Riello GI/EMME 1400 Installation and operating instructions

Installation, use and maintenance instructions
2915254 (8) - 02/2015
Dual fuel gas oil/gas burners
Progressive two-stage or modulating operation
CODE MODEL TYPE
3486683 - 3486684 GI/EMME 1400 680 T80
3487683 - 3487684 GI/EMME 2000 681 T80
3488783 - 3488784 GI/EMME 3000 682 T80
3489085 - 3489086 GI/EMME 4500 683 T80
3489087 - 3489088 GI/EMME 4500 683 T80
GB

Original instructions

1
2915254
GB
Contents
1 Declarations................................................................................................................................................................................ 2
2 Information and general warnings............................................................................................................................................ 3
2.1 Information about the instruction manual.................................................................................................................... 3
2.2 Guarantee and responsibility....................................................................................................................................... 4
3 Safety and prevention................................................................................................................................................................ 5
3.1 Introduction.................................................................................................................................................................. 5
3.2 Personnel training ....................................................................................................................................................... 5
4 Technical description of the burner......................................................................................................................................... 6
4.1 Burner designation...................................................................................................................................................... 6
4.2 Models available.......................................................................................................................................................... 6
4.3 Burner categories - Countries of destination............................................................................................................... 6
4.4 Technical data............................................................................................................................................................. 7
4.5 Electrical data.............................................................................................................................................................. 7
4.6 Maximum dimensions.................................................................................................................................................. 8
4.7 Firing rates .................................................................................................................................................................. 8
4.8 Correlation between gas pressure and burner output................................................................................................. 9
4.9 Burner equipment........................................................................................................................................................ 9
4.10 Burner description ..................................................................................................................................................... 10
4.11 Control box (LFL1.335..) ........................................................................................................................................... 11
4.12 Servomotor (SQM10.1....)......................................................................................................................................... 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
5.6 Mounting the burner on the boiler ............................................................................................................................. 14
5.7 Electrode position...................................................................................................................................................... 15
5.8 Nozzle installation ..................................................................................................................................................... 15
5.9 Combustion head adjustment.................................................................................................................................... 16
5.10 Air damper adjustment.............................................................................................................................................. 18
5.11 Pressure variator....................................................................................................................................................... 18
5.12 Light oil supply........................................................................................................................................................... 19
5.13 Gas feeding............................................................................................................................................................... 21
5.14 Electrical wiring ......................................................................................................................................................... 23
6 Start-up, calibration and operation of the burner ................................................................................................................. 29
6.1 Notes on safety for the first start-up.......................................................................................................................... 29
6.2 Adjustments for light oil operation............................................................................................................................. 29
6.3 Servomotor adjustment............................................................................................................................................. 29
6.4 Adjustments for gas operation................................................................................................................................... 29
6.5 Pressure switch adjustment ...................................................................................................................................... 30
6.6 Air/gas ratio adjustment............................................................................................................................................. 30
6.7 Operation sequence of the burner............................................................................................................................. 31
6.8 Final checks (with burner operating)......................................................................................................................... 31
7 Maintenance.............................................................................................................................................................................. 32
7.1 Notes on safety for the maintenance......................................................................................................................... 32
7.2 Maintenance programme .......................................................................................................................................... 32
8 Faults - Possible causes - Solutions...................................................................................................................................... 34
8.1 Light oil operation...................................................................................................................................................... 35
8.2 Gas operation............................................................................................................................................................ 37
A Appendix - Accessories........................................................................................................................................................... 39

2915254
2
GB
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: Dual fuel gas oil/ gas burners
Model: GI/EMME 1400
GI/EMME 2000
GI/EMME 3000
GI/EMME 4500
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 03.09.2014 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. R. Cattaneo

3
2915254
GB
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 Ser-
vice of the area;
➤is designed for use by qualified personnel;
➤offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
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 HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood 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.

2915254
4
GB
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 equipment;
➤use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
➤installation of untested supplementary components on the
burner;
➤powering of the burner with unsuitable fuels;
➤faults in the fuel supply system;
➤continuation of use of the burner when a fault has occurred;
➤repairs and/or overhauls incorrectly carried out;
➤modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
➤insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
➤use of non-original components, including spare parts, kits,
accessories and optional;
➤force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

5
2915254
GB
Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
➤The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
the type and pressure of the fuel, the voltageand frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
➤Modification of the burner to alter its performance and desti-
nations is not allowed.
➤The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
➤Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
➤Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
➤undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
➤undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
➤personnel must observe all the danger and caution indica-
tions shown on the machine.
➤Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
➤Personnel must inform their superiors of every problem or
dangerous situation that may arise.
➤The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
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.

2915254
6
GB
Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4.3 Burner categories - Countries of destination
Tab. B
4 Technical description of the burner
Designation Voltage Start-up Code
GI/EMME 1400 TC 3/220-380/60 Direct starting 3486683
GI/EMME 1400 TL 3/220-380/60 Direct starting 3486684
GI/EMME 2000 TC 3/220-380/60 Direct starting 3487683
GI/EMME 2000 TL 3/220-380/60 Direct starting 3487684
GI/EMME 3000 TC 3/220-380/60 Direct starting 3488783
GI/EMME 3000 TL 3/220-380/60 Direct starting 3488784
GI/EMME 4500 TC 3/220/60 Star/Delta 3489085
GI/EMME 4500 TC 3/380/60 Star/Delta 3489087
GI/EMME 4500 TL 3/220/60 Star/Delta 3489086
GI/EMME 4500 TL 3/220/60 Star/Delta 3489088
Series: GI/EMME
Size
Flame control system: FS1 Standard (1 stop every 24 h)
Electrical supply of the system:
3/220-380/60
3/220/60
Voltage of auxiliaries: 220/60 220V / 60Hz
GI/EMME 1400 TC 3/220-380/60
Emission: Class 1 EN267 - EN676
220/60
BASIC DESIGNATION
EXTENDED DESIGNATION
FS1
3 / 220V / 60Hz - 3N / 380V / 60Hz
3 / 220V / 60Hz
Head: TC Standard head
TL Long head
3/380/60 3N / 380V / 60Hz
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I
2H
DE I
2ELL
NL I
2L
FR I
2Er
BE I
2E(R)B
LU - PL I
2E

7
2915254
GB
Technical description of the burner
4.4 Technical data
Tab. C
(1)
Minimum pressure (measured at the sleeve) with the combustion chamber at 0 mbar to obtain maximum output.
4.5 Electrical data
Tab. D
Tab. E
(3)
The GI/EMME 4500 model is only available in a version with a “star-triangle” remote-starter; when ordering, please therefore specify the required
operating voltage.
Model GI/EMME 1400 GI/EMME 2000 GI/EMME 3000 GI/EMME 4500
Output Min - Max kW 415/814 - 1660 590/1163 - 2370 890/1744 - 3560 1190/2325 - 5100
Mcal/h 357/700 - 1428 507/1000 - 2040 765/1500 - 3061 1020/2000 - 4386
Fuel – Light oil, viscosity max. at 20 °C: 6 mm
2
/s (1.5 °E - 6 cSt)
– Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Maximum pressure
(1)
mbar 200 360 360 360
Minimum pressure mbar 20 26 30 39
Operation – Intermittent (min. 1 stop in 24 hours)
– Progressive two-stage or modulating with kit (see accessories)
Pump Output at 30 bar
Pressure range
Fuel temperature
kg/h
bar
°c max
330
7 - 40
0 - 150
495
7 - 40
0 - 150
675
7 - 40
0 - 150
Nozzle number 1
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Electrical protection IP40
Weight kg 190 200 280 500
Model GI/EMME 1400 GI/EMME 2000 GI/EMME 3000 GI/EMME 4500
3489085-86 GI/EMME 4500 3489087-88
Electrical supply
(3)
V/Hz 3/200-380/60 3/220/60 3/380/60
Fan motor IE2
rpm
kW
V
A
3525
3.0
220/380
10/5.8
3520
4.0
220/380
14.6/8.5
3500
9.2
220/380
29.1/16.8
3520
15.0
220/380
46/26.6
3500
15.0
380/660
26.6/15.4
Pump motor kW V
A
1.1
220/380
4.4/2.5
1.5
220/380
5.8/3.4
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 6 kV 2.3 A - 35 mA
Electrical power consumption kW max 5.0 6.4 12.1 17.9 17.9
Model GI/EMME 1400 GI/EMME 2000 GI/EMME 3000 GI/EMME 4500
3489085-86 GI/EMME 4500 3489087-88
Electrical supply
(3)
V/Hz 3/200-380/60 3/220/60 3/380/60
Fan motor IE3
rpm
kW
V
A
3525
3.0
220/380
10/5.8
3520
4.0
220/380
14.6/8.5
3540
9,2
220/380
30.5/17.6
3520
15.0
220/380
49.2/28.4
3520
15.0
380/660
28.4/16.4
Pump motor kW V
A
1.1
220/380
4.4/2.5
1.5
220/380
5.8/3.4
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 6 kV 2.3 A - 35 mA
Electrical power consumption kW max 5.0 6.4 10.7/12.5 16.9/18.7 16.9/18.7

2915254
8
GB
Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Tab. F
L2 Tube lenght, short head plus spacer
L2* Tube lenght, short head
L2** Tube lenght, long head
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the continuous
diagram area (Fig. 2).
Fig. 1
S8801
mm A1 A2 L1 L2 L2* L2** H1 H2
GI/EMME 1400 482 376 1090 275 385 495 250 467
GI/EMME 2000 482 396 1090 275 385 495 260 467
GI/EMME 3000 538 447 1320 346 476 606 336 525
GI/EMME 4500 538 508 1320 346 476 606 336 525
WARNING
The firing rate area values have been obtained
considering a surrounding temperature of 20°C
and an atmospheric pressure of 1000 mbar
(approx. 100 m above sea level).
Fig. 2
kW
Mcal/h
S8802
Thermal power
Combustion chamber
pressure - mbar

9
2915254
GB
Technical description of the burner
4.8 Correlation between gas pressure and burner output
Example for GI/EMME 3000:
to obtain the maximum output, a gas head pressure of 30 mbar
is measured with the combustion chamber at 0 mbar using gas
G20 with a net heat value of 10 kWh/Nm
3
(8.570 kcal/Nm
3
).
4.9 Burner equipment
Gasket for gas train flange. . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 12
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Pin extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Fair leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Wachers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 8
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 3
Thermal power
kW
Mcal/h
S8806
Pressure - mbar

2915254
10
GB
Technical description of the burner
4.10 Burner description
1 Output modulation unit (only for modulating version)
2 Air pressure switch
3 Gas butterfly control rod
4 Fan motor overload release
5 Terminal strip
6 Fair lead
7 Control box release pushbutton with lock signal
8 Head drive rod
9 Servomotor
10 Air adjustment cam
11 Oil/gas selector switch
12 gas pressure socket to sleeve
13 Gas regulator
14 Return pressure adjustment cam
15 Oil pressure switch
16 Pressure gauge on return
17 Pressure gauge on delivery
18 Electrical control board
19 Ignition transformer
20 Pump unit
21 Gas adjustment cam
Fig. 4
S8803
WARNING
The motor overload relay release on the burner
GI/EMME 4500 is located inside the starter; the
pump motor overload relay release is located in-
side the box to the side of the unit pump.

11
2915254
GB
Technical description of the burner
4.11 Control box (LFL1.335..)
Warnings
➤All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
➤Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
➤Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
➤Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
➤Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
➤Do not press the reset button or the remote reset button
of the control box for more than 10 seconds because
this will damage the internal relay.
For safety and reliability, comply with the following instruc-
tions:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Use
The control box is a control and supervision system of medium
and large capacity forced draught burners for intermittent opera-
tion (at least one controlled shut-down every 24 hours).
Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit,make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
•
Electrical 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 elec-
trocution. When connected to the electricity supply, the ioni-
sation 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).
Technical data
Tab. G
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. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ±6 %
Fuse (Internal) T6.3H250V
Primary fuse
(external) max. 10 A
Weight approx. 1 kg
Power absorption approx. AC 3.5 VA
Protection level IP40
Safety class II
Input current at terminal 1 max. 5 A continuous (peaks of
20 A / 20 ms)
Load on the control
terminals max. 4 A continuous (peaks of 20 A / 20 ms)
Environmental conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60°C
< 95% RH
Fig. 5
S8414

2915254
12
GB
Technical description of the burner
4.12 Servomotor (SQM10.1....)
Warnings
➤All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
➤Before modifying the wiring in the connection area of the
servomotor, fully disconnect the burner control device from
the power supply (omnipolar separation).
➤To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
➤Check the wiring is in order.
➤Falls and collisions can negatively affect the safety func-
tions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• When assembling the servomotor and connecting the damp-
er, the gears can be disengaged by means of a lever, allow-
ing the drive shaft to be easily adjusted in both directions of
rotation.
Technical data
Tab. H
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
Operating voltage AC 220...240V, 50 Hz –15 % / +10 %
AC 220 V, 60 Hz –15 % / +10 %
Auxiliary and limit switch-
es switching capacity 10 (3) A, AC 24...250 V
Angular positioning up to 160 ° (base scale)
Assembly position optional
Electrical protection IP 54, DIN 40050
Safety class GB
Weight approx. 1.7 kg
Actuator motor synchronous motor
Power absorption 9 VA
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-1
Class 1K3
Class 1M2
-20...+70°C
< 95% RH
Fig. 6
S8413

13
2915254
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
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, showing:
➤the model (A)(Fig. 7) and type of burner (B);
➤the year of manufacture, in cryptographic form (C);
➤the serial number (D);
➤the data for electrical supply (E);
➤the absorbed electrical power (F);
➤the types of gas used and the relative supply pressures (G);
➤the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
➤light oil maximum viscosity (I).
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 towhich you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25cm 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.
Fig. 7
S8816
A
B C
EDF
H
G
I

2915254
14
GB
Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boiler plate
Drill the combustion chamber locking plate as shown in Fig. 9.
The position of the threaded holes can be marked using the ther-
mal screen supplied with the burner.
Tab. I
5.6 Mounting the burner on the boiler
To detach the burner from the combustion head, proceed as fol-
lows:
➤remove the cover from bracket 1)(Fig. 10), pin 2), stops 4)
and screws 3).
➤Detach the hoses 6) and release the tie-rod on the gas but-
terfly, removing screw 11).
➤Slide the burner out of the combustion head by about 100-
120 mm.
➤Release the drive fork 7) by removing screws 10).
➤It is now possible to slide the burner fully out on pins 5).
➤Secure the tube to the boiler, inserting the insulating screen
9).
➤Slide the burner in on pins 5), leaving it open by about 100-
120 mm.
➤Refit fork 7), securing it with screws 10).
➤Completely close the burner, securing it with screws 3), fit
stops 4), pin with cotter 2), gas butterfly tie-rod 11), and
hoses 6).
➤When the burner is open, it is possible to detach gas sleeve
8) from the tube.
➤Before fitting the burner to the boiler, it is advisable to fit the
tube as specified below.
5.6.1 Maintenance of the combustion head
➤Repeat the operations described above using the special
extensions for pins 5) supplied as standard with the system.
➤When opening the burner, it is advisable to support its
weight by suitable means or using the wheeled support unit
available on request.
WARNING
➤The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 8).
➤Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
➤Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
➤Any other position could compromise the cor-
rect operation of the appliance.
➤Installation 5is prohibited for safety reasons.
Fig. 8
3 4 51 2
S8335
mm A B C
GI/EMME 1400 255 260 M16
GI/EMME 2000 265 260 M16
GI/EMME 3000 340 310 M20
GI/EMME 4500 340 310 M20
Fig. 9
D1366
WARNING
By lifting the burner with hooks, it is possible to se-
cure it to the boiler without detaching it from the
combustion head.

15
2915254
GB
Installation
5.7 Electrode position
5.8 Nozzle installation
The burner complies with the emission requirements of the
EN267 Standard. In order to guarantee that emissions do not
vary, recommended and/or alternative nozzles specified by Riello
in the Instruction and warning booklet should be used.
5.8.1 Recommended nozzle
Select the nozzle, with a delivery rating slightly higher than effec-
tively required, from the following types:
– types without needle valve: Bergonzo B5
– types with needle valve: Bergonzo B5
Nozzle with needle valve can also be used (in thi s case you have
a light increase of the pressure on the return line).
Angles of 45° - 50° are normally recommended.
For narrow combustion chambers, use nozzles with angles of
30° - 35°.
To set the delivery range within which the nozzle must operate,
adjust max. and min. fuel pressure on return from nozzle in rela-
tion to the graphs opposite (Fig. 12 and Fig. 13).
Fig. 10
D1375
WARNING
Place the electrode observing the dimensions
specified in Fig. 11.
Fig. 11
S8815
WARNING
It is advisable to replace the nozzle once a year
during periodical maintenance.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards
to people and objects.
The manufacturing company shall not be liable for
any such damage arising from non-observance of
the requirements contained in this manual.
WARNING
➤Do not use any sealing products such as gas-
kets, sealing compound, or tape.
➤Be careful to avoid damaging the nozzle seal-
ing seat.
➤The nozzle must be screwed into place tightly
but not to the maximum torque value pro-
vided by the wrench.

2915254
16
GB
Installation
5.8.2 Relationship between nozzle type and
delivery/return pressure
5.9 Combustion head adjustment
The combustion head moves simultaneously with cam 8) (Fig. 17
on page 18), the variable-profile cams and the gas butterfly.
Head position can be seen on cylinder 2)(Fig. 15).
The head control lever systems are factory-calibrated for maxi-
mum travel.
If a different modulation range is required, these levers must be
recalibrated so that head travel takes place as illustrated in the
graph (Fig. 14).
Example:
with burner GI/EMME 4500, for modulation from 1400 to 3400
Mcal/h, you see from the graph:notch1 for 1400 Mcal/h, notch 6.5
for 3400 Mcal/h, with a travel of 5.5 notches.
NOTE
To avoid causing knocking, never exceed maximum and mini-
mum aperture positions corresponding, respectively, on cylinder
2)(Fig. 15), to notch 9 with the servomotor at 130° and notch 0
with the servomotor at 0°.
To modify combustion head travel, proceed as follows:
➤con-rod 1), which controls drive rod 8) of the combustion
head, is fitted with a slot; when tie-rod 9) is moved towards
the outside of the slot, head travel decreases by about
20 mm (approx. 4 notches).
If a larger reduction is required, proceed as follows:
– with the servomotor at 0°, slacken screws 5) and push ring 6)
under the variable-profile cam in the direction of the arrow.
– This reduces eccentricity and thus decreases travel.
– Having established the required travel, fully secure screws
5).
– In the previous example (travel of 5.5 notches), travel start -
end must coincide with the required values of 1 and 6.5.
Fig. 12
D3602
Return pressure - bar
Delivery pressure
25 bar
Fig. 13
D3603
Return pressure - bar
Delivery pressure
25 bar

17
2915254
GB
Installation
– To obtain this, turn hex. sleeve 3) one way or the other after
having slackened nuts 4).
– With the servomotor positioned at 0°, notch 1 must coincide
with reference surface 10); when the servomotor is posi-
tioned at 130°, it must coincide with notch 6.5.
– Having completed the adjustment, fully secure nuts 4) with
ball-joint 9) positioned as shown in Fig. 15.
– Head calibrations are performed with the burner closed and
not operating and with the servomotor released.
– Having completed the adjustment, manually check cam 7)
travel to ensure there is no knocking between 0° and 130°.
Fig. 14
S8804
kW
Mcal/h
Combustion head travel notches
Burner output
Fig. 15
S8805

2915254
18
GB
Installation
5.10 Air damper adjustment
Air damper adjustment is performed by acting on the variable pro-
file cam. This operation is performed after having adjusted the
pressure variator and the combustion head.
With the burner on, remove voltage from the servomotor, detach-
ing the fast-on pin located on the electrical control panel, and
release movement by pressing on release 5)(Fig. 31 on
page 29).
Calibrate maximum output, minimum output and intermediate
outputs in this order.
Having completed the adjustment, re-check all calibrations, reset
the electrical connections of the servomotor and secure the ad-
justment screws with the crossways screws.
5.10.1 Modifying air damper tie-rod length
With the burner off, proceed as follows:
➤detach ball-joint 2)(Fig. 16) from lever 1);
➤unscrew extension 3) a few turns from tie-rod 4);
➤reconnect the ball-joint to the lever and raise the cam profile
until the air damper index returns to 0 with the servomotor
at 0°.
Key (Fig. 16)
1 Lever
2 Ball - joint
3 Extension
4 Tie-rod
5.11 Pressure variator
To calibrate cam 8)(Fig. 17):
➤remove gear - case 9), slacken screws 7), and act on screw
4) until required eccentricity is obtained;
➤turning screw 4) to the right (+ sign), eccentricity is
increased, thus increasing the difference between nozzle
maximum and minimum delivery;
➤turning screw 4) to the left (- sign), eccentricity is reduced,
thereby reducing the difference between nozzle maximum
and minimum delivery.
➤Every variation of eccentricity may require a travel offset
using nut and locknut 6).
WARNING
It is recommended to extend the tie-rod when the
air damper moves within a reduced angle (air
damper at about half travel of maximum output);
this helps avoid giving the cam too curved a pro-
file.
D1389
Fig. 16
CAUTION
➤To obtain correct calibration, cam 8) must
operate over the full travel range of the servo-
motor (20° - 130°): every variation of the ser-
vomotor must be matched by a variation in
pressure.
➤Never give the variator piston a snug fit: stop
ring 5) sets maximum travel.
➤When the adjustment has been made, manu-
ally check that there is no knocking between
20° and 130° and that maximum and mini-
mum pressures match pre-selected values as
indicated on the graph (Fig. 12).
➤If, at maximum nozzle delivery (maximum
return pressure), pressure oscillations are
seen on pressure gauge 3), slightly reduce
pressure until the oscillations are eliminated.
D1386
Key (Fig. 17)
1 Pressure switch fitting
2 Delivery pressure gauge
3 Return pressure gauge
4 Cam adjustment screw
5 Piston halt ring
6 Piston calibration nut and locknut
7 Cam locking screws
8 Variable cam
9 Gear-case
Fig. 17