Riello 40 FS5 Quick start guide

Installation, use and maintenance instructions
20065652 (6) - 02/2024
Forced draught gas burners
One-stage operation
CODE MODEL TYPE
3756615 RIELLO 40 FS5 566 M
20025106 RIELLO 40 FS5 566 M
GB

Translation of the original instructions

1 20065652
GB
Contents
1 Information and general warnings............................................................................................................................................ 3
1.1 Information about the instruction manual .................................................................................................................... 3
1.1.1 Introduction.................................................................................................................................................................. 3
1.1.2 General dangers.......................................................................................................................................................... 3
1.1.3 Other symbols ............................................................................................................................................................. 3
1.1.4 Delivery of the system and the instruction manual...................................................................................................... 4
1.2 Guarantee and responsibility....................................................................................................................................... 4
2 Safety and prevention................................................................................................................................................................ 5
2.1 Introduction.................................................................................................................................................................. 5
2.2 Personnel training ....................................................................................................................................................... 5
3 Technical description of the burner ......................................................................................................................................... 6
3.1 Burner designation ...................................................................................................................................................... 6
3.2 Models available.......................................................................................................................................................... 6
3.3 Burner categories - Countries of destination ............................................................................................................... 6
3.4 Technical data ............................................................................................................................................................. 7
3.5 Maximum dimensions.................................................................................................................................................. 7
3.6 Firing rate .................................................................................................................................................................... 8
3.6.1 Test boiler.................................................................................................................................................................... 8
3.6.2 Commercial boilers...................................................................................................................................................... 8
3.7 Correlation between gas pressure and burner output ................................................................................................. 8
3.8 Burner description ....................................................................................................................................................... 9
3.9 Burner equipment........................................................................................................................................................ 9
3.10 Flame control............................................................................................................................................................. 10
4 Installation ................................................................................................................................................................................ 11
4.1 Notes on safety for the installation ............................................................................................................................ 11
4.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 11
4.3 Handling .................................................................................................................................................................... 11
4.4 Preliminary checks .................................................................................................................................................... 12
4.4.1 Control of the supply ................................................................................................................................................. 12
4.4.2 Control of burner characteristics ............................................................................................................................... 12
4.5 Operating position ..................................................................................................................................................... 12
4.6 Securing the burner to the boiler ............................................................................................................................... 13
4.6.1 Hinge installation ....................................................................................................................................................... 13
4.7 Positioning the probe - electrode............................................................................................................................... 13
4.8 Combustion head adjustment.................................................................................................................................... 14
4.9 Gas feeding ............................................................................................................................................................... 15
4.9.1 Gas feeding line ........................................................................................................................................................ 15
4.9.2 Gas train.................................................................................................................................................................... 15
4.9.3 Gas train installation.................................................................................................................................................. 16
4.10 Electrical wiring ......................................................................................................................................................... 17
4.10.1 Notes on safety for the electrical wiring..................................................................................................................... 17
4.10.2 Ionisation current....................................................................................................................................................... 17
5 Start-up, calibration and operation of the burner ................................................................................................................. 18
5.1 Notes on safety for the first start-up .......................................................................................................................... 18
5.2 Adjustments prior to ignition ...................................................................................................................................... 18
5.3 Combustion adjustment............................................................................................................................................. 18
5.4 Air pressure switch .................................................................................................................................................... 18
5.5 Operation sequence of the burner............................................................................................................................. 19
5.5.1 Start-up programme visual diagnostics ..................................................................................................................... 19
5.5.2 Normal operation / flame detection time.................................................................................................................... 19
6 Maintenance.............................................................................................................................................................................. 20
6.1 Notes on safety for the maintenance......................................................................................................................... 20
6.2 Maintenance programme .......................................................................................................................................... 20
6.2.1 Maintenance frequency ............................................................................................................................................. 20
6.2.2 Safety test - with gas ball valve closed...................................................................................................................... 20
6.2.3 Checking and cleaning .............................................................................................................................................. 20
6.2.4 Safety components.................................................................................................................................................... 21
6.3 Opening the burner ................................................................................................................................................... 22
7 Faults - Possible causes - Solutions ...................................................................................................................................... 23

20065652 2 GB
Contents
7.1 Tracing the causes of the malfunctioning ..................................................................................................................23
7.1.1 Flame control reset ....................................................................................................................................................23
7.1.2 Visual diagnostics ......................................................................................................................................................23
7.1.3 Software diagnostics ..................................................................................................................................................23
A Appendix - Accessories ...........................................................................................................................................................27
B Appendix - Electrical panel layout...........................................................................................................................................28

3 20065652
GB
Information and general warnings
1.1 Information about the instruction manual
1.1.1 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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
1 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20065652 4 GB
Information and general warnings
1.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician. To ensure a periodic
check, the manufacturer recommends the drawing up of a
Maintenance Contract.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

5 20065652
GB
Safety and prevention
2.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the 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 envisaged by the manufacturer can be
replaced.
2.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

20065652 6 GB
Technical description of the burner
3.1 Burner designation
3.2 Models available
Tab. A
3.3 Burner categories - Countries of destination
Tab. B
3 Technical description of the burner
Designation Voltage Code
RIELLO 40 FS5 1/230/50 3756615
RIELLO 40 FS5 1/230/50 20025106
Range: RIELLO 40 F
Size
Fuel: Natural gas
Light oil
LPG
Variations:
Electrical supply of the system: 1/230/50
1/230/60
F S 5 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
1/230V/50Hz
1/230V/60Hz
Light oil - Natural gas
K Conical head
S Reduced ignition output
D Two-stage
R Light oil with pre-heater
S
-
SP
D
Head: TC Standard head
TL Long head
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L - I2E - I2 (43,46 ÷ 45,3 MJ/m3 (0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E

7 20065652
GB
Technical description of the burner
3.4 Technical data
Tab. C
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
3.5 Maximum dimensions
The maximum dimensions of the flange and burner are given in
Fig. 1.
Model RIELLO 40 FS5
Type 566 M
Heat output (Hi) (1) min - max kW
kcal/h
23  58
20.000  50.000
Fuel Family 2 NCV 8  12 kWh/m3 – 7,000 10,340 kcal/m3
Pressure: min. 16 mbar – max. 200 mbar
Operation Intermittent (FS1)
Use Boilers: water and diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Electrical supply 1/230V/50Hz
Absorbed electrical power kW 0.15
Protection level IP40
Weight kg 10
Noise levels (2) Sound pressure
Sound power dB(A) 59.4 70.8
CE No. EC-0476CT2714
Fig. 1
Flange Burner
272 100 295
Ø 170
130 28 48
45°
45°
Ø 91
233
10
140
Rp 1/2
180
138
D5066

20065652 8 GB
Technical description of the burner
3.6 Firing rate
The burner output is chosen from within the diagram area
(Fig. 2).
3.6.1 Test boiler
The firing rate has been defined according to EN 676 standard.
3.6.2 Commercial boilers
The burner-boiler matching is assured if the boiler conforms to
EN 303 and the combustion chamber dimensions are similar to
those shown in the diagram EN 676.
For applications where the boiler does not conform to EN 303, or
where the combustion chamber is much smaller than the dimen-
sions given in EN 676, please consult the manufacturers.
3.7 Correlation between gas pressure and burner output
To obtain the maximum output (Fig. 3), it is necessary to have 4.6
mbar measured on the pipe coupling, with the combustion cham-
ber at 0 mbar and gas G20 - NCV = 10 kWh/Nm3 (8,570 kcal/Nm3).
WARNING
The firing rate value (Fig. 2) 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 14.
Fig. 2
Combustion chamber
pressure - mbar
Thermal power
0.8
0
0.2
0.4
0.6
20,000 30,000 50,000 kcal/h
20 30 60 kW
D5053
1.0
40 50
40,000
20 30 40 50 60 kW
20,000 30,000 40,000 50,000 kcal/h
6
5
4
1
2
3
Gas pressure at
Thermal power
D5054
Fig. 3
combustion head - mbar

9 20065652
GB
Technical description of the burner
3.8 Burner description
1 Air damper
2 Damper fixing screws
3 Pressure test point (-)
4 Cover fixing screw
5 Air pressure switch
6 Motor
7 Lock-out signal with reset button
8 Flame control
9 6-pole socket for gas train
10 Capacitor
11 Gas train elbow
12 Flange
13 Pressure test point (+)
14 Combustion head
15 Electrode-probe
16 7-pole socket
3.9 Burner equipment
Screws with nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Insulating gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Cover fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 3
Cable grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
7-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 6
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
20066142
Fig. 4
WARNING
The cable grommet, supplied as standard, should
be assembled on the same side of the gas train.
Check that it is possible to access the cover fixing
screws once the burner has been installed. If nec-
essary, replace them with the ones supplied as
standard.

20065652 10 GB
Technical description of the burner
3.10 Flame control
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the flame control connection
area, fully disconnect the system from the power supply
(omnipolar separation). Check the system is not powered
and cannot be accidentally reconnected. Failure to do this
will lead to the risk of electrocution.
Protection against electrocution from the flame control and
all connected electric components is obtained with the cor-
rect assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions.
In this case, the flame control must not be operated, even if
it displays no evident damage.
Press the reset button of the burner lockout command or the
reset button (by applying a force of not more than 10 N),
without the aid of tools or sharp objects.
For the safety and reliability of the flame control, comply with
the following instructions:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire flame control is perfectly dry!
– Static charges must be avoided since they can damage the
flame control’s electronic components when touched.
Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the flame control and the other cables.
• When wiring the unit, make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
–
Technical data
Mechanical structure
The flame control is made of plastic to resist knocks, heat and
flame propagation.
The flame control contains the following components:
• a microprocessor that controls the program sequence, and a
relay for controlling the load;
• an electronic flame signal amplifier;
• a built-in reset button with 3 signalling colours (LED) for status
and error messages.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The flame control is a safety device! Avoid open-
ing or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Mains voltage AC 220...240 V +10 % / -15 %
Mains frequency 50 / 60 Hz ±6%
Power absorption 12 VA
Protection level IP20
Safety class I
Weight approx. 260 g
Cable length
Thermostat
Air pressure switch
Gas pressure switch
Remote reset
CPI
Ionisation probe
Max. 20 m at 100 pF/m
Max. 3 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 3 m at 100 pF/m
Max. 3 m at 100 pF/m
Operational climatic conditions:
Temperature range
Humidity
-20...+60°C
< 95 % r.h.
Fig. 5
S8906

11 20065652
GB
Installation
4.1 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.
4.2 Instructions to avoid burnout or bad combustion of the burner
1 The burner can not be installed outside as it is suitable for
operation in closed rooms only.
2 The premises the burner operates in must have openings
for the air need for the combustion. To be sure about this,
you have to control CO2 and CO in the exhaust gases with
all the windows and doors closed.
3 If there are air extractors in the premises the burner works,
make sure that there are openings for air to be taken in that
are big enough to ensure the required air change; In any
case, check that when the burner stops the extractors do
not draw hot fumes from pipes through the burner.
4 When the burner is stopped, the smoke pipe must be kept
open and a natural draft created in the combustion chamber.
If the smoke pipe is closed, the burner must be drawn back
till the extraction of blast tube from the furnace. Before oper-
ating in this way take the voltage off.
4.3 Handling
The transport weight is given in chapter "Technical data" on page 7.
Observe the permissible ambient temperatures for storage and
transport: -20 ..... + 70 °C, with max. relative humidity. 80%.
4 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
Refer to paragraph “Safety test - with gas ball
valve closed” on page 20 before the first start-
up.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
The operator must use the required equipment
during installation.

20065652 12 GB
Installation
4.4 Preliminary checks
4.4.1 Control of the supply
4.4.2 Control of burner characteristics
Check the identification label of the burner (Fig. 6), showing:
A the burner model;
B the burner type;
C the cryptographic year of manufacture;
D the serial number;
E the data for electrical supply and the protection level;
F the electrical power consumption;
G the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate).
Warning. The burner output must be within the boiler's firing
rate.
4.5 Operating position
CAUTION
After removing all the packaging, check the integ-
rity of the contents.
In the event of doubt, do not use the burner; con-
tact the supplier.
The packaging elements (cardboard box, 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 appro-
priate 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.
WARNING
The figure of the label (Fig. 6) is indicative. Some
of the data may be arranged in a different position.
Fig. 6
20065195
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 7).
Installation 1 is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Installation 5 is prohibited for safety reasons.
Fig. 7
20065196
2 3 4 51

13 20065652
GB
Installation
4.6 Securing the burner to the boiler
4.6.1 Hinge installation
Install the hinge 4), supplied as standard, as shown in Fig. 8.
Separate the combustion head assembly from the burner
body by removing nut 1) and removing the group A)(Fig. 9).
Fix the group B)(Fig. 9) to the boiler plate 2), inserting the
supplied insulating gasket 3).
4.7 Positioning the probe - electrode
Provide an adequate lifting system of the burner.
S7392 Fig. 8
4
WARNING
The seal between burner and boiler must be
airtight.
D5067
Fig. 9
A B
1 3 2
WARNING
Do not turn the ignition electrode but leave it as
shown in Fig. 10.
if the ignition electrode is put near the ionisation
probe, the flame control amplifier might be dam-
aged.
WARNING
Place the ceramic part of the electrode A) against
the diffuser disc B)(Fig. 10).
Fig. 10
D5033
ElectrodeDiffuser
2.5 - 3.5 mm
Probe
Probe
Electrode
2.0
B A

20065652 14 GB
Installation
4.8 Combustion head adjustment
To adjust, proceed as follows:
loosen the screw A)(Fig. 11), move the elbow B) so that the
rear plate of the coupling (C) coincides with the set point;
tighten the screw A).
Example:
The burner is installed in a 40 kW boiler.
Considering efficiency of 90% the burner must supply around 44
kW.
The diagram (Fig. 12) shows that for this output the adjustment
must be made on notch 3.
The diagram is to be used only for initial settings. To ensure good
air pressure switch operation it may be necessary to reduce this
combustion head opening (notch toward pos. 0).
C
A
B
S7015
Fig. 11
Fig. 12
kcal/h kW
D5137
Notch No.
70
50
40
30
20
10
60
40,000
50,000
30,000
20,000
10,000
60,000
0 21 3 4 5
44

15 20065652
GB
Installation
4.9 Gas feeding
4.9.1 Gas feeding line
Key (Fig. 13Fig. 14)
1 Gas input pipe
2 Manual gate (the responsibility of the installer)
3 Gas pressure gauge (the responsibility of the installer)
4 Filter
5 Gas pressure switch
6 Safety valve
7 Pressure stabiliser
8 Adjustment valve
M1 Gas-supply pressure test point on the pressure switch
M2 Pressure coupling test point
4.9.2 Gas train
Approved according to standard EN 676 and provided separately
from the burner. Supplied separately for its adjustment, see the
enclosed instructions.
The train-burner combination is indicated in Tab. D.
Tab. D
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
Fig. 13
1
D7733
M2
2 3 M1 4 5 6 8 7
MBC 65/1
Fig. 14
D5069
M2
1 2 3 M1 4 5 6 7 8
MB 405/1
Code Model Connections Use
Gas train Burner
3970569 MBC 65/1 - RSD 20 Rp 1/2 Rp 1/2 Natural gas and LPG
3970530 MB 405/1 - RSD 20 Rp 1/2 Rp 1/2 Natural gas and LPG

20065652 16 GB
Installation
4.9.3 Gas train installation
The gas train MBC 65/1 1)(Fig. 15) leaves the factory ready for
installation to the burner's left. If it is to be installed on the right,
fit the valve turned by 90° with respect to the gas-out flange and
with the gas pressure switch pointed upwards.
The gas train MBC 405/1 1)(Fig. 16) leaves the factory ready for
installation both on the right and left of the burner.
Connection between the gas supply line and the train must be
made using the gas-in flange 3) supplied, and fastening screws.
Connect the 6 pin plug 2)(Fig. 15 and Fig. 16) of the gas train to
the 6 pole socket 9)(Fig. 4 on page 9) of the burner.
DANGER
Disconnect the electrical power using the main
switch.
Check that there are no gas leaks.
Pay attention when handling the train: danger of
crushing of limbs.
Make sure that the gas train is properly installed
by checking for any fuel leaks.
WARNING
It is best to tighten screws in a criss-cross pattern.
Do not, under any circumstances, install the valve
with the coil facing down.
WARNING
Once installation is complete, you must check for
fuel leaks and make sure the gas train is working
properly.
20065208
MBC 65/1
Fig. 15
Fig. 16
20065572
MB 405/1

17 20065652
GB
Installation
4.10 Electrical wiring
4.10.1 Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
4.10.2 Ionisation current
The minimum current necessary for the flame control operation is
3 µA. The burner normally supplies a higher current value, so that
no control is needed. In any event, if you want to measure the ion-
isation current, you need to open the connector fitted on the red
wire and insert a microammeter as shown in Fig. 17.
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
Electrical wiring must be made in accordance with the regulations currently in force in the country of destination
and by qualified personnel. Refer to the wiring diagrams.
The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-
ing diagrams.
Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual.
The burner has been type-approved for intermittent use. In the event of continuous operation, a cycle arrest must
be ensured within 24 hours with the use of a time switch positioned in series with the thermostatic line. Refer to
the wiring diagrams.
The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event of
doubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing system
for electrical devices.
The electrical system must be suitable for the maximum power absorption of the device, as indicated on the label
and in the manual, checking in particular that the section of the cables is suitable for that level of power absorp-
tion.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use a multiple pole switch with at least a 3 mm gap between the contacts (overvoltage category III), as envis-
aged by the present safety standards.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.
DANGER
Disconnect the electrical supply from the burner
by means of the main system switch.
DANGER
Turn off the fuel interception tap.
DANGER
Avoid condensate, ice and water leaks from form-
ing. Fig. 17
D5006 Probe
Connector
Flame control

20065652 18 GB
Start-up, calibration and operation of the burner
5.1 Notes on safety for the first start-up
5.2 Adjustments prior to ignition
Check the adjustment of the head as shown on page 14.
Check the adjustment of the air damper.
Slowly open the manual valves situated upstream from the
gas train.
Adjust the air pressure switch (Fig. 18) to the start of the
scale.
Purge the air from the gas line. We recommend using a plas-
tic tube routed outside the building and to purge air until gas
is smelt.
5.3 Combustion adjustment
In conformity with EN 676 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.
It is advisable to set the burner according to the type of gas used
and following the indications in Tab. E.
Tab. E
5.4 Air pressure switch
Adjust the air pressure switch (Fig. 18) after performing all other
burner adjustments with the air pressure switch set to the start of
the scale.
With the burner function at the required output, turn the knob
slowly in a clockwise direction until burner lockout.
Then turn the knob anticlockwise to an extent that is around 20%
of the adjusted value and then check that the burner starts up
properly.
If the burner locks out again turn the knob slightly in an anticlock-
wise direction.
5 Start-up, calibration and operation of the burner
WARNING
The first start-up 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
Check the correct working of the adjustment, com-
mand and safety devices.
CAUTION
Before starting up the burner, it is good practice to
adjust the gas train so that ignition takes place in
conditions of maximum safety, i.e. with gas deliv-
ery at the minimum.
EN 676 Air excess: max. output.   1.2 – min. output  1.3
GAS
Theoretical max
CO2
0 % O2
Setting CO2 % CO
mg/kWh
NOx
mg/kWh
 = 1.2  = 1.3
G 20 11.7 9.7 9.0  100  170
G 25 11.5 9.5 8.8  100  170
G 30 14.0 11.6 10.7  100  230
G 31 13.7 11.4 10.5  100  230
WARNING
In conformity with the standard, the air pressure
switch must prevent the air pressure falling below
80% of the adjusted value and the CO in the flue
gases exceeding 1% (10,000 ppm).
To check this, insert a combustion analyser in the
flue, slowly reduce the burner air setting (for ex-
ample with a piece of cardboard) and verify that
the burner locks out before the CO value in the
flue gases exceeds 1%.
Fig. 18
D7404