Riello GAS Series Quick start guide

Installation, use and maintenance instructions
2915858 (4) - 07/2022
Forced draught gas burners
One stage operation
CODE MODEL TYPE
3751960 GAS 3 519 T55
3751961 GAS 3 516 T55
GB

Translation of the original instructions

1 2915858
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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 Background ................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Models available.......................................................................................................................................................... 7
4.2 Technical data ............................................................................................................................................................. 7
4.3 Electrical data.............................................................................................................................................................. 7
4.4 Maximum dimensions.................................................................................................................................................. 8
4.5 Burner equipment........................................................................................................................................................ 8
4.6 Firing rates .................................................................................................................................................................. 9
4.6.1 Minimum gas pressure - output................................................................................................................................... 9
4.7 Test boiler.................................................................................................................................................................. 10
4.7.1 Commercial boilers.................................................................................................................................................... 10
4.8 Burner description ..................................................................................................................................................... 11
4.9 Control box RMG88................................................................................................................................................... 12
5 Installation ................................................................................................................................................................................ 13
5.1 Notes on safety for the installation ............................................................................................................................ 13
5.2 Handling .................................................................................................................................................................... 13
5.3 Preliminary checks .................................................................................................................................................... 13
5.4 Operating position ..................................................................................................................................................... 14
5.5 Preparing the boiler ................................................................................................................................................... 14
5.5.1 Boring the boiler plate ............................................................................................................................................... 14
5.5.2 Blast tube length........................................................................................................................................................ 14
5.5.3 Securing the burner to the boiler ............................................................................................................................... 15
5.6 Positioning the probe - electrode............................................................................................................................... 15
5.7 Combustion head adjustment.................................................................................................................................... 16
5.7.1 Gas distributor ........................................................................................................................................................... 16
5.8 Gas feeding ............................................................................................................................................................... 17
5.8.1 Gas feeding line ........................................................................................................................................................ 17
5.8.2 Gas train.................................................................................................................................................................... 18
5.8.3 Gas train installation.................................................................................................................................................. 18
5.8.4 Gas pressure............................................................................................................................................................. 18
5.9 Electrical wiring ......................................................................................................................................................... 19
6 Start-up, calibration and operation of the burner ................................................................................................................. 20
6.1 Notes on safety for the first start-up .......................................................................................................................... 20
6.2 Adjustments prior to ignition ...................................................................................................................................... 20
6.3 Burner start-up .......................................................................................................................................................... 20
6.4 Burner ignition ........................................................................................................................................................... 20
6.5 Burner adjustment ..................................................................................................................................................... 21
6.5.1 Ignition output............................................................................................................................................................ 21
6.5.2 Maximum burner output ............................................................................................................................................ 21
6.6 Pressure switch adjustment ...................................................................................................................................... 22
6.6.1 Air pressure switch “1”............................................................................................................................................... 22
6.6.2 Over pressure switch “2” ........................................................................................................................................... 22

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Contents
6.6.3 Minimum gas pressure switch....................................................................................................................................22
6.7 Burner operation ........................................................................................................................................................23
6.7.1 Burner start-up ...........................................................................................................................................................23
6.8 Final checks (with burner operating)..........................................................................................................................23
6.9 Burner start-up cycle diagnostics...............................................................................................................................24
6.9.1 Resetting of control box and diagnostics use ............................................................................................................24
6.9.2 Control box reset........................................................................................................................................................24
6.9.3 Visual diagnostics ......................................................................................................................................................24
6.9.4 Software diagnostics..................................................................................................................................................24
7 Maintenance ..............................................................................................................................................................................25
7.1 Notes on safety for the maintenance .........................................................................................................................25
7.2 Maintenance programme ...........................................................................................................................................25
7.2.1 Maintenance frequency..............................................................................................................................................25
7.2.2 Safety test - with gas supply closed ...........................................................................................................................25
7.2.3 Checking and cleaning...............................................................................................................................................25
7.2.4 Ionisation current .......................................................................................................................................................26
7.2.5 Combustion control (gas)...........................................................................................................................................26
7.2.6 Safety components ....................................................................................................................................................26
7.3 Opening the burner ....................................................................................................................................................27
7.4 Closing the burner......................................................................................................................................................27
8 Faults - Possible causes - Solutions.......................................................................................................................................28
A Appendix - Accessories ...........................................................................................................................................................30
B Appendix - Electrical panel layout...........................................................................................................................................32

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Declarations
Dichiarazione di conformità secondo ISO / IEC 17050-1
Questi prodotti sono conformi alle seguenti Norme Tecniche:
• EN 12100
•EN676
Secondo quanto disposto dalle Direttive Europee:
MD 2006/42/CE Direttiva Macchine
LVD 2014/35/EU Direttiva Bassa Tensione
EMC 2014/30/EU Compatibilità Elettromagnetica
La qualità viene garantita mediante un sistema di qualità e
management certificato secondo ISO 9001:2015.
1 Declarations

2915858 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
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
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 2915858
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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
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 appliance;
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;
use of the burner even following an error and/or an irregular-
ity;
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 optionals;
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.

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Safety and prevention
3.1 Background
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
Namely:
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 follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to 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 manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from 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.
the user must take all the measures neces-
sary to prevent 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 2915858
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Technical description of the burner
4.1 Models available
4.2 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1,013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 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 rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3” measurement, as de-
scribed in EN ISO 3746.
4.3 Electrical data
Tab. B
4 Technical description of the burner
Designation Voltage Start-up Code
GAS 3 TC 1/240/50 Direct 3751960
GAS 3 TL 1/240/50 Direct 3751961
MODEL GAS 3
Type 519 T55
Output (1) kW
Mcal/h
130 - 350
130 - 300
Fuel NATURAL GAS: G20 - G25 - G31
G20 G25
- Net Calorific Value kWh/Nm310 8.6
Mcal/Nm38.6 7.4
- Absolute density kg/Nm30.71 0.78
- Max output Nm3/h35 43
- Pressure at maximum output (2) mbar 11.1 16.4
Operation - Intermittent (min. 1 stop in 24)
- One-stage
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Noise levels (3) Sound pressure
Sound power dB(A) 75 85
Combustion air temperature °C max 60
MODEL GAS 3
Type 519 T55
Electrical supply 1N ~ 240V 50 Hz
Motor
rpm
kW
V
A
2750
0.250
240
2
Motor capacitor µF
V
6.3
450
Ignition transformer V1 - V2
I1 - I2
230 V - 1x 9 kV
2A - 33 mA
Absorbed electric power kW max 0.4
Protection level IP 40

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Technical description of the burner
4.4 Maximum dimensions
The maximum 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 when open, without cover,
is given by measurement I.
Tab. C
(1) Blast tube: short-long
4.5 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 8
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
mm ABCDEFG
H (1) ILM
GAS 3 205 205 292 145 Rp1 1/2165 97 235-370 775 610 397
Fig. 1
D231

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Technical description of the burner
4.6 Firing rates
The burner output is selected from within the area of the dia-
grams.
This area is known as the FIRING RATE and provides the burner
output according to the pressure in the combustion chamber.
The work point may be found by plotting a vertical line from the
desired output and a horizontal line from the corresponding pres-
sure in the combustion chamber The intersection of these two
lines is the work point which must lie within the FIRING RATE.
Example:
for GAS 3 the area is delimited by:
• the axis of the 130 - 350 kW outputs
• the axis of the pressures in the comb. chamber 0 + 7 mbar
• the maximum pressure curve in comb. chamber
If the burner develops an output of 240 kW at a pressure in com-
bustion chamber of 5 mbar, the work point is found on the maxi-
mum pressure curve. This curve has been established with safety
margins and therefore it is possible to use the entire area of the
FIRING RATE beneath this curve.
The burner can also operate with the combustion chamber in de-
pression.
4.6.1 Minimum gas pressure - output
Pressure:
Detected at the pressure test-point 8) with mbar into the combus-
tion chamber.
Should the combustion chamber be pressurized, the pressure
necessary will be that of the graph plus the pressurization value.
Example:
To obtain 270 kW it is necessary a gas pressure of 8 mbar and
the combustion head set as indicated at page 9. If the combustion
chamber is pressurized at 2 mbar, the pressure detected at the
test-point 8) is: 8 + 2 = 10 mbar.
If this value is too high, for very low gas pipework pressures, the
gas gear 6) (page 9) could be more open. Do not decrease the
pressure at the coupling under the values shown in the diagram.
Output:
The maximum value is obtainable with gas Pci 8600 kcal/m3.
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1,013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 16.
Pressure in combustion
chamber - mbar
Heat output Fig. 2
20144735
KW
Mcal/h
Fig. 3
S10233

2915858 10
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Technical description of the burner
4.7 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 manufac-
turer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 4 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.
4.7.1 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 however the burner has to be combined with a commercial boil-
er that has not been EC approved and/or with combustion cham-
ber dimensions clearly smaller than those indicated in the
diagram (Fig. 4), consult the manufacturers.
Fig. 4
Combustion chamber
m
D44

11 2915858
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Technical description of the burner
4.8 Burner description
1 Air shutter control
2 Air shutter lock-out
3 Control box reset button
4 Fair leads
5 Wiring terminal block
6 Over pressure switch (2)
7 Air pressure switch (1)
8 Gas pressure test-point
Fig. 5
S10234

2915858 12
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Technical description of the burner
4.9 Control box RMG88...
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). Check the system is not powered
and cannot be accidentally reconnected. Failure to do this
will lead to the risk of electrocution.
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
Press the reset button of the burner lockout command or the
reset button (by applying a force of not more than 10 N),
without the aid of tools or sharp objects.
For the safety and reliability of the control box, comply with the
following instructions:
- avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
- Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Technical data
Mechanical structure
The control box is made of plastic to resist knocks, heat and
flame propagation.
The control box contains the following components:
• a microprocessor that controls the program sequence, and a
relay for controlling the load
• an electronic flame signal amplifier
• a built-in reset button with 3 signalling colours (LED) for status
and error messages.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box RMG88... is a safety device!
Avoid opening or modifying it, or forcing its opera-
tion. Riello S.p.A. cannot assume any responsibil-
ity for damage resulting from unauthorised
interventions!
Mains voltage AC 220...240 V +10 % / -15 %
Mains frequency 50 / 60 Hz ±6%
Power absorption 20 VA
Protection level IP20
Safety class I
Weight approx. 260g
Cable length
Thermostat cable
Air pressure switch
Gas pressure switch
Remote reset
CPI
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95 % r.h.
Fig. 6
S8906

13 2915858
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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 packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
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. 7), showing:
A the burner model
B the burner type
C the cryptographic year of manufacture
D the serial number
E the data for electrical supply and the protection level
F the electrical power consumption
G the types of gas used and the relative supply pressures
H the data of the burner's possible minimum and maximum
output (see Firing rate).
Warning: The burner output must be within the boiler's firing
rate;
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.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
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).
When handling, keep the load at not 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, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult
R.B.L.
GAS- KAASU
GAZ- AEPIO
RIELLOS.p.A.
I- 37045 Legnago (VR)
CE
Fig. 7
S9928
ABC
EDF
HG
GH
I

2915858 14
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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. 9.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
Tab. D
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, is as fol-
lows:
Tab. E
For boilers with a front flue gas wash 9)(Fig. 10) or flame inver-
sion chamber, a protection device in refractory material 7) must
be inserted between the boiler refractory 8) and the blast tube 6).
This protective fettling must not compromise the extraction of the
blast tube.
WARNING
The burner is set up only to operate in posi-
tions 1, 2, 3 and 4 (Fig. 8).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 8
2 3 4 51
20160220
mm ABCD
GAS 3 155 160 160 M10
Fig. 9
D46
Blast tube
L mm
GAS 3
Standard 235
Elongated 370

15 2915858
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Installation
5.5.3 Securing the burner to the boiler
Separate the combustion head from the burner body by
loosening the screws 1) and 2) and withdrawing the
group A) from the holding bars 3).
Fix the group B) to the boiler front plate 4) using the
gasket 5) provided as accessory.
5.6 Positioning the probe - electrode
Provide an adequate lifting system.
WARNING
The seal between burner and boiler must be
airtight.
Fig. 10
S10235
WARNING
Do not turn the ionization probe, maintain the
drawing position; should it be close to the ignition
electrode, damage may occur to the control box
amplifier.
The right positions of the ionisation probe and of
the ignition electrode (Fig. 11) is obtainable by co-
inciding their insulators planes with sloping planes
of the fastening support.
WARNING
Respect the dimensions shown in Fig. 11.
D101
PROBE ELECTRODE
Fig. 11

2915858 16
GB
Installation
5.7 Combustion head adjustment
Two separate adjustments have to be made: air and gas.
These adjustments can be carried out when the burner is still
open, during the installation (“Securing the burner to the boiler”
on page 15).
Air setting
Loosen the two screws 1) and move the internal part of the
combustion head 2) so that its rear edge 3) is coincident with
the desired set-point on the plate 4).
Tighten the screws 1).
Gas setting
Loosen the screw 5), move the ring 6) so that the pointer 7)
is coincident with the desired set-point 8).
Tighten the screw 5).
Example: The burner is installed on a boiler of 260 kW, assuming
an efficiency of 90% the burner output should be 290 kW.
From the diagram (Fig. 13) it can be seen that the air and gas set-
tings for this rating should be no. 5.
5.7.1 Gas distributor
WARNING
The set-point number is the same for air and gas
setting and is given by the following diagram.
Fig. 12
S10236
Fig. 13
S10237
Set-point number = for air and gas
Burner output
Fig. 14
S10238
NATURAL GAS LPG DISTRIBUTOR

17 2915858
GB
Installation
5.8 Gas feeding
5.8.1 Gas feeding line
Key (Fig. 15 - Fig. 16 - Fig. 17 - Fig. 18)
1 Gas input pipe
2 Manual valve
3 Vibration damping joint
4 Pressure gauge with push-button cock
5Filter
6A Includes:
-Filter
- working valve
- safety valve
- pressure adjuster
6B Includes:
- working valve
- safety valve
- pressure adjuster
6C Includes:
- safety valve
- working valve
6D Includes:
- safety valve
- working valve
7 Minimum gas pressure switch
8 Leak detection control, provided as an accessory or integrat-
ed, based on the gas train code. In compliance with the EN
676 standard, the leak detection control is compulsory for
burners with maximum outputs over 1200 kW.
9 Gasket, for "flanged" versions only
10 Pressure adjuster
11 Train-Burner adaptor, supplied separately
P2 Upstream pressure of valves/adjuster
P3 Upstream pressure of the filter
L Gas train, supplied separately
L1 The responsibility of the installer
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure that the fuel interception tap is closed
before performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
L1 L
6A
P2
7
4
P3
3
2
1
8
Fig. 15
D11854
MBC “threaded”
LL1
P2 6B
7
9
8
4
P3
3
2
15
11
Fig. 16
D11855
MBC “flanged”-VGD
LL1
5
6C
P2
7
3
2
1
8
10
11
9
Fig. 17
D11856
DMV “flanged or threaded”
LL1
5
6D
P2
7
3
2
1
8
10
11
9
Fig. 18
D11857
CB “flanged or threaded”

2915858 18
GB
Installation
5.8.2 Gas train
Approved according to standard EN 676 and provided separately
from the burner.
5.8.3 Gas train installation
The train can enter the burner from the right or left side, depend-
ing on which is the most convenient, see Fig. 5.
5.8.4 Gas pressure
Tab. F indicates the pressure drops of the combustion head and
gas butterfly valve, on the basis of the burner operating output.
Tab. F
The values shown in Tab. F on page 18 refer to:
- Natural gas G 20 NCV 10 kWh/Sm3(8.6 Mcal/Sm3)
- Natural gas G 25 NCV 8.6 kWh/Sm3(7.4 Mcal/Sm3)
Column 1
Combustion head pressure drop.
Gas pressure measured at test point 12)(Fig. 5 on page 11), with:
- combustion chamber at 0 mbar;
- Gas G20 (methane)
To calculate the approximate output at which the burner oper-
ates:
- subtract the pressure in combustion chamber from the gas
pressure measured at test point 12)(Fig. 5 on page 11).
- Find in Tab. F related to the burner concerned, the pressure
value closest to the result of the subtraction.
- Read the corresponding output on the left.
Example GAS 3 with natural gas G20:
Pressure of the gas at the socket = 10.3 mbar
Pressure in combustion chamber = 2 mbar
10.3 - 2 = 8.3 mbar
A pressure of 5.3 mbar, column 1, corresponds in Tab. F to an
output of 277 kW.
This value serves as a rough guide; the effective output must be
measured at the gas meter.
To find out on the other hand the gas pressure required at the
socket 12)(Fig. 5 on page 11), having fixed the output at which
you want the burner to operate:
- find the nearest output value in Tab. F for the burner in ques-
tion.
- Read on the right, column 1, the pressure at the test point
12)(Fig. 5 on page 11).
- Add this value to the estimated pressure in combustion
chamber.
Example GAS 3 with natural gas G20:
Desired output: 277 kW
Gas pressure at an output of 277 kW = 8.3 mbar
Pressure in combustion chamber = 2 mbar
8.3 + 2 = 10.3 mbar
pressure required at test point 12)(Fig. 5 on page 11).
DANGER
Disconnect the electrical power using the main
switch.
Check that there are no gas leaks.
Pay attention when handling the train: danger of
crushing of limbs.
Make sure that the gas train is properly installed
by checking for any fuel leaks.
The operator must use the required equipment
during installation.
kW 1 p (mbar)
G20 G25
130 3.6 5,3
154 4.1 6.1
179 4.8 7.1
203 5.5 8.1
228 6.3 9.4
252 7.2 10.8
277 8.3 12.3
301 9.4 13.9
326 10.6 15.8
350 11.9 17.7
WARNING
The heat output and gas pressure in the head
data refer to operating with the gas butterfly
valve fully open (90°).
Fig. 19
S9708