Riello RDB1R GRANT MILTON 20 kW Quick start guide

20166849 (3) - 09/2021
Installation, use and maintenance instructions
Light oil burner
One stage operation
CODE MODEL TYPE
20040062 RDB1R GRANT MILTON 20 kW 501T1R
GB

Original instructions

1 20166849
GB
Contents
1 Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Product ERP Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Information and general warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1.4 Delivery of the system and the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5 Firing rate (as EN 267) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.4 Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.7 Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.7.1 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.7.2 Priming pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.8 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.8.1 Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.8.2 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Combustion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3.1 Nozzle choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.4 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.5 Air damper adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.6 Electrodes setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.7 Fuel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.8 Operation programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2.1 Maintenance frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 Faults / Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

20166849 2
GB
Declaration
Declaration of Conformity in accordance with ISO / IEC 17050-1
These products are in compliance with the following Technical Standards:
• EN 12100
• EN 267
According to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
1 Declaration
2 Product ERP Guidelines
SPECIFICATION FOR THE EUROPEAN UNION ONLY
GUIDELINES FOR THE PLACING ON THE MARKET AND/OR PUTTING INTO SERVICE OF BURNERS, IN ACCORDANCE WITH
THE REGULATION (EU) No. 813/2013 IMPLEMENTING DIRECTIVE 2009/125/EC.
A RIELLO burner (Heat Generator), where it is matched with a water-based boiler (Heater Housing) with a nominal output 400 kW,
providing heat for heating purposes and heat to deliver sanitary hot water, can be installed:
• With boilers (heater housings) already in service in the field, for replacement, in conformity to Article 1, paragraph 2, point(G)of
the EU Regulation No. 813/2013;
• With boilers (heater housings) on a new installation, if they have emissions complying with the requirement of Annex II, paragraph
4 of the EU regulation No. 813/2013.

3 20166849
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Information and general warnings
3.1 Information about the instruction manual
3.1.1 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.
3.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
3.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
3 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20166849 4
GB
Information and general warnings
3.1.4 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.
3.2 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.
1
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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.

5 20166849
GB
Safety and prevention
4.1 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, diathermic
oil, and to other uses expressly foreseen by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the 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.
4.2 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:
4 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.

20166849 6
GB
Technical description of the burner
5.1 Technical data
Tab. A
(1) Conditions of reference; Ambient temperature 20 °C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(Hi = 11.86 kWh/kg).
5.2 Burner description
1Pump
2 Air damper adjustment screw
3 Reset button with lock-out lamp
4 Flame sensor
5 Control-box
6 Pump pressure adjustment screw
7 Pressure gauge port
8Blasttube
9Snorkel
10 Hose
5.3 Burner equipment
Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fitting for hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Hexagonal key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws of by-pass pump . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instruction manual + Spare part list . . . . . . . . . . . . . . . . . . No. 1
5 Technical description of the burner
Model RDB1R
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
Max power supply
Short circuit current
Single phase, ~ 50Hz, 230 V ± 10%
1 A ~
4 A ~
Fan motor Intensity 0.75 A
Velocity 2800 rpm – 294 rad/s
Capacitor 4.5 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure; 8 15 bar
Absorbed electrical power 0.25 kW
Protection level IP 20
34
2
9
1
8
5
6
7
10
Fig. 1
20173082

7 20166849
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Technical description of the burner
5.4 Overall dimensions
Tab. B
Tab. C
5.5 Firing rate (as EN 267)
H
L T P
D
E
K
J
Fig. 2
20149646
Model D E H J K L P T
RDB1R 89 170 232 75 20 276 207 86
W6
W6
D1
W3
W8W9
W5
W1
W2
Fig. 3
20152080
Model D1W1W2W3W5W6W8W9
RDB1R 92 130 150 180 11 45° 72 72
Pressure in the combustion
chamber – mbar
Thermal power - kW
D8253
1.2 1.4 1.6 1.8 2 2.2 2.4
0
0.2
0.4
0.6
0.8
1.0
1.2
Fig. 4

20166849 8
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Installation
6.1 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.
6.2 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.
6.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model A)(Fig. 5) and type of burner B);
the year of manufacture, in cryptographic form C);
the serial number D);
the electrical input power E);
the types of fuel used and the relative supply pressures F);
the data of the burner's minimum and maximum output pos-
sibilities G)(see Firing rate).
6Installation
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.
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 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.
Fig. 5
AB
G
E
EE
DC
F
20173125

9 20166849
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Installation
6.4 Working position
6.5 Boiler fixing
Put on the flange 1)(Fig. 7) the screw and two nuts.
Fix the flange 1)(Fig. 8) 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. 6).
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. 6
Fig. 7
1
E9050
Provide an adequate lifting system of the burner.
WARNING
The seal between burner and boiler must be
airtight.
5
1
E9094
2
4
3
Fig. 8

20166849 10
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Installation
6.6 Burner assembly
CF Application (Fig. 9)
In case of CF applications, the burner shall not operate without
protection (A) of the suction inlet.
BF Application (Fig. 10)
In case of BF applications an optional snorkel and gasket are
available replacing (A) with (B).
This item can be supplied separately.
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:
The 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.
The 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).
Make 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.
The inside diameter of the hose must be at least 80 mm.
The intake tube can be up to 6 metres in length.
NOTE:
Burner installation must in any case comply with the flue
systems included within the boiler approved configuration.
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.
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
Under no circumstances should the air’s
entry in the hose intake area be obstructed.
The hose must not be blocked in any way or
feature a shutting device (valves, membranes
etc.).
D5884
A
Fig. 9
B
D5883 Fig. 10

11 20166849
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Installation
6.7 Light oil supply
6.7.1 Pump
The pump is designed to allow working with one pipe.
In order to obtain two pipes working it is necessary to
unscrew the return plug 2)(Fig. 11), screw the by-pass screw
3),supplied as burner equipment and then screw the return
hose.
In 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.
Check periodically the flexible pipes conditions.
A metal bowl filter (60 µm) with replaceable micronic filter
must be fitted in the oil supply pipe.
6.7.2 Priming pump
On the system in Fig. 12 it is sufficient to loosen the suction
gauge connection 6)(Fig. 11) and wait until oil flows out.
Tab. D
H difference of level
L maximum length of the suction line
Ø internal diameter of the oil pipes
Explosion danger due to fuel leaks in the
presence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel shut-off valve is closed before
performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
WARNING
Before activating the burner, ensure that the re-
turn line in the tank 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. 11)
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
Fig. 11
7
6
5
4
3
21
8
D9630
WARNING
Periodically check the condition of the flexible
hoses.
It is necessary to install a filter on the fuel supply
line.
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. 12
60 µm

20166849 12
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Installation
On the systems in Fig. 13 and Fig. 14 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. E
H difference of level
L maximum length of the suction line
Ø internal diameter of the oil pipes
In the vacuum systems (Fig. 14) 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 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.
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 control 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 maximum 5 times the complete operation
programme, 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. 13
60 µm
60 µm
D5740
max. 4 m
H
H
Fig. 14
60 µm

13 20166849
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Installation
6.8 Electrical wiring
Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking oper-
ations:
DANGER
The electrical wiring must be carried out with the electrical supply disconnected.
Electrical 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.
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. Any inversion would cause a lockout due to fir-
ing failure.
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 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.
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 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.
For 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.
Do not touch the device with wet or damp body parts and/or in bare feet.
Do not pull the electric cables.
DANGER
Turn off the burner's power supply using the main
system switch.
DANGER
Turn off the fuel interception tap.
DANGER
Avoid condensate, ice and water leaks from form-
ing.
After carrying out maintenance, cleaning or
checking operations, reassemble the cover and
all the safety and protection devices of the burner.

20166849 14
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Installation
6.8.1 Control box
To remove the active block, follow these instructions;
Loosen the screw 1), open the protection 2) and remove all
components.
Remove the coil 3).
Loosen the two screws 4).
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.
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.
WARNING
The safety housing can be used on the burn-
ers with or without the heater.
If the heater is damaged, introduce the bridge
7) (Fig. 16) 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. 16) in place.
Fig. 15
E9151
4
4
3
12
Fig. 16
7
S7735

15 20166849
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Installation
6.8.2 Electrical diagram
Testing
Check the shut-down of the burner by opening the thermostats
and the lock-out by darkening the flame sensor.
~ 50 Hz -230 V
LN
Main switch
Fuse T6A
CONTROL BOX
Burner earth
Motor
D11631
Safety
thermostat
Capacitor
Light oil solenoid
Ignition
electrodes
Flame sensor
Heater
Fig. 17
Thermostat
TO BE DONE BY
of start up Black
White
Blue
White
Black
THE INSTALLER
CARRIED-OUT
IN THE FACTORY
Limit
thermostat
WARNING
Do not swap neutral and phase over, fol-
low the diagram shown carefully and carry
out a good earth connection.
The section of the conductors must be at
least 1 mm2.
(Unless requested otherwise by local stand-
ards and legislation).
The electrical wiring carried out by the
installer must be in compliance with the rules
in force in the country.

20166849 16
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Operation
7.1 Notes on safety for the first start-up
7.2 Combustion adjustment
In conformity with EN 267, the application of the burner on the
boiler, adjustment and testing must be carried 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.
The values in Tab. F are referred to 12.5% CO2, at sea level and
with ambient temperature and gas oil at 20 ° C.
Tab. F
7.3 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.
7.3.1 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.
7.4 Pump pressure
The pump is factory set to the values indicated. Tab. F.
7.5 Air damper adjustment
The settings indicated in the schedule are purely indicative.
Each installation however, has its own unpredictable working
conditions: actual nozzle output; positive or negative pressure in
the combustion-chamber, the need of excess air, etc.
All these conditions may require a different air-damper setting.
7Operation
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
Check the correct 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 combustion air temperature
of 20°C, adjust the CO2to 12.5% (± 0.2%).
Combustion air temperature (°C)
Fig. 18
0
-5
-10 5 10 15 20 25 30 35 40 45
10.0
10.5
11.0
11.5
12.0
12.5
13.0
13.5
14.0
20159270
% CO2
Nozzle Pump
pressure
Burner
output
Air damper
adjustment
Combustion head
adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
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 mainte-
nance 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 man-
ufacturer.

17 20166849
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Operation
7.6 Electrodes setting
Before removing or assembling the nozzle, loosen the screw B)
(Fig. 19) and move the electrodes ahead.
7.7 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.
7.8 Operation programme
WARNING
The measures in Fig. 19 must be respected.
Fig. 19
4± 0.3 mm
D5230
B
2 -2.5 mm
Fig. 20
Thermostat
Motor
Ignition transformer
Flame
Lock-out lamp
Lock-out due to failure to lightNormal
0 - 150s D5329
0 - 150s ~12s ~12s ~5s
Resistance
Valve
WARNING
Lock out is indicated by a lamp on the control box
5) Fig. 1 to page 6

20166849 18
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Maintenance
8.1 Notes on safety for the maintenance
The periodic maintenance is essential for the good operation,
safety, yield and duration of the burner.
It allows you to reduce consumption and polluting emissions and
to keep the product in a reliable state over time.
Before carrying out any maintenance, cleaning or checking oper-
ations:
8.2 Maintenance programme
8.2.1 Maintenance frequency
8.2.2 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 tank 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.
Tank
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.
8 Maintenance
DANGER
The maintenance interventions and the calibration
of the burner must only be carried out by qualified,
authorised personnel, in accordance with the con-
tents of this manual and in compliance with the
standards and regulations of current laws.
DANGER
Turn off the burner's power supply using the main
system switch.
DANGER
Turn off the fuel interception tap.
Wait for the components in contact with heat
sources to cool down completely.
The combustion system should be checked at
least once a year by a representative of the man-
ufacturer or another specialised technician.
The operator must use the required equipment
during maintenance.
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.