Riello RDB1R GRANT MILTON 20 kW Quick start guide

20040515 (2) - 07/2011
Installation, use and maintenance instructions
Light oil burner
One stage operation
CODE MODEL TYPE
20040062 RDB1R GRANT MILTON 20 kW 501T1R

1 20040515
GB
Contents
1 Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Information and general warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.3 Danger energised components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Firing rates, (as EN 267). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.6 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.7 Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.7.1 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.7.2 Priming pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2.1 Nozzle choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5 Electrodes setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.6 Fuel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Instructions regarding maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2.1 Maintenance frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Notes on safety for the electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Operation programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Faults / Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

20040515 2 GB
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 burner
Model: RDB1R GRANT MILTON 20 kW
These products are in compliance with the following Technical Standard:
EN 12100
EN 267
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, 30.07.2010 Mr. G. Conticini
Burners Division Department
RIELLO S.p.A.

3 20040515
GB
Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction booklet is provided with the product:
³it is a fundamental part of the product and must never be
separated from it; it must always be kept carefully so that it
can be consulted as necessary and must remain with the
product, in the case that it is transferred to another owner or
user. If it is damaged or lost, ask for another copy at your
local customer service centre;
³it was drafted to be used by trained personnel;
³it provides instructions and important information regarding
safe installation, initial operation, use and maintenance of
the burner.
Symbols used in the manual
In some parts of the manual there are triangular signals indicating
DANGER. Be extremely careful because these indicate potential-
ly dangerous situations.
2.1.2 General dangers
There are three levels of danger as indicated below.
2.1.3 Danger energised components
Other symbols
Abbreviations used
Chap. Chapter
Fig. Figure
P. Page
Sect. Section
Tab. Table
Delivery of the appliance and instruction manual
Upon receiving the appliance it is necessary that;
³The technical instructions for installation and use be given to
the user by the installer, with the recommendation to keep
them in the room where the heat generator must be
installed.
³In the instructions the following information is provided;
– the registration number of the burner;
– the address and telephone number of the customer
service centre;
³The supplier of the appliance informs the user in details
regarding;
– use of the appliance,
– any tests which may be necessary before the activation of
the appliance,
– its maintenance and the need for the appliance to be
checked at least once a year by a person entrusted by the
manufacturer's technical station or by another specialist
technician.
To ensure a periodic inspection, it is recommended to pur-
chase a maintenance contract.
2 Information and general warnings
DANGER
Highest danger level!
This symbol indicates operations that can cause
serious injury, death or long-term health risks, if
they are not carried out correctly.
WARNING
This symbol indicates operations that can cause
serious injury, death or long-term health risks, if
they are not carried out correctly.
CAUTION
This symbol indicates operations that can cause
harm to people or damage the machine, if not car-
ried out correctly.
DANGER
This symbol indicates operations that involve po-
tentially deadly electric shocks.
ENVIRONMENTAL PROTECTION
This symbol provides instructions to use the ma-
chine while respecting the environment.
³This symbol denotes a list.
........................................................................................
........................................................................................
........................................................................................
........................................................................................

20040515 4 GB
Information and general warnings
2.2 Guarantee and responsibility
The manufacturer guarantees its new products starting from the
date of the installation in accordance with current standards and/
or in accordance with the sale contract. When performing the in-
itial operation, it is essential to check that the burner is integrated
and complete.
And in particular, guarantee and liability rights are forfeited in
case of harm to persons and/or things if the damage is due to one
or more of the following;
³incorrect installation, initial operation, use or maintenance of
the burner;
³improper, erroneous or unreasonable use of the burner;
³intervention by unauthorised personnel;
³unauthorised modifications to the appliance;
³use of the burner with safety devices which are defective,
applied incorrectly and/or not working;
³installation of additional untested components
simultaneously with the burner;
³supplying the burner with unsuitable fuel;
³defects in the fuel supply installation;
³use of the burner after having found an error and/or abnor-
mality;
³repairs and/or services performed incorrectly;
³modification of the combustion chamber by introducing
inserts that prevent the flame from spreading evenly as set
at the time of construction;
³inappropriate or inadequate supervision and a lack of care of
the burner components most prone to wear;
³use of non original parts, as well as spare parts, kits, acces-
sories and optional components;
³causes of force majeure.
Furthermore, the manufacturer accepts no liability for failure
to comply with that set forth in the manual.
WARNING
The burner warranty will be considered void by the
manufacturer due to: non-compliance with in-
structions contained in the manual, operational
negligence, improper installation, and the imple-
mentation of unauthorised changes.

5 20040515
GB
Safety and prevention
3.1 Introduction
The burners have been designed and constructed according to
the standards and guidelines in force, applying the acknowl-
edged technical safety rules and foreseeing all potentially dan-
gerous situations.
It is however necessary to take into account that clumsy or care-
less use of the appliance can lead to potentially life-threatening
situations for the user or others, as well as damage to the burner
or other property. Distraction, thoughtlessness and an excess of
confidence are often the cause of accidents; as are tiredness and
drowsiness.
It is necessary to take the following into consideration;
³The burner may only be used for the purpose for which it
was designed. All other use is considered improper and
therefore dangerous.
In particular;
the type and pressure of the fuel, the voltage and frequency of the
electric power supply, the maximum and minimum output to
which the burner is set, the pressurization of the combustion
chamber, the dimensions of the combustion chamber, and the
ambient temperature must be within the limit values specified in
the instruction manual.
³It is forbidden to modify the burner to distort performance
and destinations.
³The burner must be used in perfect condition of technical
safety. Any disturbance which could compromise safety
must be eliminated as quickly as possible.
³It is forbidden to open or modify the burner components
without permission, except the parts indicated for
maintenance.
³The only parts that can be replaced are those indicated by
the manufacturer.
3.2 Personnel training
The user is the person or organisation or company that bought
the machine with the intention to use it for the purpose for which
it was designed. It is this person who bears responsibility for the
machine and the training of those working on it.
The user;
³agrees not to entrust the machine to personnel who are
unqualified or trained in its use;
³is obliged to take all necessary measures to prevent unau-
thorised people from accessing the machine;
³undertakes to appropriately oblige its staff to apply and
observe all safety requirements. undertakes, to this end, that
everyone knows the safety instructions and requirements;
³must inform the manufacturer of any defect or malfunction in
the accident protection systems, as well as every probable
dangerous situation.
³Staff must always use the legally required personal
protective equipment and follow everything contained in this
manual.
³Staff must follow all directions indicating danger and
warnings indicated on the machine.
³The staff shall never perform upon its own initiative opera-
tions or interventions outside of its competence.
³Staff is required to notify the supervisor of all problems or
dangerous situations which may arise.
³The assembly of parts of other brands or of any changes
may cause differences in the machine characteristics and
thus undermine operational safety. The manufacturer there-
fore declines any responsibility for any damage that may
arise due to the use of non-original parts.
3 Safety and prevention

20040515 6 GB
Technical description of the burner
4.1 Technical data
(1) Conditions of reference; Ambient temperature 20 °C - Barometric pressure 1013 mbar - Altitude 0 m above sea level. (Hi = 11.86
kWh/kg).
Tab. A
4.2 Burner description
1Pump
2 Air damper adjustment screw
3 Reset button with lock-out lamp
4 Photoresistance
5 Control-box
6 Pump pressure adjustment screw
7 Pressure gauge port
8Blasttube
9 Snorkel
4 Technical description of the burner
Model 501T1R
Output (1)
Thermal power (1)
1.4 - 2.2 kg/h
16.6 - 26 kW
Fuel Light oil, viscosity 4 ÷ 6 mm2/s at 20°C
Electrical supply Single phase, ~ 50Hz, 230 V ± 10%
Max power supply 1 A ~
Short circuit current 4 A ~
Motor Intensity 0.7 A
Velocity 2700 tr/min. – 283 rad/s
Capacitor 4.5 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure; 8 ÷15 bar
Absorbed electrical power 0.17 kW
Protection level IP 40
Fig. 1
1
2
5
3
6
7
48
9
D4138

7 20040515
GB
Technical description of the burner
4.3 Dimensions
4.4 Firing rates, (as EN 267)
Fig. 2
D4087
Flange Burner
130
45°
11
72 72
150
45°
180 86 207
20
ø89
225
170
ø75
232
136 140
Pressure in the combustion
chamber – mbar
Fuel output - kg/h
Thermal power - kW
D8253
1.2
16
1.4 1.6 1. 8 2 2.2 2.
4
18 20 22 24 26 28
0
0.2
0.4
0.6
0.8
1.0
1.2
501T1R
Fig. 3

20040515 8 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 packaging of the burner includes a carton box, so it is possi-
ble 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:
³the model A)(Fig. 4) and type of burner B);
³the year of manufacture, in cryptographic form C);
³the serial number D);
³the electrical input power E);
³the types of fuel used and the relative supply pressures F);
³the data of the burner's minimum and maximum output pos-
sibilities G)(see Firing rate).
5Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
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.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
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.
Fig. 4
D9370
WARNING
The output of the burner 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.

9 20040515
GB
Installation
5.4 Working position
5.5 Boiler fixing
³Put on the flange 1)(Fig. 6) the screw and two nuts.
³Fix the flange 1)(Fig. 7) to the boiler door 4) using screws 2)
and (if necessary) the nuts 3) interposing the insulating gas-
ket 5).
WARNING
The burner is designed to operate only in the po-
sitions 1, and 3 (Fig. 5).
Installation 1is preferable, as it is the only one that
allows performing maintenance operations as de-
scribed in this manual. Installations 2, 3and 4 al-
low working operations but not maintenance with
hooking to the boiler.
DANGER
Any other position could compromise the correct
operation of the appliance. Installation 5is forbid-
den for safety reasons.
D4618
1 2 3 4 5
Fig. 5
Fig. 6
1
E9050
WARNING
The seal between burner and boiler must be
airtight.
5
1
E9094
2
4
3
Fig. 7

20040515 10 GB
Installation
5.6 Burner assembly
CF Application
In case of CF applications, the burner shall not operate without
protection (A) of the suction inlet.
BF Application
In case of BF applications an optional snorkel and gasket are
available replacing (A) with (B).
This item can be supplied separately.
CAUTION
The temperature of the incoming air must not
exceed 70 °C.
D5884
A
Fig. 8
WARNING
For correct BF application, the burner must be in-
stalled on an appropriate BF boiler.
B
D5883 Fig. 9

11 20040515
GB
Installation
The combustion air supply is through a flexible or rigid pipe con-
nected to the air intake.
Consequently, you must comply with the following requirements
and instructions:
³The combustion air intake tube must be:
- fastened securely to the burner;
- made of a suitable material, with temperature characteris-
tics in the range - 30 °C to 80 °C;
- in compliance with all requirements of applicable regula-
tions in force in the country of destination.
³The intake-tube / burner system must not allow a loss of
over 2 m3/h at 0.5 mbar:
for instance, the above requirements will be met if you use flues
for pressure exhaust of flue gases (the condensation kind).
³Make sure the air intake tube’s inlet is positioned so that it is
not likely to be obstructed by foreign matter and, where nec-
essary, use suitable screens.
³The inside diameter of the hose must be at least 80 mm.
³The intake tube can be up to 6 metres in length.
NOTE
:
Burner installation must comply with one of the installations
illustrated in the figures below.
WARNING
Length is reduced if there are bends in the intake
section.
For instance, using a tube with a smooth inside
surface, you must allow for the following losses:
– for each 45° bend, tube length is reduced by
0.5 m;
– for each 90° bend, tube length is reduced by
0.8 m.
WARNING
³Under no circumstances should the air’s
entry in the hose intake area be obstructed.
³The hose must not be blocked in any way or
feature a shutting device (valves, mem-
branes etc.).
³Coaxial tubes must not be installed for any
reason.
S7851 Fig. 10
S7876 Fig. 11
S7853 Fig. 12

20040515 12 GB
Installation
5.7 Light oil supply
5.7.1 Pump
³The pump is designed to allow working level of filtration with
two pipes. In order to obtain one pipe working it is necessary
to unscrew the return plug (2), remove the by-pass screw (3)
and then screw again the return flexible oil pipe (see
Fig. 13).
³In the two pipes systems, before starting the burner make
sure that the return pipe-line is not clogged. An excessive
back pressure would cause the damage of the pump seal.
³Check periodically the flexible pipes conditions.
³A metal bowl filter (60 µm) with replaceable micronic filter
must be fitted in the oil supply pipe.
5.7.2 Priming pump
On the system in Fig. 14 it is sufficient to loosen the suction
gauge connection (6, Fig. 13) and wait until oil flows out.
Tab. B
Hdifference of level
Lmax. lenght of the suction line
Øinterminal diameter of the oil pipes
WARNING
Before activating the burner, ensure that the re-
turn line in the vat is not clogged.
The presence of any obstacle would cause the
rupture of the seal device located on the pump
shaft.
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. 13)
1 Suction line
2 Return line
3 By-pass screw
4 Gauge connection
5 Pressure adjuster
6 Suction gauge connection
7Valve
8 Auxiliary pressure test
point
WARNING
Periodically check the condition of the flexible
hoses.
It is necessary to install a filter on the fuel supply
line.
Fig. 13
7
6
5
4
3
21
8
D9630
H
metres
L metres
Ø (8 mm) Ø (10 mm)
0.5 10 20
120 40
1.5 40 80
260 100
H
max. 4 m
max. 0.1 m
D5741
Fig. 14
60 µm

13 20040515
GB
Installation
On the systems in Fig. 15 and Fig. 16 start the burner and wait
for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least
20 seconds before repeating the operation.
Tab. C
Hdifference of level
Lmax. lenght of the suction line
Øinterminal diameter of the oil pipes
In the vacuum systems (Fig. 16) the return line should terminate
within the oil tank at the same level as the suction line. In this
case a non-return valve is not required. Should however the re-
turn line arrive over the fuellevel,a non-returnvalveisrequired.
This solution however is less safe than previous one, due to the
possibility of leakage of the valve.
NOTE
:
In case of digital applications the priming pump is possible
not only with the previous procedure but also with a specific
function implemented into the digital coltrol box (see 4.7.9,
page 10). In this case the priming pump time could be longer.
WARNING
In order to purging air from oil lines and filters re-
peat for max. 5 times the complete operation pro-
gramme, to protect the pump.
The pump suction should not exceed a maximum
of 0.4 bar (30 cm Hg). Beyond this limit gas is re-
leased from the oil. Oil pipes must be completely
tight.
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
max. 4 m
H
H
D1842
Fig. 15
60 µm
60 µm
D5740
max. 4 m
H
H
Fig. 16
60 µm

20040515 14 GB
Operation
6.1 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 CO2concentration in the flue gases,
their temperatures and the average temperature of the water in
the boiler.
To suit the required appliance output, fit the proper nozzle, then
adjust the pump pressure, the setting of the combustion head and
the air damper opening in accordance with the following sched-
ule.
Adjustments made in the factory
The values in Tab. D refer to 12.50% CO2, at sea level, with am-
bient temperature and light oil temperature of 20° C.
Tab. D
6.2 Recommended nozzles
The burner complies with the emission requirements set by the
EN 267 standard.
To ensure continuity of emissions, it is necessary to use the
recommended nozzles.
6.2.1 Nozzle choice
To adjust the flow range in which the nozzle must operate, adjust
the minimum and maximum fuel pressure of on the back of the
jet.
6.3 Pump pressure
The pump is factory set to the values indicated. Tab. D.
6.4 Air damper adjustment
The settings indicated in the schedule are purely indicative. Each
installation however, has its own unpredictable working condi-
tions: actual nozzle output; positive or negative pressure in the
combustion-chamber, the need of excess air, etc. All these con-
ditions may require a different air-damper setting.
6Operation
Model Nozzle Pump
pressure
Burner
output
Air damper
adjustment
Combustion head
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
501T1R 0.40 80° S 14.5 1.7 3.5 Fixed
WARNING
It is advisable to replace the nozzles every
year during routine maintenance.
CAUTION
The use of nozzles different to those prescribed
by the manufacturer or incorrect periodic
maintenance can cause emissions that exceed
the limits foreseen by the standard in force, and in
extreme cases cause harm to people or objects.
It is understood that the damage caused by failure
to comply with the requirements contained in this
manual are not in any way attributable to the
manufacturer.

15 20040515
GB
Operation
6.5 Electrodes setting
Before removing or assembling the nozzle, loosen the screw B)
(Fig. 17) and move the electrodes ahead.
6.6 Fuel heating
In order to obtain smooth starting and operation across its output
range the burner is fitted with an electric resistance, which heats
up the light oil in the nozzle line.
This resistance is energized when the thermostat calls for heat
and after a delay of approximately two minutes depending on
room temperature, the motor will start.
The resistance remains energised during working and cuts out
when burner shuts-down.
WARNING
The measures in Fig. 17 must be respected.
Fig. 17
4± 0.3 mm
D5230 B
2 -2.5 mm

20040515 16 GB
Maintenance
7.1 Instructions regarding maintenance safety
Regular maintenance is essential for proper operation, security,
performance and long operating life of the burner.
It can reduce consumption and pollution emissions, and allow the
product to remain reliable over time.
Before performing any maintenance operation, cleaning or
check;
7.2 Maintenance programme
7.2.1 Maintenance frequency
The fuel system must be checked at least once a year by a tech-
nical station approved by the manufacturer, or by a specialised
technician.
7.2.2 Checking and cleaning
Fan cleaning
Combustion
Perform an analysis of combustion gases.
Significant differences compared to the previous test indicate the
points where the maintenance operation will need to be more
thorough.
Combustion head
Open the burner and check that all parts of the combustion head
are intact, are not distorted by the high temperatures, are free of
environmental impurities, and are positioned correctly.
Boiler
Clean the boiler according to the instruction booklet, so as to be
able to find the original combustion data, in particular; pressure in
the combustion chamber and flue gas temperatures.
Pump
In case of unstable pressure or excessively noisy pump, remove
the flexible hose from the line filter and suck up the fuel from a
tank located near the burner. This operation can identify if it is the
suction line which is responsible for the fault or the pump.
On the contrary, if the cause of anomalies is related to the suction
line, check that there is no clogged filter on the line or air intake
on the line.
Filters
Check the line filters and the nozzle present in the system. If nec-
essary, clean or replace them.
If you notice rust or other impurities inside the burner, suck up
any water and impurities deposited at the bottom of the vat with
a separate pump.
Nozzles
It is advisable to replace the nozzles every year during routine
maintenance.
Avoid cleaning the nozzle openings.
Flexible hoses
Check that they are in good condition.
Vat
Every 5 years, or as needed, remove water or impurities that
have been deposited at the bottom of the tank, using a separate
pump.
Combustion
If combustion values recorded at the start of the intervention do
not meet the standards in force or do not allow for good combus-
tion, see the table below and contact the after-sales service so
that any necessary adjustments can be made.
Allow the burner to work at full speed for about 10 minutes,
checking all the parameters specified in this manual.
Then perform a combustion analysis by checking;
• Flue gases temperature.
• CO2 percentage;
• CO content (ppm);
• The smoke index on the Bacharach scale.
7 Maintenance
DANGER
Maintenance operations and adjustment of the
burner must be performed by qualified personnel
according to the instructions in this manual and in
accordance with standards and regulations in
force.
DANGER
cut the electrical supply to the burner, by pressing
the main equipment switch;
DANGER
isolate the fuel stop tap.
WARNING
Make sure there is no dust accumulated inside the
fan or its blades, as this could reduce the air out-
put, causing polluting combustion.
Perform maintenance operations, being careful
not to damage or disrupt the fan during cleaning.

17 20040515
GB
Electrical system
8.1 Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
Use flexible cables in compliance with the EN 60 335-1 standard.
8 Electrical system
DANGER
³The electrical wiring must be carried out with the electrical supply disconnected.
³Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in
force in the country of destination. Refer to the wiring diagrams.
³The manufacturer declines all responsibility for modifications or connections different from those shown in the
wiring diagrams.
³Do not invert the neutral with the phase in the electrical supply line. Any inversion would cause a lockout due to
firing failure.
³Check that the electrical supply of the burner corresponds to that shown on the identification label and in this
manual.
³The burners have been set for intermittent operation. This means they should compulsorily be stopped at least
once every 24 hours to enable the control box to perform checks of its own start-up efficiency. Normally the
boiler's thermostat/pressure switch ensures the stopping of the burner.
If this is not the case, it is necessary to apply in series with IN a timer switch that turns off the burner at least once
every twenty-four hours. Refer to the wiring diagrams.
³The 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.
³The electrical system must be suitable for the maximum input power of the device, as indicated on the label and in
the manual, checking in particular that the section of the cables is suitable for the input power of the device.
³For the main power supply of the device from the electricity mains:
do not use adapters, multiple sockets or extensions;
use an omnipolar switch, as indicated by the current safety standards.
³Do not touch the device with wet or damp body parts and/or in bare feet.
³Do not pull the electric cables.
DANGER
disconnect the electrical supply from the burner by
means of the main system switch;
DANGER
isolate the fuel supply
DANGER
Condensation, water infiltration and formation of
ice are not permitted!

20040515 18 GB
Electrical system
8.2 Control box
To remove the active block, follow these instructions;
³Loosen the screw (1), open the protection (2) and remove all
components.
³Remove the coil (3).
³Loosen the two screws (4).
WARNING
All the installation, maintenance and dismantling
operations should be performed voltage free.
The replacement of the Control box must be per-
formed by qualified personnel, as indicated in this
manual and in accordance with standards and
regulations in force.
Fig. 18
E9151
4
4
3
12
WARNING
³The safety housing can be used on the burn-
ers with or without the heater.
³If the heater is damaged, introduce the bridge
7) (Fig. 19) into the safety housing so that the
burner can operate without the heater until
the heater is replaced.
NOTE
:
As a spare part, the housing is delivered with the bridge
7) (Fig. 19) in place.
If you replace a housing and if the heater is in operating state,
you must remove the bridge 7) before putting the cabinet in
place.
The resistor cables and thermostat must also be connected.
Fig. 19
7
S7735