Riello 40 GS5 Quick start guide

Installation, use and maintenance instructions
20063761 (2) - 09/2013
Forced draught gas burner
One-stage operation
CODE MODEL TYPE
3755219 RIELLO 40 GS5 552 T1
GB

Translation of the original instructions

1 20063761
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual.................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination............................................................................................................... 7
4.4 Technical data............................................................................................................................................................. 8
4.5 Maximum dimensions.................................................................................................................................................. 8
4.6 Firing rate.................................................................................................................................................................... 9
4.6.1 Test boiler.................................................................................................................................................................... 9
4.6.2 Commercial boilers...................................................................................................................................................... 9
4.7 Correlation between gas pressure and burner output................................................................................................. 9
4.8 Burner description..................................................................................................................................................... 10
4.9 Burner equipment...................................................................................................................................................... 10
4.10 Electrical control box................................................................................................................................................. 11
4.11 Actuator..................................................................................................................................................................... 12
5 Installation ................................................................................................................................................................................ 13
5.1 Notes on safety for the installation............................................................................................................................ 13
5.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 13
5.3 Handling.................................................................................................................................................................... 13
5.4 Preliminary checks.................................................................................................................................................... 14
5.4.1 Control of the supply ................................................................................................................................................. 14
5.4.2 Control of burner characteristics ............................................................................................................................... 14
5.5 Operating position..................................................................................................................................................... 14
5.6 Securing the burner to the boiler............................................................................................................................... 15
5.6.1 Hinge installation....................................................................................................................................................... 15
5.7 Positioning the probe - electrode............................................................................................................................... 15
5.8 Combustion head adjustment.................................................................................................................................... 16
5.9 Air damper adjustment.............................................................................................................................................. 16
5.10 Gas feeding............................................................................................................................................................... 17
5.10.1 Gas feeding line ........................................................................................................................................................ 17
5.10.2 Gas train.................................................................................................................................................................... 17
5.10.3 Gas train installation.................................................................................................................................................. 18
5.11 Electrical wiring ......................................................................................................................................................... 19
5.11.1 Notes on safety for the electrical wiring..................................................................................................................... 19
5.11.2 Control box................................................................................................................................................................ 19
5.11.3 Electrical diagram...................................................................................................................................................... 20
5.11.4 Ionisation current....................................................................................................................................................... 20
6 Start-up, calibration and operation of the burner ................................................................................................................. 21
6.1 Notes on safety for the first start-up.......................................................................................................................... 21
6.2 Adjustments prior to ignition...................................................................................................................................... 21
6.3 Combustion adjustment............................................................................................................................................. 21
6.4 Air pressure switch.................................................................................................................................................... 21
6.5 Operation sequence of the burner............................................................................................................................. 22
6.5.1 Regular operation...................................................................................................................................................... 22
6.5.2 Lockout due to ignition failure.................................................................................................................................... 23
6.5.3 Lockout due to a flame or flame simulation detected during pre-purging.................................................................. 23
6.5.4 Lockout types and triggering times in case of burner malfunction ............................................................................ 24
6.6 Control box reset....................................................................................................................................................... 24
6.6.1 Reset using built-in button......................................................................................................................................... 24
6.6.2 Reset using remote connection................................................................................................................................. 24

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Contents
6.6.3 Colour code of the control box reset button LED.......................................................................................................24
6.7 Recycle function (in the event of flame disappearance during operation) .................................................................24
6.8 Logging of burner operating parameters....................................................................................................................24
6.9 Additional, programmable control box functions........................................................................................................25
6.9.1 Post-purging function (t6)...........................................................................................................................................25
6.9.2 Continuous purging function (only for applications in which this is provided for).......................................................25
6.9.3 Function setting procedure using the reset button.....................................................................................................25
6.10 Visual diagnostics of the control box..........................................................................................................................25
7 Maintenance ..............................................................................................................................................................................27
7.1 Notes on safety for the maintenance.........................................................................................................................27
7.2 Maintenance programme...........................................................................................................................................27
7.2.1 Maintenance frequency..............................................................................................................................................27
7.2.2 Checking and cleaning...............................................................................................................................................27
7.3 Opening the burner....................................................................................................................................................28
8 Faults - Possible causes - Solutions.......................................................................................................................................29
8.1 Start-up problems ......................................................................................................................................................29
8.2 Operating faults..........................................................................................................................................................30
A Appendix - Accessories ...........................................................................................................................................................31

3 20063761
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burner
Model: RIELLO 40 GS5
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.rielloburners.com
Distributed by: RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration of
Conformity and has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of
January 8th 2004 and July 17th 2009.
Type of product: Forced draught gas burner
Model: RIELLO 40 GS5
Regulation applied: EN 676 and A.R. of January 8th 2004 - July 17th 2009
Controlling organisation: Kiwa Gastec Italia S.p.A.
Via Treviso, 32/34
31020 San Vendemiano (TV)
Italy
Values measured: Max. CO: 70 mg/kWh
Max. NOx: 93 mg/kWh
Legnago, 01.03.2013 Operating Manager
RIELLO S.p.A. - Burners Department Research and Development Director RIELLO S.p.A. - Burners Department
Ing. I. Zinna Ing. R. Cattaneo
EC-0694CN7805

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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance
Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
ATTENTION
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.

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Information and general warnings
2.1.4 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 Assist-
ance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 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.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
ATTENTION
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.

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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for 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 toother 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.
3.2 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:
3 Safety and prevention
ATTENTION
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.

7 20063761
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4.3 Burner categories - Countries of destination
Tab. A
4 Technical description of the burner
Designation Voltage Code
RIELLO 40 GS5 1/230/50 3755219
Range: RIELLO 40 G
Size
Fuel: Natural gas
Light oil
LPG
Variations:
Electrical supply of the system: 1/230/50
1/230/60
G 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
FR I2Er
BE I2E(R)B
LU - PL I2E

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Technical description of the burner
4.4 Technical data
Tab. B
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ= ± 1.5 dB, in the manufacturer's combustion chamber
with burner operating on test boiler at maximum output.
4.5 Maximum dimensions
The maximum dimensions of the flange and burner are given in
Fig. 1.
Model RIELLO 40 GS5
Type 552 T1
Heat output (Hi) (1) min - max kW
kcal/h 18 58 15,500 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
Fan motor
rpm - rad/s
V - Hz
W
A
2800 - 294
230 - 50
90
0.75
Ignition transformer Primary 230V / 0.2A – Secondary 8 kV
Capacitor F 2
Absorbed electrical power kW 0.15
Protection level IP40
Weight kg 11
Noise levels (2) Sound pressure
Sound power dB(A) 59.4 70.8
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

9 20063761
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Technical description of the burner
4.6 Firing rate
The burner output is chosen from within the diagram area (Fig. 2).
4.6.1 Test boiler
The firing rate has been defined according to EN 676 standard.
4.6.2 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.
4.7 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).
ATTENTION
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20°C, an
atmospheric pressure of 1013 mbar (approx. 0m
above sea level), and with the combustion head
adjusted as shown on page 16.
Combustion chamber
pressure - mbar
Fig. 2
Thermal power
0.8
0
0.2
0.4
0.6
15,000 20,000 30,000 50,000 kcal/h
16 20 30 60 kW
D5135
1.0
40 50
40,000
16 20 30 40 50 60 kW
15,000 20,000 30,000 40,000 50,000 kcal/h
6
5
4
0
1
2
3
Thermal power
D5136
Fig. 3
Gas pressure to the
combustion head - mbar

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Technical description of the burner
4.8 Burner description
1 Air dampers
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 Control box
9 6-pole socket for gas train
10 Capacitor
11 Actuator
12 Flange
13 Pressure test point (+)
14 Combustion head
15 Electrode-probe
16 Gas train elbow
4.9 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
Fig. 4
20065193
ATTENTION
The supplied grommet and the cover fixing screw
should be assembled on the same side as the gas
train.

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Technical description of the burner
4.10 Electrical control box
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
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 control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following instruc-
tions:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’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 control box 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.
Electrical characteristics
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Description Unit of meas-
urement Parameters
Rated power supply voltage
(range), tolerance V A.C. 210...230, +10 -15%
Rated power supply frequency
(range), tolerance Hz 50...60, +5%, -5%
Operation temperature °C -20...+60
Protection level IP 00
Auxiliary circuit voltage V230AC, 48DC, 5DC
Electrical input power VA 40
Extreme operating current:
- terminals V1, V2, S3
- terminals MV, SM
- terminals B4
A
Extreme length of the input signals:
- inputs T1, T2, RS
- inputs PA, PG
- input SO m20
1
0.5
Internal fuse F1, T4AL250V
Classification EN298 F T C L B N
Fig. 5
E9256
05 cos 0 6,=,
3cos 0 6,=
01 cos,06,=

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Technical description of the burner
4.11 Actuator
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the connection area or the
actuator, fully disconnect the burner control device from the
power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• The actuator is mounted on the burner air setting with an in-
clination of 7°.
• Check the relevant national safety standards are respected.
Technical characteristics
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
Voltage and frequency 230V(+10%;-15%) - 50Hz
Operating temperature 70 °C
Working times:
- opening of the suction line
- closure of the suction line 3.35” sec 4.35” sec
Protection level IP20 - according to DIN 40 050
mounted on the burner
Fig. 6
20065194

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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 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 cham-
ber.
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.
5.3 Handling
The transport weight is given in chapter Technical data on
page 8.
Observe the permissible ambient temperatures for storage and
transport: -20 ..... + 70 °C, with max. relative humidity. 80%.
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
ATTENTION
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.
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.

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Installation
5.4 Preliminary checks
5.4.1 Control of the supply
5.4.2 Control of burner characteristics
Check the identification label of the burner(Fig. 7), 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.
5.5 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.
ATTENTION
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.
ATTENTION
The figure of the label (Fig. 7) is indicative. Some
of the data may be arranged in a different position.
Fig. 7
20065195
ATTENTION
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 8).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 8
20065196
2 3 4 51

15 20063761
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Installation
5.6 Securing the burner to the boiler
5.6.1 Hinge installation
Install the hinge 4), supplied as standard, as shown in Fig. 9.
Separate the combustion head assembly from the burner
body by removing nut 1) and removing the group A)(Fig. 10).
Fix the group B)(Fig. 10) to the boiler plate 2), inserting the
supplied insulating gasket 3).
5.7 Positioning the probe - electrode
Provide an adequate lifting system of the burner.
S7392 Fig. 9
4
ATTENTION
The seal between burner and boiler must be
airtight.
D5067
Fig. 10
AB
1 3 2
ATTENTION
Do not turn the ignition electrode but leave it as
shown in Fig. 11.
if the ignition electrode is put near the ionisation
probe, the control box amplifier might be dam-
aged.
ATTENTION
Place the ceramic part of the electrode A) against
the diffuser disc B)(Fig. 11).
Fig. 11
D5033
ElectrodeDiffuser
2.5 - 3.5 mm
Probe
Probe Electrode
2.0
B A

20063761 16
GB
Installation
5.8 Combustion head adjustment
To adjust, proceed as follows:
loosen the screw A) (Fig. 12 ), 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. 13) 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).
5.9 Air damper adjustment
Actuator 1)(Fig. 14) controls the air damper 6); the burner does
not start until the damper 6) is completely open.
To adjust the fixed damper 4) it is necessary to:
loosen the screws 3) and 5) and rotate the damper as far as
the required point 2).
Once optimum adjustment has been reached, fix the screws
3) and 5).
The adjustment of the damper varies in each single application,
so it is necessary to use a calibration tool to obtain an efficient
combustion result.
C
A
B
S7015
Fig. 12
Fig. 13
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
021345
44
ATTENTION
It is advisable to carry out an analysis of the com-
bustion values with the cover assembled.
Fig. 14
D7305
1
5
4
3
2
6

17 20063761
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Installation
5.10 Gas feeding
5.10.1 Gas feeding line
Key (Fig. 15 - Fig. 16)
1 Gas input pipe
2 Manual gate (the responsibility of the installer)
3 Gas pressure gauge (the responsibility of the installer)
4Filter
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
5.10.2 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. C.
Tab. C
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.
ATTENTION
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
Fig. 15
1
D7733
M2
2 3 M1 4 5 6 8 7
MBC 65/1
Fig. 16
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

20063761 18
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Installation
5.10.3 Gas train installation
The gas train MBC 65/1 1)(Fig. 17) 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. 18) 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. 17 and Fig. 18) of the gas train to
the 6 pole socket 9)(Fig. 4 on page 10) 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.
ATTENTION
It is best to tighten screws in a criss-cross pattern.
Do not, under any circumstances, install the valve
with the coil facing down.
ATTENTION
Once installation is complete, you must check for
fuel leaks and make sure the gas train is working
properly.
20065208
Fig. 17
MBC 65/1
Fig. 18
20065572
MB 405/1