Riello RDB 2.2R BG 24 kW Quick start guide

20094184 (6) - 06/2015
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Light oil burners
Quemadores de gasóleo
One stage operation
Funcionamiento a 1 llama
MODEL - MODELO CODE - CÓDIGO TYPE - TIPO
20091750 RDB2.2R BG 15 kW L002BG1
20091751 RDB2.2R BG 24 kW L003BG2
20091752 RDB2.2R BG 32 kW L004BG3
GB
E

Translation of the original instructions
Traducción de las instrucciones originales

1 20094184
GB
Contents
1 Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.5 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.6 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.7 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.7.1 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.7.2 Priming pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Combustion adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Recommended nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.5 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5.1 Main air damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5.2 Two-stage air damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.6 Electrodes setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.7 Fuel heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.8 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.8.1 Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.9 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.10 Operating programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.11 Table of times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.11.1 Operations status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.11.2 Fault diagnostics - lockouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.11.3 Fuel preheating function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.4 Shut-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.5 Intermittent operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.6 Recycle and limit of repetitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.7 Presence of an extraneous light or parasite flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.8 Pre and post spark ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.11.9 Reset protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.10 Remote reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.11 Reset push-button anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.12 External lockout indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.13 Frequency main supply anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.14 Internal voltage anomaly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.11.15 Checking the fan motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents
20094184 2
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6.11.16 Checking the electronic circuit controlling the oil valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.11.17 EEprom check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.12 Automatic pre-heating deactivation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.13 Post-purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.14 Programming menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.14.1 Shut-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.14.2 Post-purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.14.3 Intermittent operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.14.4 Displaying the last lockout that occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.15 Lockout types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
7 Faults / Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2 Maintenance programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2.1 Maintenance frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3 20094184
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Declaration
1 Declaration
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burners
Model: RDB 2.2R BG 15 kW
RDB 2.2R BG 24 kW
RDB 2.2R BG 32 kW
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and according to the European Directives:
BED 92/42/EC Efficiency Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 21.05.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
EC-0036xxxxx Class 2

20094184 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 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 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 important information that
you must bear in mind.
This symbol indicates a list.

5 20094184
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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 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.
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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.

20094184 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
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 voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, 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.
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 20094184
GB
Technical description of the burner
4.1 Technical data
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(Hi = 11.86 kWh/kg) Tab. A
4.2 Burner description
1 Oil pump
2 Control box
3 Reset button with lockout lamp
4 Flange with insulating gasket
5 Air damper adjustment screw
6 Air intake (BF)
7 Capacitor
8 Combustion head
9 UV sensor
10 Motor
11 Oil valve
12 Pump pressure adjustment screw
13 PTC heater
4 Technical description of the burner
Model L002 BG1 L003 BG2 L004 BG2
Delivery (1)
Thermal output(1)
kg/h
kW 1.26 15 2.02 24 2.7 32
Fuel Light oil, viscosity 4 6 mm2/s at 20°C
Electrical supply Single-phase, ~ 50Hz 230V ± 10%
Motor A
rpm
rad/s
0.75
2800
294
Capacitor F4.5
Ignition transformer Secondary 18 kV - 25 mA
Pump bar Pressure: 8 15
Absorbed electrical power kW 0.175
Fig. 1
20093879

20094184 8
GB
Technical description of the burner
4.3 Overall dimensions
4.4 Burner equipment
Flange with insulating gasket ............................................. No. 1
Nuts for fixing the flange to the boiler ................................. No. 5
Screw and nuts for flange .................................................. No. 1
Screws for fixing the flange to the boiler ............................ No. 4
Flexible hoses with nipples ................................................ No. 2
Hexagonal wrench .............................................................. No. 1
Fig. 2
Flange Burner
20100061
Type A B
L002 BG1 80 191
L003 BG1 89 201
L004 BG1 89 201

9 20094184
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner is shipped in cardboard packaging, so it is possible to
move it when it is still packaged with a transpallet or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label (Fig. 3) of the burner, showing:
the model and the code burner (A), the type (B);
Year of manufacture, in cryptographic form (C);
the serial number (D);
the electrical supply data (E);
the types of light oil used and the relative supply pressures
(F);
the minimum and maximum possible output data of the
burner (G) (see Firing rate).
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
The burner output must be within the boiler's firing
rate.
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. 3
D9370

20094184 10
GB
Installation
5.4 Operating position
5.5 Boiler fixing
Fix the bolt (6) and nut (7) onto the flange (1) as in Fig. 5.
Fix the flange (1) to the appliance (4) using the supplied nuts
(3) with the gasket (5) inbetween as in Fig. 6.
Insert the burner tube through the flange and push to ensure
full insertion. With the burner collar fully inserted into the
flange the O-ring will form a seal.
Fix the securing nut (8)(Fig. 6) onto the bolt (6).
WARNING
The burner is designed to operate only in the po-
sitions 1, 2, 3 and 4.
Installation 1is preferable, as it is the only one that
allows the maintenance operations as described
in this manual.
The installations 2, 3 and 4 permit operation but
make maintenance and inspection of the combus-
tion head more difficult, pag. 27.
WARNING
Any other positioning could compromise the cor-
rect operation of the appliance.
The installation 5is prohibited for safety reasons.
Fig. 4
D4618
1 2 3 4 5
1Fig. 5
87
6
WARNING
The seal between burner and boiler must be
airtight.
Fig. 6
3
1
5
4

11 20094184
GB
Installation
5.6 Burner assembly
BF application
In case of applying BF (Fig. 7), the air supply takes place by
means of a flexible hose connected to the air intake (A).This
component can be supplied separately.
5.7 Hydraulic systems
5.7.1 Pump
The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to unscrew the
return plug 2)(Fig. 8), remove the by-pass screw (3) and then
screw again the plug (2).
CAUTION
The temperature of the incoming air must not
exceed 70°C.
WARNING
For correct BF application, the burner must be in-
stalled on an appropriate BF boiler.
A
Fig. 7
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
WARNING
Before starting the burner, make sure that the tank
return line is not clogged.
Obstructions in the line could cause the sealing
organ located on the pump shaft to break.
WARNING
The suction plug 1) is made of plastic. Once
removed, it must not be used again.
In single-pipe installations, the plug in the re-
turn line 2) must be totally in steel.
Key (Fig. 8)
1 Gas oil suction line
2 Return line plug
3 By-pass screws
4 Manometer connection
5 Pressure adjuster
6 Vacumeter connection
7 Gas oil solenoid
8 Auxiliary pressure test
points
WARNING
Check periodically the flexible pipes conditions.
If necessary, install a filter on the fuel supply line.
Fig. 8
7
6
5
4
3
21
8
D9630

20094184 12
GB
Installation
5.7.2 Priming pump
In the system of Fig. 9 just loosen the connection of the vacume-
ter 6)(Fig. 8) and wait for the fuel to come out.
Tab. B
In the systems of Fig. 10 and Fig. 11 start the burner and wait for
the priming.
Should lockout occur prior to the arrival of the fuel, await at least
20 seconds before repeating the operation.
The pump vacuum should not exceed a maximum of 0.4 bar
(30 cm Hg).
Above that level, gas leaks out from the fuel.
The pipes must all be perfectly sealed.
Tab. C
In vacuum systems (Fig. 11) you are advised to bring the return
line to the same height as the suction line.
In this case a non-return valve is not required.
Should however the return line arrive over the fuel level, a non-
return valve is required.
This solution however is less safe than previous one, due to the
possibility of leakage of the valve.
H= Difference of level
L= Maximum suction line length
Ø= Inner diameter of the pipe
H
metres L metres
Ø (8 mm) Ø (10 mm)
0.5 10 20
120 40
1.5 40 80
260 100
H
metres L metres
Ø (8 mm) Ø (10 mm)
035 100
0.5 30 100
125 100
1.5 20 90
215 70
3 8 30
3.5 620
H
max. 4 m
min. 0.1 m
D5741
Fig. 9
max. 4 m
H
H
D1842
Fig. 10
D5740
max. 4 mH
H
Fig. 11

13 20094184
GB
Start-up, calibration and operation of the burner
6.1 Notes on safety for the first start-up
6.2 Combustion adjustment
In conformity with Efficiency Directive 92/42/EEC, the application
of the burner on the boiler, adjustment and testing must be car-
ried out observing the instruction manual of the boiler, including
verification of the CO and CO2 concentration in the flue gases,
their temperatures and the average temperature of the water in
the boiler.
To suit the required appliance output, choose the proper nozzle
and adjust the pump pressure and the air damper opening in ac-
cordance with the following data.
The values refer to 11.6% of CO2at sea level, and with the light
oil and ambient temperature at 10°C.
The values in Tab. D are obtained on a THERMITAL boiler (ac-
cording to EN267). They refer to 12.5 % CO2, at sea level and
with an ambient and light oil temperature of 20 °C.
Tab. D
6.3 Recommended nozzles
The burner complies with the emission requirements of the EN
267 standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by manufacturer in the In-
struction and warning booklet should be used.
To set the delivery range within which the nozzle must work, noz-
zle return line fuel pressure must be adjusted.
6.4 Pump pressure
14 bar:
The pump is calibrated in the factory as shown in Tab. D.
6 Start-up, calibration and operation of the burner
WARNING
The first start-up 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.
WARNING
Checkthecorrect working of the adjustment,com-
mand and safety devices.
WARNING
The combustion air is sucked from outside, there-
fore, there can be sensitive temperature varia-
tions that can influence the percentage value of
the CO2. It is advisable to adjust the CO2accord-
ing to the diagram.
For example: with an external air temperature of
10°C, adjust the CO2to 12.5% (± 0.2%).
BURNER Nozzle Pump
pressure Burner output Burner output Damper adjustment
Code Type GHP Angle Type bar kg/h ± 4% kW Set-point
20091750 L002BG1 0.4 80° Fluidics
HF 91.26 15 2.9-B
20091751 L003BG2 0.6 80° Fluidics
HF 12 224 2
20091752 L004BG3 0.75 80° Fluidics
HF 12 2.7 32 5.75
WARNING
It is advisable to replace nozzles every year dur-
ing regular maintenance operations.
CAUTION
The use of nozzles other than those specified by
manufacturer and inadequate regular mainte-
nance may result into emission limits non-con-
forming to the values set forth by the regulations
in force, and in extremely serious cases, into po-
tential 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.

20094184 14
GB
Start-up, calibration and operation of the burner
6.5 Air damper adjustment
The air damper is adjusted in the factory.
This adjustment is purely indicative. However, each installation
has its own operating conditions: nozzle flow rate, positive or
negative pressure in the combustion chamber, air excess re-
quirement, etc. All these conditions can require different adjust-
ments of the air damper.
6.5.1 Main air damper
The main air damper A)(Fig. 12) can be regulated in position B)
for the burner code 20091750.
To adjust the positions of the air damper, proceed as follows:
remove the secondary damper B) by loosening the screw 1);
loosen the screw 2) and turn the main damper A) to the
required position;
tighten the screw 2) and re-install the secondary damper B).
6.5.2 Two-stage air damper
The purpose of the damper B)(Fig. 13) is to optimise the air in-
take.
Optimisation is possible by using the screw 3)(Fig. 13).
WARNING
Only for code 20091750
The adjustment of the air is carried out using two
independent dampers (Fig. 12).
Fig. 12
20093890
20091750
B3
E9172 Fig. 13

15 20094184
GB
Start-up, calibration and operation of the burner
6.6 Electrodes setting
6.7 Fuel heating
The burner uses a heater powered by the presence of electricity
to the boiler.
At first start-up, during the winter period and with a light-oil tem-
perature less than 8 °C, some ignition difficulties could occur be-
cause the fuel is not warm enough. This problem disappears
when the fuel reaches an optimal temperature.
For this reason the burner is fitted with a pre-heater to avoid such
difficulties. The burner will not attempt to start up until the fuel has
reached the optimal temperature.
WARNING
These dimensions Fig. 14 must be respected.
Fig. 14
20093889

20094184 16
GB
Start-up, calibration and operation of the burner
6.8 Electrical system
Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
6.8.1 Control box
To remove the control box from the burner, proceed as follows:
unscrew the screw 1)(Fig. 15) and open the protection 2).
Disconnect all the components.
Remove the coil 3) from the oil pump.
Unscrew the two screws 4) and remove the control box.
Refit the control box following the procedure in the reverse
order to the one described above.
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
The electrical wiring must be carried out in conformity with the regulations in force in the countries of destination,
and by qualified personnel. Refer to the wiring diagrams.
The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-
ing diagrams.
Do not invert the neutral with the phase in the electrical supply line.
Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual.
The burners have been calibrated for intermittent operation. This means that they must stop once every twenty
four hours to permit the control box to check its efficiency at start up. Normally the boiler's thermostat/pressure
switch ensures the stopping of the burner.
If this is not the case, a timer should be fitted in series to L-N to stop the burner at least once every 24 hours.
Refer to the wiring diagrams.
The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event of
doubt, have the electrical system checked by qualified personnel.
The electrical system must be suitable for the maximum power absorption of the device, as indicated on the label
and in the manual, checking in particular that the section of the cables is suitable for that level of power absorp-
tion.
For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- provide for an omnipolar switch, as required by current safety regulations.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.
DANGER
Disconnect the electrical supply from the burner
by means of the main system switch.
DANGER
Turn off the fuel interception tap.
Avoid condensate, ice and water leaks from form-
ing.
DANGER
All installation, maintenance and dismantling op-
erations should be carried out with the power
switched off.
WARNING
The replacement of the electric control box must
be carried out by qualified personnel, as indicated
in this manual and in accordance with standards
and regulations in force.
Fig. 15
4
4
3
12

17 20094184
GB
Start-up, calibration and operation of the burner
6.9 Electrical diagram
Fig. 16
~ 50Hz- 230V
TS
RR SB
F1
HT
TB
L
N
PE
White
Green/yellow
Black Red Grey Violet
HEAT DEMAND
20104050
CONTROL BOX
Black
White
Blue
Main switch
TO BE DONE BY
THE INSTALLER
CARRIED OUT
IN THE FACTORY
Key (Fig. 16)
C: Capacitor
E: Electrodes
F: UV detector
F1: T4A Fuse
HT: Heat request thermostat
K: Pre-heater thermostat
MV: Fan motor
R: Pre-heater
RR: Remote reset
SB: Remote lockout signal (230V - 0.5A max.)
TB: Burner-earth
TS: Safety thermostat
V: Oil valve
X6: 6-pin plug
XP6: 6-pin socket
WARNING
Do not invert the neutral with the phase in the
electrical supply line.
Check that the electrical supply of the burner
corresponds to that shown on the identifica-
tion label and in this manual.
The section of the conductors must be at
least 1 mm2. (Unless requested otherwise by
local standards and legislation).
WARNING
Test the burner by checking the shut-down of the
burner by opening the thermostats and the lockout
by darkening the UV detector.
CAUTION
If the cover is still on, remove it and proceed with
the electric wiring following the wiring diagrams.
Use flexible cables in compliance with EN 60 335-
1 standards.
WARNING
This control box has a post-purging function
Do not replace it with other versions!

20094184 18
GB
Start-up, calibration and operation of the burner
6.10 Operating programme
Normal operation
Lockout due to extraneous light during pre-purging
Lockout due to ignition failure
Key (Fig. 17 - Fig. 18 - Fig. 19)
FFlame detector
HT Heat request thermostat
ID Ignition device
KEnabling switch thermostat for start up after preheating
FM Fan motor
PH Heater
V1 Oil valve
LED Reset button LED colour
t1 Standby time
t2 Time for checking initialisation
t3 Pre-purging time
t3i Pre-ignition time
t3l Checks for extraneous light during pre-purging
t4i Total ignition time
t4l Reaction time to achieve safety shut-down due to flame
failure
t5i Post-ignition time
tpp Post-purging time
ts Safety time
20076737
Flame loss during operation (Recycle: max. 3 attempts)
Green
blink Orange
blink
Green blink
Green
Lockout
Green
blink Orange
blink
Green blink
Green
POWER SUPPLY
Fast red
Signal not requested Fig. 17
link
F
LED
t
2
t
1
HT
FM
ID
V1
P
M
t
3
l
PH
K
t
s
20083033
Lockout
Green
blink Red
Red, green blink
Orange blink
POWER SUPPLY
Fig. 18
Fig. 19
D11374
Red
Green
blink Orange
blink
POWER SUPPLY
Green
blink
Lockout