . . . . . . . . . . . . . No. 4

Flange shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . No. 2

Guide extensions (for the lengthened head version).No. 2 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Fitting for operation with emulsified

oil fuel (see page 9) . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1

1. BURNER DESCRIPTION. . . . . . . . . . . . . . 1

1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . 2

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2

2.3 Field of operation . . . . . . . . . . . . . . . . . . . 2

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3

3.1 Fuel oil supply systems . . . . . . . . . . . . . . . . 3

3.2 Electrical system . . . . . . . . . . . . . . . . . . . . 4

3.3 Electrical connections . . . . . . . . . . . . . . . . 5

4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Choice of nozzles . . . . . . . . . . . . . . . . . . . 6

4.2 Pump pressure . . . . . . . . . . . . . . . . . . . . . 6

4.3 Combustion head setting. . . . . . . . . . . . . . . . 6

4.4 Adjustment of the air damper motor . . . . . . . 6

4.5 Air pressure switch . . . . . . . . . . . . . . . . . . . . 7

4.6 Atomisation temperature adjustment . . . . . . . 7

4.7 Start-up programme. . . . . . . . . . . . . . . . . . . . 9

4.8 Ecological oil burners . . . . . . . . . . . . . . . . . . 9

4.9 Emulsified fuel oil functioning . . . . . . . . . . . . 9

4.10 Start-up programme diagnostic . . . . . . . . . . 10

4.11 Operating fault diagnostics . . . . . . . . . . . . . 10

2893

OThe burner meets protection level of IP 40, EN 60529.

OBurner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage

73/23/EEC and Machines 98/37/EEC.

1 - Suction line

2 - Return line

3 - Pump pressure adjustment screw

4 - Manometer fitting (G1/8)

5 - Vacuometer fitting (G1/2)

6 - Air damper opening motor

7 - Control box reset push-button and

lock-out indication

8 - Fan overload cutout reset

9 - Combustion head regulating screw

10 - Double filter

11 - Valve assembly

12 - Manometer with protection valve

13 - Adjustment thermostat

14 - Pre-heater contact maker

15 - Ignition transformer

16 - Terminal strip

17 - Cable glands

18 - Antigas valve

19 - Thermometer

20 - Pump motor starter with reset

21 - Air pressure switch

Fig. 1

6193 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 DIMENSIONS

2.3 FIELD OF OPERATION (2 nozzles in operation)

TYPE 627 T

Thermal power - Flow rate 114/205 - 513 kW – 10/18 - 45 kg/h

Fuel Oil with max. viscosity at 50° C 115 sq. mm/sec (15° E)

Electrical supply Three-phase, 230V ±10% ~50Hz without neutral

400V ±10% ~50Hz with neutral

Motor 230V - 400V Fan: 2.4A - 1.4A

Pump: 2.1A - 1.2A

Ignition transformer Primary 2 A – Secondary 2 x 6.5 kV – 35 mA

Heaters 2.8 kW

Electrical intake power 4.1 kW

Pump 60 kg/h at 20 bar

D2715

D2628

BurnerBoiler plate

NOTE

The weight of the rear part of the pumping assembly exerts flexure stress on the guides; you are advised

to hold the burner while it is being extracted so as not damage the flame disc and the said guides.

For long - head version.

Use the pin extensions provided to move the burner back.

783 235

370

625

290

Diam.161

305

Burner capacity

Pressure in combustion

chamber – mbar

D2673

When the burner operates with only one nozzle, the pressurization conditions are better and no problems

arise. Minimal flow rate with one only nozzle: 10 kg/h - 114 kW.

kg/h

6193 3GB

3. INSTALLATION

3.1 FUEL OIL SUPPLY SYSTEMS

GRAVITY SYSTEM

SUCTION SYSTEM

LOOP SYSTEM (max loop pressure 3 bar)

metres

L metres

diam.

3/4”

diam.

1” gas

0510

0.5 8 15

11120

1.5 14 25

21730

Pump priming:

loosen the cap of the vacuometer fitting

(5, fig. 1) and wait for the fuel to flow out.

H: Difference in height

L: Length of the suction tube

For light oil with viscosity max. 7°E at 50°C.

D2720

max. 30m

metres

L metres

diam.

1” gas

diam.

1 1/4”

02445

0.5 21 40

11835

1.5 15 30

21225

2.5 9 20

3615

Not advised, to be used only in case of

previously existing system.

Never exceed the max. vacuum of 0.5 bar

(38 cm Hg) measured at the vacuometer

fitting (5, fig. 1).

The pipes should be perfectly airtight.

When the tank is placed below of the burn-

er level, the return pipe should arrive at the

same level as the suction pipe.

In this case the foot valve is not required.

For light fuel oil with viscosity max. 7°E at 50°C.

D2721

max. 30m

1- Tank (properly heated for heavy oil) 5- Transfer pump

2- Filter (with resistor for oil > 7°E / 50°C) 6- Check Manometer

3- Burner 7- Burner pump

4- Air dampers to exclude the burner (coupled) 8- Pressure adjuster

For heavy oil with viscosity up to 20°E / 50°C.

Important note: to let the fuel flow properly all the pipes have to be properly sized, insulated and heated

(with elec. resistor or steam or hot water).

Warning: before to starting up the burner, make sure that there are obstructions in the pipes.

ny obstruction may damage the sealing of the pump.

D2631

6193 4GB

3.2 BURNER ELECTRICAL SYSTEM (carried out in the factory)

RMO88.53A2

PMP

246 96

135

13 A1

RT1

1512 16

171318 9 5 8114

ST2

ST1

ST0

HS1

MV2

R2 R3

246 95

135

13 A1

531

624

L1R

NL1 L2 L3 LN S3 T1 30T2T6T8

V21

V22

L1P

L2P

L3P

CMP

CMV

CMP Pump motor contact maker

CMV Fan motor contact maker

CR Pre-heater contact maker

FSuppressor

FR Photocell

MB Burner terminal strip

MP Pump motor

MV Fan motor

PA Air pressure switch

R1 Atomiser holder resistor

R2 Pump resistor

R3 Valve assembly resistor

RMO Electrical control box

RT Fan motor thermal relay

RT1 Pump motor thermal relay

SPre-heater tank

SM Servomotor

TA Ignition transformer

TB Burner earth

TE Regulation thermostat and start-up enabling

signal

Tm Minimum contact thermostat

Tm Maximum contact thermostat

V1 1st stage valve

V2 2nd stage valve

2598

6193 5GB

3.3 ELECTRICAL CONNECTIONS TO THE TERMINAL STRIP (to be made by the installer)

FASTENING OF THE ELECTRICAL WIRES

All the wires, which have to be connected to the burner terminal strip (16, fig. 1) shall pass through the cable

glands (17, fig. 1), see the figure below.

Further prospective signals or controls can be connected to the burner terminal strip pushing out the pre-sheared

disc from the holes and inserting a common cable gland for the passage and the clamping of the leads. To ensure

the IP 40 degree of protection in compliance with EN 60529 close the passage holes of the cables and any un-

used cable entries with appropriate discs.

NOTES

- Make a safe earth connection.

- Verify the burner stop by opening the boiler thermostat and the burner lock-out by darkening the photocell.

IN Manual switch

MB Burner terminal strip

HLock-out signal

TL Limit remote control

TR Adjustment remote control

TS Safety remote control

NOTE

Wire cross sections: min. 1 sq. mm.

(Unless required otherwise by local standards

and legislation).

TWO STAGE OPERATION

This is achieved by the remote control device

connected to terminals 5-6 (removing the jump-

er), that controls the second valve. RESISTOR CONNECTIONS

D2634

PRE-HEATER

2610

230V 400V

A Ampere 10 6

B Ampere 6 4

C sq.mm 1.5 1.5

D sq.mm 2.5 1.5

D2635

1- Single phase pre-heated resistor

power supply: . . . . . . . . . . . . . . . . . . . . . .cable entry Pg 21

2 - Motor three-phase supply:. . . . . . . . . . . . .cable entry Pg 16

3 - Single phase power supply and

safety thermostat: . . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

4- Control thermostat: . . . . . . . . . . . . . . . . . .cable entry Pg 13.5

5- Second stage thermostat: . . . . . . . . . . . . .cable entry Pg 13.5

6193 6GB

4. OPERATION

4.1 CHOICE OF NOZZLES

Recommended nozzles:

- Monarch F 80 H0.

4.2 PUMP PRESSURE

Recommended pressure:

- Fluid oil: 20 bar

- Heavy oil: 25 bar

The flow rates of the nozzles indicated on the table are

nominal and refer to a light oil having viscosity from 3 to 5°E

at 50° C pre-heated to 100°C. The actual flow rate may vary

by ± 5% against the rated one.

If flowrate values between those in the table are required, the

pump pressure may be varied or the nozzles arranged

differently.

The pump leaves the factory set at 20 bar.

4.3 COMBUSTION HEAD ADJUSTMENT

Turn the screw A, fig. 2 till the set-point, shown in the diagram,

is in line with the level of the sleeve B, fig. 2.

4.4 ADJUSTMENT OF THE AIR DAMPER MOTOR

PARK - Blue lever

This lever leaves the factory vertically positioned and corre-

sponds to the air damper completely closed.

A partial opening of the air damper might be obtained by mov-

ing this lever leftwards (+on the plate).

The new position of the air damper is detectable when the

burner is off.

Do not exceed the position of the orange lever for the 1st

stage.

1st STAGE - Orange lever

The orange lever controls the air damper position for the first

flame, it is adjustable on both opening and closing.

2nd STAGE - Red and black levers

The red lever controls the air damper position for the second

flame, it is adjustable on both closing and opening.

The black lever controls the opening of the second oil valve

and it must always be slightly earlier than the red lever, but

never the first stage orange one.

D2638

Black lever

Red lever

Orange lever

Blue lever

Opening +–Closure

Nozzle

GPH (45° - 60°)

20 bar

kg/h

25 bar

kg/h

1.50 + 1.50 18.00 20.30

1.75 + 1.75 21.00 23.80

2.00 + 2.00 24.00 27.10

2.25 + 2.25 27.00 30.50

2.50 + 2.50 30.00 34.00

3.00 + 3.00 36.00 40.60

3.50 + 3.50 42.00 –

3.50 + 4.00 45.00 –

kg/h

Set-points

D2677

D2637

Set-point 4

Fig. 2

6193 7GB

4.5 AIR PRESSURE SWITCH

4.6 ATOMISATION TEMPERATURE ADJUSTMENT

Thermostat for adjustment - maximum value - minimum value

Adjustment thermostat prevents burner start up if the fuel temperature has not reached the required value for

a better atomisation as indicated in the diagram below.

Example

Fuel oil with viscosity of 7 °E at 50 °C is pre-heated to approximately 110 °C.

The thermostat has to be generally set at a value higher than the required one (120°C indicated on the knob

to get approximately 100°C at the nozzles).

The value read has to be done after some minutes of operation and later the necessary adjustments could be

carried out.

Minimum value contact thermostat intervenes by stopping the burner if the fuel temperature decreases

under the value necessary for better combustion.

Maximum value contact thermostat switches off the resistors when in case of failure of the adjustment

thermostat, the temperature increases inside the pre-heater. In case of abnormal temperature, make sure

of the regular functioning of control thermostat and of the resistor in contact with the probe of the thermostat.

D2640

D2719

Thermostat

adjustment knob

Pre-heater

Purge

Atomisation temperature

Viscosity at 50° C

sq. mm/sec °E

°C

Carry out the regulation of the air pressure switch after

carrying out all the other regulations of the burner with

the air pressure switch adjusted to the beginning of the

scale.

With the burner operating at the MIN power increase

the pressure of the adjustment by slowly turning the

appropriate knob clockwise until the burner locks out.

Then turn the knob counterclockwise to a value equal

to about 20% of the regulated value and then check

the correct turning on of the burner. If the burner locks

out again turn the knob a bit further in a counterclock-

wise direction.

D521

6193 8GB

IMPORTANT NOTES

If the pre-heater thermostat or the resistor in contact with

the probe should be replaced, the probe has to be posi-

tioned in contact with the resistor and with the pipes of the

last aluminium plate, after loosening of the fixing screws

of the aluminium plate packs, see drawing.

If during the operation exceptional differences or temper-

ature peaks that are too high should be detected, verify

the continuity of the resistor, using and ohmmeter in con-

tact with the temperature probe (approximately 35 Ohm).

Use only filters marked with a groove on the tightening hexagon.

NOTES

yThe pre-heater might be fitted with a second maximum value contact thermostat.

That thermostat can be used to act on an external contact maker by means of a switch to cut off the current

from the pre-heater, in case of excess temperature (Kit code no. 3000800).

yThe resistor Rplaced on the atomiser holder is wired to the supply line of the pre-heater (see page 4).

When the burner is off, the pre-heater supply line shall remain fed.

Should the pre-heater line be turned off, the fuel must be pre-heated for approximately 30 minutes before the

burner start-up. On the contrary, the nozzle-holder resistor shall be supplied with an independent single-phase

line, protected by a fuse of 1A.

This line shall never be switched off, when the burner is off.

yBefore the burner start-up, verify that the pump is filled of fuel in order to avoid any idling for too long time.

yFilter cleaning:

periodically clean the filters in order to avoid any trouble in the burner operation.

ySupply line filter:

positioned on the suction line, it causes the increase of the vacuum in the pump with the consequent flow of

gas and noise. Do not exceed the vacuum of 38 cm Hg (5 m W.c.) (5, fig. 1).

yPre-heater filter (10, fig. 1):

positioned in the delivery line, it causes a decrease of the atomisationing pressure which is detectable by

use of a manometer (12, fig. 1).

MANOMETER PROTECTION VALVE

After atomisation pressure has been checked, it is recommended to cut out the manometer (12, fig. 1) to avoid

pressure shocks that it might be subjected to at every burner start up.

To achieve this, close the protection valve when the burner is not working and the manometer indicates 0 bar.

Thermostat probe

Resistor

Aluminium plate pipes

Plate

D2751

6193 9GB

4.7 START-UP PROGRAMME

Motor lock-out

It is caused by the motor overload relay if there is an overload or no phase.

4.8 ECOLOGICAL OIL BURNERS

WARNING

The transition from normal fuel oil to ecological fuel oil requires:

yThe tank to be emptied of normal fuel oil.

yCleaning of the cistern and the pipes that carry the fuel oil to the burner.

yApplication of a filter if there is not one already on the burner fuel line with a filtering grade of 0.3 mm maxi-

mum.

If this is not done, Riello S.p.A. declines all liability if the burner fails to work properly or wears out prematurely.

NOTES

These burners are the result of careful study that allows them to be used with ecological fuels as well; oils, that

in certain temperature and speed conditions, are particularly aggressive for the vital parts of the burner.

The objective has been achieved with the reduction of the transiting speed in some of the parts and an appropri-

ate choice of materials (in particular surface treatments) as well as a redefinition of the backlashes and coupling

tolerances.

The burners for ecological oils are very different from normal fuel oil burners because they have a separate

pump (worked by its own motor at 1400 rpm) and for the presence of double filtration between pump and nozzle.

4.9 EMULSIFIED FUEL OIL FUNCTIONING

Lock-out because there is no ignitionNormal

Thermostat

Motors

Ignition transformer

1st flame valve

2nd flame valve

Lock-out

2894

indicator light

D3435

WARNING

In the case of functioning with emulsi-

fied fuel oil it is necessary to change

the fitting on the burner (*) with the one

supplied with it.

Ce manuel convient aux modèles suivants

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