Riello GAS 8 P/M Quick start guide

Installation, use and maintenance instructions
20148758 (3) - 10/2021
Forced draught gas burners
Two stage progressive or modulating operation
CODE MODEL TYPE
20147902 GAS 8 P/M 538 T1
20147903 GAS 8 P/M 538 T1
20147904 GAS 9 P/M 540 T1
20147794 GAS 9 P/M 540 T1
20147795 GAS 9 P/M 540 T1
20147906 GAS 9 P/M 540 T1
20147907 GAS 9 P/M 540 T1
20147908 GAS 9 P/M 540 T1
20148024 GAS 10 P/M 541 T1
20148960 GAS 10 P/M 541 T1
20147796 GAS 10 P/M 541 T1
20147797 GAS 10 P/M 541 T1
GB

Translation of the original instructions

1 20148758
GB
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 Technical data ............................................................................................................................................................. 8
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Maximum dimensions.................................................................................................................................................. 9
4.6 Burner equipment........................................................................................................................................................ 9
4.7 Firing rates ................................................................................................................................................................ 10
4.8 Test boiler.................................................................................................................................................................. 11
4.8.1 Commercial boilers.................................................................................................................................................... 11
4.9 Burner description ..................................................................................................................................................... 12
4.10 Electrical panel description........................................................................................................................................ 13
4.11 Control box RFGO-A22 ............................................................................................................................................. 14
4.12 Servomotor SQM40 .................................................................................................................................................. 15
5 Installation ................................................................................................................................................................................ 16
5.1 Notes on safety for the installation ............................................................................................................................ 16
5.2 Handling .................................................................................................................................................................... 16
5.3 Preliminary checks .................................................................................................................................................... 16
5.4 Operating position ..................................................................................................................................................... 17
5.5 Preparing the boiler ................................................................................................................................................... 17
5.5.1 Boring the boiler plate ............................................................................................................................................... 17
5.5.2 Blast tube length........................................................................................................................................................ 17
5.5.3 Securing the burner to the boiler ............................................................................................................................... 18
5.6 Positioning the probe - electrode............................................................................................................................... 19
5.7 Combustion head adjustment.................................................................................................................................... 20
5.7.1 Fixed gas delivery 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
5.9.1 Supply cables and external connections passage .................................................................................................... 24
5.10 Calibration of the thermal relay ................................................................................................................................. 25
5.11 Motor rotation ............................................................................................................................................................ 25
6 Start-up, calibration and operation of the burner ................................................................................................................. 26
6.1 Notes on safety for the first start-up .......................................................................................................................... 26
6.2 Adjustments prior to ignition ...................................................................................................................................... 26
6.3 Burner start-up .......................................................................................................................................................... 26
6.4 Burner ignition ........................................................................................................................................................... 26

20148758 2
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Contents
6.5 Burner adjustment......................................................................................................................................................27
6.5.1 Combustion head.......................................................................................................................................................27
6.6 Servomotor adjustment..............................................................................................................................................29
6.6.1 Output upon ignition...................................................................................................................................................29
6.6.2 Preliminary calibrations, if necessary.........................................................................................................................30
6.6.3 Maximum output ........................................................................................................................................................31
6.6.4 Minimum output .........................................................................................................................................................31
6.6.5 Intermediate outputs ..................................................................................................................................................32
6.7 Pressure switch adjustment .......................................................................................................................................33
6.7.1 Air pressure switch.....................................................................................................................................................33
6.7.2 Maximum gas pressure switch...................................................................................................................................33
6.7.3 Minimum gas pressure switch....................................................................................................................................33
6.7.4 Flame presence check...............................................................................................................................................34
6.8 Burner operation ........................................................................................................................................................35
6.8.1 Burner start-up ...........................................................................................................................................................35
6.8.2 Steady state operation ...............................................................................................................................................35
6.8.3 Ignition failure.............................................................................................................................................................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...........................................................................................................................................49

3 20148758
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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) Italy
Product: Forced draught gas burners
Model and type: GAS 8 P/M
GAS 9 P/M
GAS 10 P/M
538 T1
540 T1
541 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 Devices 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 follows:
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-0085AP0941 GAS 8 P/M
CE-0085AP0942 GAS 9 P/M
CE-0085AP0943 GAS 10 P/M

20148758 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 Cen-
tre 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
Table 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.
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.

5 20148758
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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 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 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
sale 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.

20148758 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 safety
technical 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 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.
Specifically:
it can be applied to boilers operating with water, steam, diather-
mic 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 cham-
ber and the ambient temperature must all be within the values in-
dicated 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, 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 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
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.

7 20148758
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4 Technical description of the burner
Designation Blast tube length (mm) Voltage Start-up Code
GAS 8 P/M 391 3/230-400/50 Direct 20147902
GAS 8 P/M 501 3/230-400/50 Direct 20147903
GAS 9 P/M 444 3/400/50 Direct 20147904 - 20147794
GAS 9 P/M 574 3/400/50 Direct 20147795
GAS 9 P/M 444 3/230/50 Star-triangle 20147906
GAS 9 P/M 444 3/400/50 Star-triangle 20147907
GAS 9 P/M 574 3/400/50 Star-triangle 20147908
GAS 10 P/M 476 3/230/50 Star-triangle 20148024
GAS 10 P/M 606 3/230/50 Star-triangle 20148960
GAS 10 P/M 476 3/400/50 Star-triangle 20147796
GAS 10 P/M 606 3/400/50 Star-triangle 20147797
Series: Gas
Size
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation with the only use of
Operation: ... One Stage
Voltage of auxiliaries:
230/50
110/50/60
GAS 9P/M FS2 3/230-400/50 230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
TC
/2 Two Stage
P/M Modulating
230V / 50Hz
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
flame detection electrode (ionisation)
Electrical supply of the system:
3/400/50
3/230/50
3N / 400V / 50Hz
3N / 230V / 50Hz

20148758 8
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Technical description of the burner
4.3 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 13)(Fig. 6 on page 12) 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 the EN 15036 standard, and according to an “Accuracy: Category 3” measurement, as
described in EN ISO 3746.
4.4 Electrical data
Tab. B
MODEL GAS 8 P/M GAS 9 P/M GAS 10 P/M
Type 538 T1 540 T1 541 T1
Output (1)
2nd stage kW
Mcal/h
1163 - 2210
1000 - 1900
1744 - 3488
1500 - 3000
2441 - 4885
2100 - 4200
1st stage kW
Mcal/h
640 - 1163
550 - 1000
870 - 1744
750 - 1500
1140 - 2441
980 - 2100
Fuel NATURAL GAS: G20- G25
G20 G25 G20 G25 G20 G25
- Lower 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
- Absolute density kg/Nm30,71 0,78 0,71 0,78 0,71 0,78
- Max delivery Nm3/h 221 257 348 406 488 568
- Pressure at maximum delivery (2) mbar 18,6 27,8 20,9 32,3 32,4 48,4
OPERATION
- Continuous (FS2)
These burners are suitable also for intermittent operation with
the only use of the UV flame sensor kit
- Progressive two-stage or modulating by kit (see ACCESSO-
RIES)
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
NOISE LEVEL (3) Sound pressure
Sound power dB(A) 86 96
89
99
90
100
Combustion air temperature °C max 60
MODEL GAS 8 P/M GAS 9 P/M GAS 9 P/M GAS 10 P/M GAS 10 P/M
Type 538 T1 540 T1 540 T1 541 T1 541 T1
Electrical power supply 3 ~ 230 - 400V +/- 10% 50 Hz
Electrical motor IE3
rpm
kW
V
A
2900
4
230/400
13.3 - 7.7
2930
9.2
230/400
28.6 - 16.5
2930
9.2
400/690
16.5 - 9.6
2920
15
230/400
46.8 - 27
2915
15
400/690
26.8 - 15.5
Ignition transformer V1 - V2
I1 - I2
230 V - 1x 8 kV
1.5 A - 30 mA
Absorbed electric power kW max 510.6 10.6 17 17
Protection level IP 40

9 20148758
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Technical description of the burner
4.5 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 U-U.
Tab. C
(1) Blast tube: short-long
4.6 Burner equipment
Seal for train connection . . . . . . . . . . . . . . . . . . . . . . .No. 1
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 12
Cable grommets for electrical cables . . . . . . . . . . . . . .No. 4
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 8
Extensions (only in extended head models) . . . . . . . . .No. 2
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Motor starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Cable grommets for the starter electrical connections .No. 2
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
PT-T(1) L
MG
E
D
F
C
U-U(1)
Fig. 1
20178663
mm C D E F G L M P T-T (1) U-U (1)
GAS 8 P/M 158 260 467 DN 80 396 755 359 1090 391 - 501 1541 - 1644
GAS 9 P/M 168 295 496 DN 80 498 871 373 1200 444 - 574 1627 - 1757
GAS 10 P/M 203 336 525 DN 80 508 917 409 1320 476 - 606 1730 - 1860

20148758 10
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Technical description of the burner
4.7 Firing rates
The burner output is to be chosen from within the diagram area.
This area is known as FIRING RATE and provides the burner out-
put according to the pressure in the combustion chamber.
The work point is found by drawing a vertical line from the re-
quired output and an horizontal line from the corresponding pres-
sure 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 8 the area is delimited by:
• 1163 - 2210 kW output axis
• 0 + 14 mbar combustion chamber pressure axis
• combustion chamber maximum pressure curve.
If the burner output is 2000 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 below it can be used.
Warning:
The burner can operate also in depressurised combustion cham-
bers.
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
a.s.l.), and with the combustion head adjusted as
shown on page 20.
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Pressure in the chamber
pressure - mbar
Thermal power Fig. 2
GAS 8 P/M S9734
kW
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Pressure in the chamber
pressure - mbar
Thermal power Fig. 3
GAS 9 P/M S9735
kW
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













                  
Pressure in the chamber
pressure - mbar
Thermal power Fig. 4
GAS 10 P/M S9736
kW

11 20148758
GB
Technical description of the burner
4.8 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. 5).
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 manufac-
turer.
The firing rates were obtained in special test boilers, according to
standard EN 676.
In Fig. 5 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 1500 Mcal/h: diameter 80 cm - length 2.5 m.
4.8.1 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. 5).
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. 5), consult the manufacturers.
Fig. 5
Combustion chamber
m
D44

20148758 12
GB
Technical description of the burner
4.9 Burner description
1 Flame inspection window
2 Lifting rings
3 Slide bars for opening the burner and inspecting the com-
bustion head (see note)
4 Combustion head (two lengths)
5 Closed air damper in stand-by to reduce heat losses
6 Air pressure switch
7 Gas butterfly valve control rod
8 Control box with lockout pilot light and reset button
9 Combustion head control rod
10 Air-gas control servomotor
11 Air adjustment cam
12 Pipe coupling gas pressure test point
13 Maximum gas pressure switch
14 Butterfly valve (gas input pipe)
15 MIN output gas adjustment disk
16 Pipe coupling
17 Fan pressure test point
18 Fan motor
1
1627 3 4
8 5 17 15 14
1210 1311
18 69
Fig. 6
20194412

13 20148758
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Technical description of the burner
4.10 Electrical panel description
1 Motor contactor and thermal relay (GAS 8-9 direct start-up)
2 Terminal board
3 Cable grommets supplied as standard (for electrical wirings
to be carried out by the installer)
4 Plug-socket on ionisation probe cable
5 Plug-socket on servomotor cable
6 Control box base
7 Ignition transformer
8 Filter to protect against radio disturbance
74
6
3
1
2
8
5
Fig. 7
20159977

20148758 14
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Technical description of the burner
4.11 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).
WARNING
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. 8
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Technical description of the burner
4.12 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
WARNING
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 10 VA
Motor Synchronous
Drive angle Varying between 0° and 135°
Protection level Max. IP 66, with appropriate cable
entry
Cable entry 2 x M20
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 30 s. at 90°
Weight approx. 2 kg
Environmental conditions:
Operation
Transport and storage
-20....+60° C
-20...+60°C
Fig. 9
S8907

20148758 16
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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. 10), showing:
Athe burner model
Cthe cryptographic year of manufacture
Dthe serial number
Ethe data for electrical supply and the protection level
Fthe electrical power consumption
Gthe types of gas used and the relevant supply pressures
Hthe 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;
Ithe category of the appliance/countries of destination.
5Installation
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
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 fre-
quently.
WARNING
Burner handling operations can be highly danger-
ous 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 quick-
ly 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 burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board 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.
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
A B
CD
E F
GH
H
I
I I I I
I I I I
G
GH
R.B.L.
Fig. 10
20189374

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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. 12.
The position of the threaded holes can be marked using the ther-
mal 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 in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling. The range of lengths available, L (mm), is as
follows:
Tab. G
For boilers with front flue passes 9)(Fig. 13 on page 18), 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.
WARNING
The burner is set up to operate only in posi-
tions 1, 2, 3 and 4 (Fig. 11).
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 forbidden for safety reasons.
Fig. 11
2 3 4 51
mm D1 DF Ø
GAS 8 P/M 265 368 M16
GAS 9 P/M 300 368 M18
GAS 10 P/M 350 438 M20
Fig. 12
D46
Blast tube L mm GAS 8
P/M
GAS 9
P/M
GAS 10
P/M
Extended head 501 574 606
Short head 391 444 476
Short head plus spacer 281 314 346

20148758 18
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Installation
5.5.3 Securing the burner to the boiler
Separate the combustion head as shown:
- Remove the screws 5)(Fig. 13) from the two slide bars 6).
- Remove the pin 2) and disengage the head control rod 11).
- Remove the screw 3) and disengage the gas butterfly
valve control rod 4).
- Remove the screws 7) securing the fan to the combustion
head.
- Draw the burner back by about 100-120 mm.
- Remove the screws 12) and disengage the shifting fork 8).
- Now remove the burner from the slide bars 6) completely;
by removing the burner, also the gas tube 9) will slide out
of the elbow 10).
Before securing the combustion head to the boiler, make
sure the probe and electrode are positioned correctly as in
(Fig. 14 on page 19). If the position is incorrect, remove the
elbow 10)(Fig. 13) from the pipe coupling 13).
Fix the blast tube to the boiler plate (Fig. 12 on page 17),
inserting the supplied insulating flange gasket 14)(Fig. 13).
Use the 4 screws, also supplied, after protecting their thread
with anti-locking product.
The seal between burner and boiler must be airtight.
Adjust the combustion head as described below.
Then refit the burner on the slide bars 6)(Fig. 13) and the
gas tube 9) into the elbow 10).
Leave the burner open by about 100-120 mm.
Refit the fork 8)(Fig. 13) fixing it with the screws 12).
Close the burner.
Tighten the screws 7)(Fig. 13) securing the fan to the com-
bustion head.
Fit the retainers and the screws 5)(Fig. 13) to the two slide
bars 6).
Engage the rods 4) and 11) again.
Provide an adequate lifting system.
CAUTION
Do not rotate the probe but leave it as in Fig. 14; if
it is too close to the ignition electrode, it could
damage the control box amplifier.
Fig. 13
D48
WARNING
The seal between burner and boiler must be
airtight.