Riello Burners Gulliver RG3 Quick start guide

Installation, use and maintenance instructions
2903281 (0)
Light oil burner
One stage operation
CODE MODEL TYPE
3739354 RG3 393 T1
GB

3281
1GB
INDEX
1. BURNER DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. BURNER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Electrodes adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Maintenance position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.6 Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.7 Air damper adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.8 Operating programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.8.1 Normal operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.8.2 Lockout due to firing failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.8.3 Lockout due to extraneous light during pre-purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.8.4 Lockout types and triggering times in case of burner malfunction . . . . . . . . . . . . . . . . . . . . . . . 11
4.8.5 Control box reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8.6 Recycle function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8.7 Logging of burner operation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.9 Additional, programmable control box functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.9.1 Post-purging function (t6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.9.2 Continuous purging function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.9.3 Long pre-purging function (t7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.9.4 Function setting procedure using reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Control box visual diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Start-up problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Operating irregularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. WARNINGS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Burner identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Basic safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3281
2GB
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket . . . . . . . No. 1 Screws and nuts for flange to be fixed to boiler. . .No. 4
Screw and nuts for flange . . . . . . . . . . No. 1 Flexible oil pipes with nipples . . . . . . . . . . . . . . . .No. 2
Remote reset connection . . . . . . . . . . No. 1
1.2 ACCESSORIES
SOFTWARE DIAGNOSTIC KIT
A special kit is available that, by an optical link to a PC, shows the burner life together with operating hours, type
and number of failures, serial number, etc.
To visualise the diagnostics proceed as follows:
³Connect the kit supplied separately to the control box socket.
Reading of the information begins when the software programme included in the kit starts.
REMOTE RESET KIT
The burner has a remote reset kit (RS) consisting of a connection and a push-button operating at a dis-
tance of 20 metres max.
In order to install it remove the protective lock-out installed at the factory and insert the lock-out supplied
with the burner (see electrical diagram on page 6).
³CE Certification No.: 0036 0348/04 as 92/42/EEC.
³The burner meets protection level of IP XOD (IP 40), EN 60529.
³Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
³The burner is approved for intermittent operation as per Directive EN 267.
1– Oil pump
2– Control-box
3– Reset button with lock-out lamp
4– Flange with insulating gasket
5– Air damper adjustment assembly
6– Nozzle holder assembly
7– Flame detector
8– Flame tube
9–Motor
Fig. 1
1
2
3
4
8
9
7 56
D4681

3281
3GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 FIRING RATES (as EN 267)
TYPE 393 T1
Output - Thermal power 7 −15kg/h–83−178 kW
Fuel Light oil, viscosity 4 – 6 mm2/s at 20 °C
Electrical supply Single phase, ~50Hz 230 V ±10%
Motor Run current 1.9A – 2750 rpm – 289 rad/s
Capacitor 6.3 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 8 −15 bar
Absorbed electrical power 0.385 kW
228 142 300 213
160
190
12
36
285
345
11
9999
127
45°
45°
D5353
ø123
Light oil output – kg/h
Thermal power – kW
Pressure in combustion
chamber – mbar
0
678
80 100 120
2.0
1.6
1.2
0.8
0.4
D5086
910
140 160
11 12 13 14 15 16
180
2.4

3281
4GB
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 WORKING POSITION
The burner is programmed to operate only in positions 1and 2.
Installation 1 is to be preferred since it is the only position where maintenance can be carried out as de-
scribed in this manual.
With installation 2, operation is ok but maintenance cannot be carried out with the burner hooked to the boiler.
Any other installation would affect the burner operation.
Installations 3, 4 and 5are forbidden on safety grounds.
3.2 BOILER FIXING
To fit the burner to the boiler it is necessary to carry out the following:
³Put on the flange (1) the screw and two nuts, (see fig. 3).
³Widen, if necessary, the insulating gasket holes (4).
³Fix the flange (1) to the boiler door (3) using screws (5) and (if necessary) the nuts (2) interposing the
insulating gasket (4), (see fig. 2).
³After installation ensure that burner is lightly inclined as in fig. 4.
D7088
1 2 3 4 5
Fig. 4
D5025
Fig. 2
Fig. 3
S7071

3281
5GB
3.3 HYDRAULIC SYSTEMS
ONLY FOR ITALY: Automatic cut-off device as per Ministry of Internal Affairs’ regulation n° 73 dated 7/29/71.
H= difference of level; L= max. length of the suction line; øi= internal diameter.
PRIMING PUMP:
On the system in fig. 6 it is sufficient to loosen the suction gauge connec-
tion (5, fig. 6) and wait until oil flows out.
On the systems in fig. 7 and 8 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds
before repeating the operation.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 9) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not
required. Should however the return line arrive over the fuel level, a non-return
valve is required. This solution however is less safe than previous one, due to
the possibility of leakage of the valve.
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
³The burner is designed to allow installation of the oil-
lines on either side of the burner.
³It is necessary to install a filter on the fuel supply line.
³The pump is designed for use with a two-pipe system.
In order to obtain one-pipe working, it is necessary to
unscrew the return plug (2), remove the by-pass screw
(3) and then screw the plug (2) up again, (see fig. 5).
³Before starting the burner make sure that the return
pipeline is not clogged. An excessive back pressure
would cause the damage of the pump seal.
WARNING:
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Valve
8- Auxiliary pressure test point
D5338
H
max. 4 m
Fig. 6

SYSTEM
NOT PERMITTED
IN GERMANY
1
324
8
76
D5487
5
Fig. 5
H
max. 4 m
max. 4 m
H
H
H
D5337
Fig. 7 Fig. 8


3281
6GB
4
3.4 ELECTRICAL WIRING
D4684
230V ~ 50Hz
ATTENTION:
³Do not swap neutral and phase over, follow the diagram
shown carefully and carry out a good earth connection.
³The section of the conductors must be at least 1mm². (Unless
requested otherwise by local standards and legislation).
³The electrical wiring carried out by the installer must be in
compliance with the rules in force in the country.
CONTROL BOX, (see fig. 9)
To remove the control box from the burner it is necessary to:
³disconnect all the connectors, the 7-pin plug, the high voltage cables
and the earth wire (TB);
³unscrew the bolt (A) and pull the control box in the direction of the
arrow.
To install the control box it is necessary to.
³screw the bolt (A) in at a torque of 1 - 1.2 Nm;
³reconnect all the connectors previously disconnected.
NOTES:
The burners have been type-approved for intermittent operation.
This means they must stop at least once every 24 hours in order to al-
low the electrical control box to check its efficiency on start-up.
The boiler limit thermostat (TL) normally ensures the burner halts. If
this does not happen a time switch halting the burner at least once
every 24 hours must be applied in series to (TL).
AE9275
KEY TO LAY-OUT:
C– Capacitor
E– Electrode
F– Flame detector
h1 – Hour counter
MV – Motor
P– Bridge socket
RS – Remote reset
SER – Safety lockout device
S3 – Lock-out signal
(230V - 0.5 A max)
T6A –Fuse
TB – Burner-earth
TL – Limit thermostat
TS – Safety thermostat
V1 –Oilvalve
V2 – Safety lockout device
X7 – 7 pin plug
XP7 – 7 pole socket
TESTING
³Check the burner stops by opening the ther-
mostats.
³Check the burner stops by shading the
flame detector.
CONTROL BOX
MO550
Main switch
Fig. 9
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN FACTORY

3281
7GB
4. BURNER OPERATION
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and
testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of
the combustion head, and the air damper opening in accordance with the following schedule.
The values shown in the table are measured on a CEN boiler (as per EN 267).
They refer to 12.5% CO2at sea level and with light oil and room temperature of 20 °C.
4.2 RECOMMENDED NOZZLES:
Delavan type W - B ; Danfoss type S - B;
Monarch type R ; Steinen type S - Q.
For 3.00 - 3.50 GPH nozzles it is advisable to use full cones.
4.3 PUMP PRESSURE
The pump leaves the factory set at 12 bar.
To change it act on pump pressure adjust screw (4, fig. 5, page 5).
4.4 ELECTRODES ADJUSTMENT (see fig. 10)
MEASURES MUST BE
RESPECTED
Lean the diffuser disc-holder assem-
bly (1) on the nozzle-holder (2) and
lock it by screw (3).
For prospective adjustments loosen
screw (4) and move the electrodes
assembly (5).
To have access to the electrodes car-
ry out operation as described in chap-
ter “4.5 MAINTENANCE POSITION”
(page 8).
Nozzle Pump
pressure
Burner
output
Combustion head
adjustment
Air damper
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
1.75 60° 12 7.0 0 1.3
2.00 60° 12 8.0 1 2.3
2.25 60° 12 9.0 3 2.6
2.50 60° 12 10.0 3.5 3.0
3.00 60° 12 12.0 5 3.5
3.50 60° 12 14.0 6 4.4
3.50 60° 14 15.2 6 5.6
QUALIFIED PERSONNEL WITH THE RIGHT INSTRUMENTS MUST HANDLE THE BURNER'S FIRST
START-UP
!
WARNING
D5085
2
4
3
4.5 – 0.5 mm
0
6 ÷7 mm
1
5
Fig. 10
WARNING

3281
8GB
4.5 MAINTENANCE POSITION
To access the nozzle, do the following:
³Undo the wires (4) from the control box, the
flame detector (5) and undo the nut (3) from
the pump.
³Loosen the screws (2) and extract the nozzle
holder assembly (1) by turning to the right.
³Remove the small cables (4) from the elec-
trodes, loosen the screw (3, fig. 10, page 7)
and remove the diffuser disc-holder assembly
(7) from the nozzle-holder assembly (1).
³Screw up the nozzle (6) holding the nozzle
support with a spanner.
³Refit following the operations in the reverse
order to the one described above.
ATTENTION
During the reassembly of the nozzle-holder as-
sembly screw the nut (3) as shown in the figure
below.
4.6 COMBUSTION HEAD ADJUSTE-
MENT, (see fig. 13)
The adjustment of the combustion head varies
depending on the burner output.
Do the following to adjust it:
³Rotate the setting screw (8) clockwise or counter-
clockwise until the set-point marked on the regu-
lating rod (9) is level with the outside plane of the
nozzle-holder assembly (1).
³In the example the regulating rod (9) is set at
notch 3; this means that the burner is regulated
for an output of 9 Kg/h with pump pressure at
12 bar and with the use of a nozzle of 2.25 GPH,
as indicated in the reference table.
4.7 AIR DAMPER ADJUSTMENT,
(see fig. 13)
To regulate the air damper, do the following:
³Loosen the nut (10) and set the air damper by
turning the screw (11).
³When burner shuts down the air damper automat-
ically close still a max. chimney depressure of 0.5 mbar.
³When the adjustment is completed do the nut (10) up again.
4 12
3
5
7
Fig. 11
6
E9317
TIGHTEN WITHOUT MOVING
BACKWARDS TO THE END D5684
3
Fig. 12
118
9
Fig. 13
1
10

3281
9GB
4.8 OPERATING PROGRAMME
4.8.1 NORMAL OPERATION WITH PREHEATING
KEY TO LAY-OUT
F– Flame detector
I– Ignition transformer
LED – Reset button LED indicating operating
status
MV – Fan motor
TL – Limit thermostat
V1 –Oilvalve
t1 Waiting time of a control box input signal: reaction time,
the control box stands still for the time t1.t4i Transformer turn on time: total turn on time ts +t5i.
t1I Presence of extraneous light before the heat request: if
the presence of light during the t1l time, a block follows. t5i Transformer post- turn on time: additional turn on time after ts.
t2 Wait time after a request for heat:
the control box stays still for the t2 time. t4I Flame loss in operation: maximum oil valve drop reac- tion time, after three recycle attempts a block follows.
t3 Pre-purging time:
start of the fan motor. t6
Post-purging time:
additional purging time on the opening of the heat limit
thermostat (TL)
t3I Presence of an extraneous light during pre-purging:
immediate block. t6I Presence of an extraneous light during post-purging. if the presence of light lasts the t6l time, a block follows.
ts Safety time: if at the end of the ts time there is no flame,
a block follows. t7 Long pre-purging time: pre-purging time more than t3.
OPERATING TIMES
Time is expressed in seconds
t1 max 1 t4i -8
t1I max 30 t5i -3
t2 -3 t4I max 1
t3 -15 t6 max 360
t3I max 1 t6I max 30
ts -5 t7 -120
Red
Green + Yellow slow blinking
Green + Yellow fast blinking
Green
Green + Yellow medium blinking
Red + Yellow fast blinking
Yellow fast blinking
t 2
t 1
t 3
t 4i
t s t 5i
TL
MV
I
V1
F
LED
F
LED
P
M
.
t 4l
D7359
Yellow Yellow
MV = stopped
Yellow Yellow Yellow
Red
Lockout
No signal needs to be received
Green
Green
Loss of flame during operation (Recycle max. 3 attempts)

3281
10 GB
4.8.2 LOCKOUT DUE TO FIRING FAILURE
KEY TO LAY-OUT
F– Flame detector
I– Ignition transformer
LED – Reset button LED indicating operating
status
MV – Fan motor
TL – Limit thermostat
V1 –Oilvalve
4.8.3 LOCKOUT DUE TO EXTRANEOUS LIGHT
DURING PRE-PURGING
OPERATING TIMES
Time is expressed in seconds
t1 max 1 t4i -8
t1I max 30 t5i -3
t2 -3 t4I max 1
t3 -15 t6 max 360
t3I max 1 t6I max 30
ts -5 t7 -120
Red
Green + Yellow slow blinking
Green + Yellow fast blinking
Green
Green + Yellow medium blinking
Red + Yellow fast blinking
Yellow fast blinking
t 2
t 1
t 3
t 4i
t s
TL
MV
I
V1
F
LED
P
M
t 2
t 1
t 3
t s
TL
MV
I
V1
P
M
.
LED
F
t 3l
D7360
Green Red
Green+Yellow
Green Red+Yellow
Lockout
D7361

3281
11 GB
COLOUR CODE OF THE CONTROL BOX RESET BUTTON LED
(*) only for applications where this is an option.
4.8.4 LOCKOUT TYPES AND TRIGGERING TIMES IN CASE OF BURNER MALFUNCTION
(*) only for applications where this is an option.
4.8.5 CONTROL BOX RESET
To carry out the control box reset, proceed as follows:
³Hold the reset button down for between 1 and 2 seconds. If the burner does not restart, you must make sure
the limit point thermostat (TL) is closed.
³If the control box reset button keeps flashing, reporting the cause of the malfunction (RED LED), you
must press the button again, holding it down for no more than 2 seconds.
4.8.6 RE-CYCLE FUNCTION
The control box allows re-cycling, i.e. the complete repetition of the starting programme, for 3 attempts maxi-
mum, in the event the flame goes out during operation.
If the flame goes out again, this will cause the burner to lock out. If there is a new demand for heat during the
recycle, the 3 attempts are reset when the limit thermostat (TL) switches.
4.8.7 LOGGING OF BURNER OPERATION PARAMETERS
With this control box, data - i.e. the number of lockouts that have occurred, the type of lockout that has
occurred (just the last one) and the oil valve opening operating time - can be logged even when there is no
power supply. That way, you can determine how much fuel has been consumed during operation.
To view these parameters, you will need to connect the software diagnostics kit, as described in section
(1.2) on page 2.
Operating status LED colour codes Flashing
speed
ON OFF
Seconds
Standby LED unlit
Pre-purging Green
Long pre-purging Green
Transformer ignition Green + Yellow flashing Fast 0.3 0.3
Regular flame Green + Yellow flashing Slow 0.3 2
Post-purging Green + Yellow
Recycle Green + Yellow flashing Medium 2 1
Continuous purging (*)Green
Extraneous light during standby Yellow blinking Fast 0.3 0.3
Extraneous light during post- or continuous purging (*)Green + Yellow flashing Fast 0.3 0.3
Extraneous light during lockout Red + Yellow flashing Fast 0.3 0.3
Lockout Red
Lockout with continuous purging (*)Red + Green
DESCRIPTION OF FAULT TYPES LOCKOUT
Extraneous light when the burner is turned on and off After max. 30 seconds
Extraneous light detected during pre-purging Within 1 second
Extraneous light detected during post-purging or continuous purging (*) After max. 30 seconds
Flame goes out during operation After 3 recycles
No flame is detected after safety time Immediate

3281
12 GB
4.9 ADDITIONAL PROGRAMMABLE CONTROL BOX FUNCTIONS
4.9.1 POST-PURGING FUNCTION (t6)
Post-ventilation is a function that maintains air ventilation even after the burner is switched off. The burner
switches off when the limit thermostat (TL) opens, cutting off the fuel supply to the valves.
To use this function the reset button must be pressed when the limit thermostat is not switched over
(burner switched off). Post-ventilation time can be set to a maximum of 6 minutes. Proceed as follows:
³Press and hold the reset button for at least 5 seconds till the LED indicator changes to red.
³Set the desired time pressing the button repeatedly: once = post-ventilation for 1 minute.
³After 5 seconds the control box automatically shows the minutes set by the red LED flashing:
1 pulse = post-ventilation for 1 minute.
To reset this function, press and hold the button for at least 5 seconds, till the LED indicator changes to red then
release it without carrying out any operation, then wait for 20 seconds for the burner to start.
If during post-purging there is a new request for heat, post-purging time is halted and a new operating cycle
starts when the limit thermostat (TL) switches over.
If there is extraneous light during post-purging, the burner locks out after 30 seconds.
The control box leaves the factory with the following setting: 0 minutes = no post-purging.
4.9.2 CONTINUOUS PURGING FUNCTION, (only for applications where this is an option)
Continuous purging is a function that keeps air purging on regardless of whether burner ignition is being
requested. As soon as this mode is set, the motor keeps running both when the limit thermostat (TL) is not
switched (burner off) and when the burner is locked out.
Only when the limit thermostat (TL) switches will the motor stop for the standby time of 4 seconds (standby posi-
tion = t2 + t1).
The function can be set with the reset button, when the limit thermostat (TL) is not switched (burner off),
following the procedure in section 4.9.1 post-purging function, by pressing the button 7 times = continu-
ous purging.
To reset this function, simply hold the button down for 5 seconds until the indicator LED goes red and release it
without performing any operation, then wait at least 20 seconds to allow the burner to restart.
If there is extraneous light when the limit thermostat (TL) switches, the motor stops for as long as the extrane-
ous light persists, after which there is a lockout.
The control box's factory setting is as follows: 0 minutes = no continuous purging.
4.9.3 LONG PRE-PURGING FUNCTION (t7)
Long pre-purging is a feature that can be used to lengthen the air purging period to 2 minutes from when the
limit thermostat (TL) switches to when the flame ignites. The function can be set with the reset button, when the
limit thermostat (TL) is not switched (burner off), following the procedure in section 4.9.1 post-purging function,
by pressing the button 8 times = long pre-purging.
To reset this function, simply hold the button down for 5 seconds until the indicator LED goes red and release it
without performing any operation, then wait at least 20 seconds to allow the burner to restart.
The control box's factory setting is as follows: 0 minutes = no long pre-purging.
4.9.4 FUNCTION SETTING PROCEDURE USING RESET BUTTON
Control box
function
Action with
reset button
Reset button
in enabled status
Reset 1 to 2 seconds After control box lockout
Visual diagnostics of lockout causes
(5.1) 3 seconds After control box lockout
Post-purging (4.9.1) 5 seconds then
press once = 1 minute
With limit thermostat (TL) not
switched (burner off)
Continuous purging (4.9.2)
(only for applications where this is an
option)
5 seconds then
press 7 times = continuous purging
With limit thermostat (TL) not
switched (burner off)
Long pre-purging (4.9.3) 5 seconds then
press 8 times = long pre-purging
With limit thermostat (TL) not
switched (burner off)
Resetting set functions 5 seconds With limit thermostat (TL) not
switched (burner off)
Resetting operation parameters 5 seconds With limit thermostat (TL) switched
during pre-purging

3281
13 GB
5. MAINTENANCE
Disconnect the electric supply to the burner by switching off the main power switch and close the light
oil shut-off valve before maintaining or checking the system.
The burner requires scheduled maintenance that must be carried out by qualified personnel and in compliance
with local legislation.
Scheduled maintenance is vital for the smooth operation of the burner; it avoids waste of fuel and reduces harm-
ful emissions into the atmosphere.
THE FUNDAMENTAL OPERATIONS TO CARRY OUT ARE AS FOLLOWS:
³Check there are no occlusions or obstructions in the inlet or return pipes, in the air suction areas and in the
combustion product waste pipe.
³Check that the positioning of the combustion head is correct and that it is properly fixed to the boiler.
³Clean the combustion head at the fuel outlet.
³Clean the fuel suction line filter and the pump filter.
³Check that the burner electrical connections are correct.
³Clean the flame detector.
³Check for correct fuel consumption.
³Check that the combustion head (fig. 13, page 8) and the air damper (fig. 13, page 8) have been regulat-
ed properly.
³Replace the nozzle (fig. 11, page 8) if necessary and check the correct position of electrodes (fig. 10,
page 7).
³Clean the fan.
Leave the burner working without interruptions for 10 min. and check the right settings at 1st and 2nd stage
of all components stated in this manual. Then carry out the analysis of the combustion by checking:
- Smoke index as per the Bacharach scale; - CO2percentage (%); - CO content (ppm);
- NOx content (ppm); - Smoke temperature at the chimney.
5.1 CONTROL BOX VISUAL DIAGNOSTIC
The control box has a diagnostic function that can identify the likely causes of any malfunctions (indicator:
RED LED).
In order to be able to use this function, press and hold the reset button for at least 3 seconds from when the
appliance is made safe (lock-out).
The control box sends a sequence of pulses that are repeated at 2-second intervals.
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are
listed in the table below.
SIGNAL PROBABLE CAUSE
2pulses
The flame does not stabilise at the end of the safety time:
– flame detector faulty or dirty;
– oil valve faulty or dirty;
– faulty ignition transformer;
– poor burner regulation.
4pulses
Light present in the chamber before the burner’s switching on or off:
– presence of a strange light before or after the limit thermostat switching
over;
– presence of a strange light during pre-purging;
– presence of a strange light during post-ventilation.
2sPulses Pulses
RED LED illuminated
press reset for 3 sec.
Interval

3281
14 GB
To reset the control box after the diagnostics display, press the lockout-reset button.
6. FAULTS / SOLUTIONS
Below is a list of some of the causes and possible solutions to a series of problems that might be encountered
and could cause a failure to start or irregular burner operation.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box (3, fig.
1, page 2).
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the
burner functions correctly, the lock-out can be attributed to a temporary fault.
However, if lockout continues, you must determine the cause of the problem and take the action illustrated in the
solution column in the tables below.
6.1 START-UP PROBLEMS
SIGNAL PROBABLE CAUSE
7pulses
Loss of flame during operations:
– poor burner regulation (insufficient gas);
– oil valve faulty or dirty;
– flame detector faulty or dirty.
8pulses
Check and monitor oil heater (if fitted):
– check the correct position of the bridge socket "P".
FAULT POSSIBLE CAUSES SOLUTION
The burner doesn’t
start when the limit
thermostat closes.
Lack of electrical supply.
Check presence of voltage in the
L1 - N clamps of the 7 pin plug.
Check the conditions of the fuses.
Check that safety thermostat is not
lock out.
Bridge socket “P” missing or discon-
nected. Connect it up properly.
The connections in the control box
are wrongly inserted.
Check and connect completely all the
plugs.
The burner goes in
safety lock-out
before or during the
pre-purge phase.
The flame detector sees strange light. Eliminate the light.
Burner runs normal-
ly in the prepurge
and ignition cycle
and locks out after 5
seconds ca.
The flame detector is dirty. Clear it.
The flame detector is defective Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve.
ATTENTION

3281
15 GB
6.2 OPERATING IRREGULARITIES
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned.
Adjust them according to the
instructions of this manual.
Air output is too high. Set the air output according to the
instructions of this manual.
Nozzle dirty or worn. Replace it.
FAULT POSSIBLE CAUSES SOLUTION
Burner locks out
during operation.
Flame disappears 4 times.
Clean or replace flame detector.
Replace dirty or deteriorated nozzle.
Does not shut down.
Check efficiency of flame detector.
Check efficiency of pressure regulator's
piston.
Check efficiency of pump's on-off valve.
FAULT POSSIBLE CAUSES SOLUTION

3281
16 GB
7. WARNINGS AND SAFETY
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.
You are therefore advised to consult the Technical Assistance Department before choosing this type of burn-
er for the combination with a boiler. Qualified personnel are those with the professional and technical re-
quirements indicated by law No. 46 dated March 5, 1990 n° 46.
The commercial organisation has a widespread network of agencies and technical offices whose personnel
participates periodically in instructional and refresher courses at the company training centre.
This burner must only be used for the purposes it has specifically been designed for.
All contractual and other liability on the part of the manufacturer is excluded for injury caused to people, an-
imals or damage caused to property due to faulty installation, calibration, adjustment, maintenance or im-
proper use.
7.1 BURNER IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and performance
data. If the Identification Plate is tampered with, removed or missing, the product cannot be clearly identi-
fied thus making any installation or maintenance work potentially dangerous.
7.2 BASIC SAFETY MEASURES
³Children or inexpert persons must not use the appliance.
³Under no circumstances must the intake grids, dissipation grids and ventilation vents in the installation
room be covered up with cloths, paper or any other material.
³Unauthorised persons must not attempt to repair the appliance.
³It is dangerous to pull or twist the electric leads.
³Cleaning operations must not be performed if the appliance is not disconnected from the main power supply.
³Do not clean the burner or its parts with inflammable substances (e.g. petrol, alcohol, etc.). The cover
must be cleaned with soapy water.
³Do not place anything on the burner.
³Do not block or reduce the size of the ventilation vents in the installation room.
³Do not leave containers and inflammable products in the installation room.

RIELLO S.p.A.
I-37048 San Pietro di Legnago (VR)
Tel.: [phone]
http:// www.rielloburners.com