Riello GAS 3 P/M Quick start guide

Installation, use and maintenance instructions
20159111 (3) - 02/2022
Forced draught gas burners
Two stage progressive or modulating operation
CODE MODEL TYPE
20159096 GAS 3 P/M 533 T1
20159118 GAS 4 P/M 534 T1
20159126 GAS 5 P/M 535 T1
20159129 GAS 6 P/M 536 T1
20159133 GAS 7 P/M 537 T1
GB

Translation of the original instructions

1 20159111
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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 ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions................................................................................................................................................ 10
4.7 Burner equipment...................................................................................................................................................... 10
4.8 Firing rates ................................................................................................................................................................ 11
4.9 Test boiler.................................................................................................................................................................. 12
4.9.1 Commercial boilers.................................................................................................................................................... 12
4.10 Burner description ..................................................................................................................................................... 13
4.11 Electrical panel description........................................................................................................................................ 14
4.12 Control box RFGO-A22............................................................................................................................................. 15
4.13 Servomotor SQM40 .................................................................................................................................................. 16
5 Installation ................................................................................................................................................................................ 17
5.1 Notes on safety for the installation ............................................................................................................................ 17
5.2 Handling .................................................................................................................................................................... 17
5.3 Preliminary checks .................................................................................................................................................... 17
5.4 Operating position ..................................................................................................................................................... 18
5.5 Preparing the boiler ................................................................................................................................................... 18
5.5.1 Boring the boiler plate ............................................................................................................................................... 18
5.5.2 Blast tube length........................................................................................................................................................ 18
5.5.3 Securing the burner to the boiler ............................................................................................................................... 19
5.6 Positioning the probe - electrode............................................................................................................................... 19
5.7 Combustion head adjustment.................................................................................................................................... 20
5.8 Gas supply ................................................................................................................................................................ 21
5.8.1 Gas feeding line ........................................................................................................................................................ 21
5.8.2 Gas train.................................................................................................................................................................... 22
5.8.3 Gas train installation.................................................................................................................................................. 22
5.8.4 Gas pressure............................................................................................................................................................. 22
5.9 Electrical connections................................................................................................................................................ 24
5.10 Calibration of the thermal relay ................................................................................................................................. 26
5.11 Motor rotation ............................................................................................................................................................ 26
6 Start-up, calibration and operation of the burner ................................................................................................................. 27
6.1 Notes on safety for the first start-up .......................................................................................................................... 27
6.2 Adjustments prior to ignition ...................................................................................................................................... 27
6.3 Burner start-up .......................................................................................................................................................... 27
6.4 Burner ignition ........................................................................................................................................................... 27
6.5 Servomotor adjustment ............................................................................................................................................. 28

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Contents
6.6 Burner adjustment......................................................................................................................................................29
6.6.1 Ignition output ............................................................................................................................................................29
6.6.2 Preliminary calibrations, if necessary.........................................................................................................................29
6.6.3 MAX output ................................................................................................................................................................30
6.6.4 MIN output .................................................................................................................................................................30
6.6.5 Intermediate outputs ..................................................................................................................................................31
6.7 Pressure switch adjustment .......................................................................................................................................32
6.7.1 Air pressure switch.....................................................................................................................................................32
6.7.2 Maximum gas pressure switch...................................................................................................................................32
6.7.3 Minimum gas pressure switch....................................................................................................................................33
6.7.4 Flame presence check...............................................................................................................................................33
6.8 Burner operation ........................................................................................................................................................34
6.8.1 Burner start-up ...........................................................................................................................................................34
6.8.2 Steady state operation ...............................................................................................................................................34
6.8.3 Ignition failure.............................................................................................................................................................34
6.8.4 Burner flame goes out during operation.....................................................................................................................34
6.9 Final checks (with burner operating)..........................................................................................................................35
7 Maintenance ..............................................................................................................................................................................36
7.1 Notes on safety for the maintenance .........................................................................................................................36
7.2 Maintenance programme ...........................................................................................................................................36
7.2.1 Maintenance frequency..............................................................................................................................................36
7.2.2 Safety test - with no gas supply .................................................................................................................................36
7.2.3 Checking and cleaning...............................................................................................................................................36
7.2.4 Combustion control (gas)...........................................................................................................................................37
7.2.5 Safety components ....................................................................................................................................................37
7.3 Opening the burner ....................................................................................................................................................38
7.4 Closing the burner......................................................................................................................................................38
8 LED indicator and special function.........................................................................................................................................39
8.1 Description of LED lamps ..........................................................................................................................................39
8.2 Check mode function .................................................................................................................................................39
8.3 Flame control lockout or emergency stop condition...................................................................................................39
8.4 LED lamps: burner operating status ..........................................................................................................................40
9 Problems - Causes - Remedies signalled by LED indicators ...............................................................................................41
A Appendix - Accessories ...........................................................................................................................................................46
B Appendix - Electrical panel layout...........................................................................................................................................48

3 20159111
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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 burners
Model and type: GAS 3 P/M
GAS 4 P/M
GAS 5 P/M
GAS 6 P/M
GAS 7 P/M
533 T1
534 T1
535 T1
536 T1
537 T1
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
Such products are marked as indicated below:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
CE-0085AQ0707

20159111 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance
Centre 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
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not
carried out correctly, cause serious injury, death
or long-term health risks.
ATTENTION
This symbol indicates operations which, if not
carried out correctly, may cause serious injury,
death or long-term health risks.
CAUTION
This symbol indicates operations which, if not
carried out correctly, may cause damage to the
machine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not
carried out correctly, lead to electric shocks with
lethal 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
atmosphere may be present. An explosive
atmosphere 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
DEVICES
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.

5 20159111
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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
Assistance 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.
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,
incorrectly 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
established 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
responsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
ATTENTION
Failure to observe the information given in this
manual, operating negligence, incorrect
installation and carrying out of non authorised
modifications will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

20159111 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
safety rules 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
confidence 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
dangerous.
Specifically:
it can be applied to boilers operating with water, steam,
diathermic oil, and to other uses expressly named by the
manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion
chamber and the ambient temperature must all be within the
values indicated in the instruction manual.
Modification of the burner to alter its performance and
destinations is not allowed.
The burner must be used in exemplary technical safety
conditions. 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
responsible for the machine and for the training of the people
working 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, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties;
Personnel must observe all the danger and caution
indications shown on the machine.
Personnel must not carry out, on their own initiative,
operations 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
compromise 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
operation only if all burner components are intact
and correctly positioned.
must take all the measures necessary to
prevent unauthorised people gaining access
to the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident
prevention systems are noticed, along with
any presumed danger situation;
personnel must always use the personal
protective equipment envisaged by legislation
and follow the indications given in this
manual.

7 20159111
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4 Technical description of the burner
Designation Voltage Start-up Code
GAS 3 P/M TC FS2 1/230/50 Direct 20159096
GAS 4 P/M TC FS2 1/230/50 Direct 20159118
GAS 5 P/M TC FS2 3/230-400/50 Direct 20159126
GAS 6 P/M TC FS2 3/230-400/50 Direct 20159129
GAS 7 P/M TC FS2 3/230-400/50 Direct 20159133
Series: Gas
Size
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation only with the use of
Operation: ... One Stage
Voltage of auxiliaries:
230/50/60
110/50/60
GAS 7P/M FS2 3/230-400/50 230/50/-60
BASIC DESIGNATION
EXTENDED DESIGNATION
TC
/2 Two Stage
P/M Modulating
230V / 50-60Hz
110V / 50-60Hz
Head: TC Standard head
TL Extended head
Emission: C01 - ...
C02 - MZ
C03 - BLU
C03 - MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
a flame detection electrode (ionisation)
Electrical supply of the system:
3/400/50
3/230/50
3N / 400V / 50Hz
3 / 230V / 50Hz

20159111 8
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Technical description of the burner
4.3 Burner categories - Countries of destination
4.4 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 11)(Fig. 5 a pag. 13) with zero pressure in combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output. The sound power
is measured using the "Free Field" method, required by EN 15036 standard, and according to an “Accuracy: Category 3” measurement, as
described in EN ISO 3746.
(4) Burners are shipped in cardboard packages. GAS 7 P/M model rests on a wooden platform specially suitable for lift trucks.
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
MODEL GAS 3 P/M GAS 4 P/M GAS 5 P/M GAS 6 P/M GAS 7 P/M
TYPE 533 T1 534 T1 535 T1 536 T1 537 T1
OUTPUT (1) 2nd stage kW
Mcal/h
130 - 350
112 - 301
180 - 470
155 - 404
320 - 660
275 - 568
520 - 1050
447 - 903
800 - 1760
688 - 1514
1st stage kW
Mcal/h
80 - 175
69 - 150
120 - 235
104 - 202
155 - 330
133 - 284
300 - 520
258 - 447
400 - 880
344 - 757
FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25
G20 G25 G20 G25 G20 G25 G20 G25 G20 G25
- Net calorific value kWh/Nm3
Mcal/Nm3
10
8.6
8.6
7.4
10
8.6
8.6
7.4
10
8.6
8.6
7.4
10
8.6
8.6
7.4
10
8.6
8.6
7.4
- Absolute density kg/Nm30.71 0.78 0.71 0.78 0.71 0.78 0.71 0.78 0.71 0.78
- max delivery Nm3/h 35 41 47 54 66 77 105 122 176 205
- pressure at maximum delivery (2) mbar 11.1 16.4 9.8 14.5 9.8 14.5 12.3 18.2 14.5 21.4
OPERATION • Continuous (min. 1 stop in 72 hours). These burners are also suitable for
intermittent operation, only with the use of the UV flame sensor kit.
• Progressive two-stage or modulating by kit (see ACCESSORIES)
STANDARD USE Boilers: water, steam, diathermic oil
AMBIENT TEMPERATURE °C 0 - 40
COMBUSTION
AIR TEMPERATURE °C max 60
NOISE LEVEL (3) Sound pressure
Sound power
dB(A) 75
85
77
87
82
92
84
94
85
95
Weight (including packaging) (4) kg 37 43 46 63 101

9 20159111
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Technical description of the burner
4.5 Electrical data
Tab. B
MODEL GAS 3 P/M GAS 4 P/M
TYPE 533 T1 534 T1
ELECTRICAL POWER SUPPLY V
Hz
230 ~ +/- 10%
50 - single-phase
ELECTRICAL MOTOR rpm
kW
V
A
2750
0,250
230
1.9
2800
0,370
230
2.8
MOTOR CAPACITOR F
V
8
450/500
12.5
400/450
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1.5 A - 30 mA
ELECTRICAL POWER
CONSUMPTION
kW max 0.69 0.79
PROTECTION LEVEL IP 40
MODEL GAS 5 P/M
TYPE 535 T1
ELECTRICAL POWER SUPPLY V
Hz
230 - 400 ~ +/- 10%
50 - three-phase
ELECTRICAL MOTOR IE2 rpm
kW
V
A
2900
0,740
230 - 400
2.6 - 1.5
MOTOR CAPACITOR F
V
8
450/500
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1.5 A - 30 mA
ELECTRICAL POWER
CONSUMPTION
kW max 1.3
PROTECTION LEVEL IP 40
MODEL GAS 6 P/M GAS 7 P/M
TYPE 536 T1 537 T1
ELECTRICAL POWER SUPPLY V
Hz
230 - 400 ~ +/- 10%
50 - three-phase
ELECTRICAL MOTOR IE3 rpm
kW
V
A
2890
1.5
200-240 346-415
6.1-7.1/3.5-4.1
2900
3.0
230/400
9.7 - 5.6
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1.5 A - 30 mA
ELECTRICAL POWER
CONSUMPTION
kW max 2.2 3.85
PROTECTION LEVEL IP 40

20159111 10
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Technical description of the burner
4.6 Maximum dimensions
The dimensions of the burner are given in Fig. 1.
Note that to inspect the combustion head the burner must be
moved backward and turned upward.
The maximum dimension of the burner, without casing, when
open is given by measurement I.
Tab. C
4.7 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Seal for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 8
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
mm A B C D E F G H I L M
GAS 3 P/M 205 380 292 140 Rp 1 1/2 225 97 185 775 610 397
GAS 4 P/M 205 380 292 150 Rp 1 1/2 225 97 187 775 610 397
GAS 5 P/M 226 355 332 155 Rp 1 1/2 225 97 207 810 645 437
GAS 6 P/M 258 377 370 175 Rp 2 250 131 207 966 770 485
GAS 7 P/M 358 400 445 220 Rp 2 305 140 240 1142 920 590
Fig. 1
D89

11 20159111
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Technical description of the burner
4.8 Firing rates
During operation, burner output varies between:
– MINIMUM OUTPUT in 1st stage
– MAXIMUM OUTPUT in 2nd stage
The MINIMUM OUTPUT (MIN) is to be chosen from within
the range of values indicated on diagrams.
Example:
for GAS 3 P/M, it can be chosen from 80 and 175 kW (equivalent
to 69 and 150 Mcal/h)
It is not required to know the pressure in combustion chamber in
1st stage.
The MAXIMUM OUTPUT (MAX) is to be chosen from within
the diagram area on the side. This area is known as FIRING
RATE and provides the burner maximum output according to
the pressure in the combustion chamber. The work point is
found by drawing a vertical line from the required output and
an horizontal line from the corresponding pressure in the
combustion chamber. The intersection point of the two lines
is the work point, which must fall within the FIRING RATE.
Example:
for GAS 3 P/M the area is delimited by:
– 130 - 135 kW output axis
– axis of pressures in comb. chamber 0 + 7 mbar
– combustion chamber maximum pressure curve.
If the burner output is 250 kW at a pressure of 5 mbar in the
combustion chamber, the work point is on the maximum pressure
curve.
This curve has been set with safety margins, so that all the
FIRING RATE area can be used.
The burner output to be matched with the boiler is to be chosen
from the MAX area, namely from the FIRING RATE.
The burner can operate also in depressurised combustion
chambers.
ATTENTION
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on pag. 20.
Fig. 2
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S9729
Pressure in the chamber
pressure - mbar
Thermal power - kW
GAS 3 P/M
Fig. 3
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S9730
Thermal power - kW
Pressure in the chamber
pressure - mbar
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

                             
S9731
Pressure in the chamber
pressure - mbar
Thermal power - kW
















         
S9732
Pressure in the chamber
pressure - mbar


















                 
S9733
Thermal power - kW
Thermal power - kW
Pressure in the chamber
pressure - mbar
GAS 4 P/M
GAS 5 P/M
GAS 6 P/M
GAS 7 P/M

20159111 12
GB
Technical description of the burner
4.9 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 4).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the
manufacturer.
The firing rates were obtained in special test boilers, according to
EN 676 standard.
In Fig. 4 you can see the diameter and length of the test
combustion chamber.
Example:
Output 1500 Mcal/h: diameter 80 cm - length 2.5 m.
4.9.1 Commercial boilers
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 4).
If the burner must be combined with a commercial boiler that has
not been EC approved (CE mark) and/or its combustion chamber
dimensions are clearly smaller than those indicated in diagram
(Fig. 4), consult the manufacturers.
Fig. 4
Combustion chamber
m
D44

13 20159111
GB
Technical description of the burner
4.10 Burner description
1 Slide bars for opening the burner and inspecting the
combustion head
2 Combustion head
3 Closed air damper in stand-by to reduce heat losses
4 Air pressure switch
5 Air damper control lever
6 Gas butterfly valve control rod
7 Control box with lockout pilot light and reset button
8 Air-gas control servomotor
9 Fan pressure test point
10 Air adjustment cam
11 Pipe coupling gas pressure test point
12 Gas butterfly valve
13 Gas input pipe
14 Pipe coupling
15 Maximum gas pressure switch
16 Fan motor
7
15 11
16
10 9
3
2
114
12
13
6
5
8
4
Fig. 5
20159978

20159111 14
GB
Technical description of the burner
4.11 Electrical panel description
1 Capacitor (in GAS 3-4 P/M models)
2 Motor contactor and thermal relay (in GAS 5-6-7 P/M models)
3 Terminal board
4 Cable grommets for electrical wiring (to be carried out by the
installer)
5 Plug-socket on ionisation probe cable
6 Plug-socket on servomotor cable
7 Control box base
8 Ignition transformer
9 Filter to protect against radio disturbance
8
56
9347
1
8
6
7
4
3
2
5
9
Fig. 6
20159979

15 20159111
GB
Technical description of the burner
4.12 Control box RFGO-A22
Important notes
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
operations, 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
functions. 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
instructions:
– avoid conditions that can favour the development of
condensate 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.
Use
The control box is a control and supervision system of medium
and large capacity forced draught burners.
If used with the flame detection electrode the system can operate
continuously whereas, with the use of UV sensors it operates
intermittently with stop and restart request at least once every
24h.
Installation notes
• Make sure that the electrical wiring inside the boiler complies
with national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with
neighbouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as
possible 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.
Technical data
Tab. D
Electrical wiring of the flame detector
It is important for signal transmission to be almost totally free of
any disturbances or loss:
• Always separate the detector cables from the other cables:
– The capacitive reactance of the line reduces the size of the
flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
• The ionisation probe is not protected against the risk of
electrocution. When connected to the electricity supply, the
ionisation probe must be protected against any accidental
contact.
• Position the ignition electrode and the ionisation probe so
that the ignition spark cannot form an arc on the probe (risk
of electric overcharge).
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. The
Manufacturer cannot assume any responsibility
for damage resulting from unauthorised work!
Mains voltage AC 230 V -15 % / +10 %
Mains frequency 50 / 60 Hz
Primary fuse (external) Refer to the electric
system
Weight approx. 1.1 kg
Power absorption approx. AC 7 VA
Protection level IP40
Safety class II
Environmental conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K2
Class 1M2
-40...+60 °C
< 90% RH (non-condensing)
Fig. 7
20152163

20159111 16
GB
Technical description of the burner
4.13 Servomotor SQM40 ...
Important notes
 All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
 Falls and collisions can negatively affect the safety
functions. In this case, the servomotor must not be
operated, even if it displays no evident damage.
 Fully disconnect the burner from the mains when working
near terminals and servomotor connections.
 Condensation and exposure to water are not allowed.
 For safety reasons, the servomotor must be checked after
long periods of non-use.
•
Technical data
Tab. E
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the
servomotor.
Mains voltage 230 V -15% +10%
Mains frequency 50 / 60 Hz
Power absorption 7... 15 VA
Motor Synchronous
Drive angle Varying between 0° and 135°
ATTENTION
Never adjust the red cam No. 1 more than 90° to
prevent serious or irreversible damage to the
mechanical adjustment parts.
Protection level Max. IP 66, with appropriate cable
entry
Cable entry 2 x M16
Cable connection terminal board for 0.5 mm2(min.)
and 2.5 mm2(max)
Rotation direction Anticlockwise
Rated torque (max.) 10 Nm
Holding torque 5 Nm
Operation time 45 s. at 90°
Weight approx. 2 kg
Environmental conditions:
Operation
Transport and storage
-20....+60° C
-20...+60°C
Fig. 8
S8907

17 20159111
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to handle the burner (still packaged) with a pallet truck
or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 9), 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 types of gas used and the relevant supply pressures;
H the data of the burner possible minimum and maximum
output (see Firing rate).
Warning. The burner output must be within the firing rate of
the boiler;
I the category of the appliance/countries of destination.
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
regulations of the laws in force.
DANGER
The combustion air inside the boiler must be free
from hazardous mixes (e.g.: chloride, fluoride,
halogen); if present, it is highly recommended to
carry out cleaning and maintenance more
frequently.
ATTENTION
Burner handling operations can be highly
dangerous if not carried out with the greatest
attention: distance unauthorised personnel, check
integrity and suitability of the means available.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can
quickly move if the burner should fall).
During handling, keep the load at no more than
20-25 cm from the ground.
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
burner will be installed.
CAUTION
After removing all the packaging, check the
integrity of the contents. In the event of doubt, do
not use the burner; contact the supplier.
The packaging elements (wooden cage or
cardboard box, nails, clips, plastic bags, etc.)
must not be abandoned as they are potential
sources of danger and pollution; they should be
collected and disposed of in the appropriate
places.
ATTENTION
A burner label that has been tampered with,
removed or is missing, along with anything else
that prevents the definite identification of the
burner makes any installation or maintenance
work difficult
Fig. 9
R. B. L.
GAS- KAASU
GAZ- AEPI O
0085
RI ELLO S. p. A.
I- 37045 Legnago (VR)
CE
ABC
EDF
HG
GH
I
D7738

20159111 18
GB
Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the
thermal insulation screen supplied with the burner.
Tab. F
5.5.2 Blast tube length
The length of the blast tube must be selected according to the
indications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door
complete with its fettling. The range of lengths available, L (mm),
is as follows:
Tab. G
For boilers with front flue passes 9)(Fig. 12 a pag. 19), or flame
inversion chamber, a protection in refractory material 7) must be
inserted between the boiler fettling 8) and the blast tube 6).
This protection must not compromise the extraction of the blast
tube.
ATTENTION
The burner is set up to operate only in
positions 1, 2, 3 and 4 (Fig. 10).
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
correct operation of the appliance.
The installation 5is prohibited for safety
reasons.
Fig. 10
2 3 4 51
20160220
mm ABCD
GAS 3 P/M 155 160 160 M10
GAS 4 P/M 165 160 160 M10
GAS 5 P/M 165 160 160 M10
GAS 6 P/M 185 195 195 M12
GAS 7 P/M 230 230 230 M12
Fig. 11
D46
Blast tube
L mm
GAS 3
P/M
GAS 4
P/M
GAS 5
P/M
GAS 6
P/M
GAS 7
P/M
Shortened 43 45 65 85 -
Standard 185 187 207 227 240
Elongated 320 320 365 360 400