Riello RDB2.2 GKD Quick start guide

Installation, use and maintenance instructions
20063165 (3) - 05/2016
Light oil burner
Two stage operation
CODE MODEL
20063119 RDB2.2 GKD

Original instructions

1
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual........................................................................................................................ 4
2.1.1 Introduction..................................................................................................................................................................... 4
2.1.2 General dangers............................................................................................................................................................. 4
2.1.3 Other symbols................................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual......................................................................................................... 5
2.2 Guarantee and responsibility.......................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction..................................................................................................................................................................... 6
3.2 Personnel training........................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Models available............................................................................................................................................................. 7
4.2 Technical data ................................................................................................................................................................ 7
4.3 Maximum dimensions..................................................................................................................................................... 7
4.4 Burner description........................................................................................................................................................... 8
4.5 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 Working position ........................................................................................................................................................... 10
5.5 Fixing the burner to the boiler....................................................................................................................................... 10
5.6 Burner assembly........................................................................................................................................................... 11
5.6.1 Suction cup application................................................................................................................................................. 11
5.7 Fuel supply ................................................................................................................................................................... 11
5.7.1 Pump ............................................................................................................................................................................ 11
5.7.2 One pipe system........................................................................................................................................................... 12
5.8 Two pipe system........................................................................................................................................................... 13
5.9 Pump pressure ............................................................................................................................................................. 13
5.10 Electrical wiring............................................................................................................................................................. 14
5.10.1Control box ................................................................................................................................................................... 14
6 Start-up, calibration and operation of the burner ................................................................................................................. 16
6.1 Notes on safety for the first start-up.............................................................................................................................. 16
6.2 Combustion adjustment................................................................................................................................................ 16
6.3 Combustion check ........................................................................................................................................................ 16
6.4 Accessing the nozzle, diffuser disc and electrodes...................................................................................................... 17
6.5 Electrodes setting......................................................................................................................................................... 17
6.6 Positionning the optical fibre......................................................................................................................................... 18
6.7 Combustion head adjustment....................................................................................................................................... 18
6.8 Air damper adjustment.................................................................................................................................................. 19
6.9 Fuel heating.................................................................................................................................................................. 19
6.10 Operation programme................................................................................................................................................... 20
6.10.1Normal operation.......................................................................................................................................................... 20
6.10.2Lock-out due to extraneous light during pre-purging .................................................................................................... 20
6.10.3Lock-out due to ignition failure...................................................................................................................................... 20
6.11 Table of timings ............................................................................................................................................................ 21
6.12 Operations status indication ......................................................................................................................................... 21
6.13 Fault diagnostics........................................................................................................................................................... 21
6.13.1Pre-heating function...................................................................................................................................................... 22
6.13.2Shutdown test............................................................................................................................................................... 22
6.13.3Light diagnosis of flame quality..................................................................................................................................... 22
6.13.4Intermittent operation.................................................................................................................................................... 22
6.13.5Recycle and limit of repetitions..................................................................................................................................... 22
6.13.6Presence of an extraneous light or parasite flame ....................................................................................................... 22

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Contents
6.13.7Pre and post spark ignition............................................................................................................................................22
6.13.8Remote reset and reset protection................................................................................................................................22
6.13.9Frequency main supply anomaly...................................................................................................................................22
6.13.10Internal voltage monitor anomaly.................................................................................................................................23
6.13.11Reset push-button or remote reset anomaly................................................................................................................23
6.13.12Checking the fan motor................................................................................................................................................23
6.13.13Checking the oil valve ..................................................................................................................................................23
6.13.14EEprom check..............................................................................................................................................................23
6.14 Post-purging..................................................................................................................................................................23
6.15 Automatic pre-heating disabling....................................................................................................................................23
6.16 Programming menu.......................................................................................................................................................24
6.16.1Sequence for enable/disable. Shutdown test................................................................................................................24
6.16.2Sequence for enable/disable. Light diagnosis...............................................................................................................24
6.16.3Sequence for enable/disable. Intermittent operation.....................................................................................................25
6.16.4Sequence for enable/disable. Post-purging ..................................................................................................................25
6.16.5Sequence for enable/disable second stage delay.........................................................................................................25
6.17 Lockout types................................................................................................................................................................26
7 Maintenance ..............................................................................................................................................................................27
7.1 Notes on safety for the maintenance.............................................................................................................................27
7.2 Burner maintenance position.........................................................................................................................................27
7.3 Maintenance programme ..............................................................................................................................................27
7.3.1 Maintenance frequency.................................................................................................................................................27
7.3.2 Checking and cleaning..................................................................................................................................................27
8 Faults / Solutions......................................................................................................................................................................30

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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burner
Model: RDB2.2 GKD
These products are in compliance with the following Technical Standards:
EN 267
EN 12100
and 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 UNI EN ISO 9001.
Legnago, 01.12.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

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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 is present. An explosive atmosphere is
defined as a mixture of dangerous substances
with air, under atmospheric conditions, in the form
of gases, vapours, mist or dust in which, after ig-
nition 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.
MOUNT CASING
This symbol indicates that it is mandatory to
mount casing again after maintenance, cleaning
or checks.
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.

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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 installa-
tion date, 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;
➤use of the burner even following an error and/or an irregularity;
➤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;
➤the use of non-original components, including spare parts,
kits, accessories and optional;
➤force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

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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 named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
➤Modification of the burner to alter its performance and desti-
nations is not allowed.
➤The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
➤Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
➤Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
➤undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
➤undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
➤Personnel must observe all the danger and caution indica-
tions shown on the machine.
➤Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
➤Personnel must inform their superiors of every problem or
dangerous situation that may arise.
➤The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
➤the user must take all the measures neces-
sary to prevent unauthorised people gaining
access to the machine;
➤the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation.
➤Personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

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Technical description of the burner
4.1 Models available
4.2 Technical data
Tab. A
4.3 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
4 Technical description of the burner
Designation Voltage Code
RDB2.2 GKD 1/230/50 20063119
Model RDB2.2 GKD
Output - Thermal power 1.73 - 2.2 kg/h −20.5 - 26 kW
Fuel Light oil, viscosity 1.6 – 6 mm
2
/s at 20 °C (Hi = 11.97 kWh/kg)
Electrical supply Single phase, ~ 50Hz ± 5%, 230 V ± 10%
Max power supply 1 A ~ – Short circuit current 4 A ~
Motor Intensity 0.75 A – Output 90 W – Velocity 2800 tr/min. – 294 rad/s
Capacitor 4.5 µF
Ignition transformer Secondary 18 kV – 25 mA
Pump pressure 8 - 20 bar
Absorbed electrical power 0.18 kW
Protection level IP 40
Conditions of reference Ambient temperature 20 °C - Barometric pressure 1013 mbar - Altitude 0 m above sea level
Fig. 1
20066274
180
130
150
72
11
72
45°
45°
D9293

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Technical description of the burner
4.4 Burner description
1 Pump
2 1st stage coil
3 2nd stage coil
4 Reset button with lock-out lamp
5 Photocell
6 Control box and electronic igniter
7 Hydraulic jack
8 Manometer connection
9 Combustion head adjustment screw
10 Combustion head
11 Electrical motor
12 1st stage air damper adjustment screw
13 2nd stage air damper adjustment screw
14 Electrical motor start up capacitor
15 Head air pressure test point
16 Light oil suction line
17 Light oil return live vat
18 Air intake BF
19 One stage pump pressure adjustment screw
20 Two stage pump pressure adjustment screw
21 Flange - gasket
4.5 Burner equipment
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 2
20066289

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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 wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Check the identification label of the burner, showing:
➤the model A)(Fig. 3) 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).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area towhich you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected and
disposed of in the appropriate places.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
and makes any installation or maintenance work
difficult.
Fig. 3
D9370

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Installation
5.4 Working position
5.5 Fixing the burner to the boiler
To fix the burner to the boiler proceed as indicated below;
➤Insert the screw and two screw nuts 6)(Fig. 5) into the
flange 1) .
➤Fix the flange 1)(Fig. 6) onto the boiler plate 4) using screws
2) and (if necessary) screw nuts 3), interposing the insulat-
ing gasket 5).
WARNING
➤The burner is designed to operate only in the
positions 1, and 3 (Fig. 4).
➤Installation 1is preferable, as it is the only
one that allows performing maintenance
operations as described in this manual.
➤Installations 2, 3and 4 allow working opera-
tions but not maintenance with hooking to the
boiler.
DANGER
Any other position could compromise the correct
operation of the appliance.
Installation 5is forbidden for safety reasons.
D4618
1 2 3 4 5
Fig. 4
6
Fig. 5
D9413
6
1
E9145
5
Fig. 6
1
2
4
3

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Installation
5.6 Burner assembly
5.6.1 Suction cup application
The air supply for the combustion takes place thanks to a flexible
hose connected to the air intake 1)(Fig. 7).
5.7 Fuel supply
5.7.1 Pump
The pump is designed for twin-tube operation.
For single-tube operation, it is necessary to unscrew the return
line plug 2)(Fig. 8), remove the by-pass screw 3) and then re-
screw the plug 2).
Key (Fig. 8)
WARNING
To ensure that the suction cup application is cor-
rect the burner must be installed on the boiler
properly.
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.
Fig. 7
D1840
1
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure that the fuel interception tap is closed
before performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
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 line plug 1) is made of plastic.
Once removed, it must not be used again.
In the single-tube appliances it is absolutely nec-
essary that the plug on the return 2) be steel.
WARNING
Periodically check the condition of the flexible
hoses.
It is necessary to install a filter on the fuel supply
line.
1 Suction line
2 Return line vat
3 By-pass screws
4 Manometer connection
5 Two stage pressure
adjuster
6 Vacuum meter connection
7 One stage solenoid
8 Auxiliary pressure test points
9 One stage pressure adjuster
10 Two stage solenoid
Fig. 8
D11445

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Installation
5.7.2 One pipe system
Pressurised one pipe systems (Fig. 9) have a positive fuel pres-
sure on intake to the burner.
Usually the tank is higher than the burner, or the fuel pumping
systems are on the outside of the boiler.
Vacuum one pipe systems (Fig. 10) have a negative fuel pres-
sure (depression) on intake to the burner.
Usually the tank is lower than the burner.
Priming pump
On the system in Fig. 9 it is sufficient to loosen the plug of the
vacuum meter connection 6)(Fig. 8) and wait until the fuel flows
out.
On the system in Fig. 10 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. B
Tab. C
Hdifference of level
Lmax. lenght of the suction line
I.D. interminal diameter of the oil pipes
NOTE:
The Tab. B and Tab. C show the maximum approximate lengths
for the supply line, depending on the difference in level, length,
and the diameter of the fuel conduit.
CAUTION
You are advised touse additional filters on the fuel
supply line.
Riello recommends a good quality fuel filter at the
tank (Fig. 9 - Fig. 10) and a secondary filter (15 µ
for kerosene) are used to protect the burner pump
and nozzle from contamination.
WARNING
The installer must ensure that the supply pressure
is not above 0.5 bar.
Above that level, the pump seal is subject to too
much stress.
H (meters) L (meters)
I.D. (8 mm) I.D. (10 mm)
0.5 10 20
1 20 40
1.5 40 80
2 60 100
H
max. 4 m
min. 0.1 m
D11009
Fig. 9
H (meters) L (meters)
I.D. (8 mm) I.D. (10 mm)
0 35 100
0.5 30 100
1 25 100
1.5 20 90
2 15 70
3 8 30
3.5 6 20
H
max. 4 m
D11010
Fig. 10
H

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Installation
5.8 Two pipe system
Vacuum two pipe systems (Fig. 11) have a negative fuel pressure
(depression) on intake to the burner.
Usually the tank is lower than the burner.
The return line should terminate in the oil tank at the same level
as the suction line; in this case a non-return valve is not required.
Should however the return line arrives over the fuel level, the
non-return valve is indispensable. This solution however is less
safe than previous one, due to the possibility of leakage of the
valve.
Priming pump
On the system in Fig. 11 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. D
Hdifference of level
Lmax. lenght of the suction line
I.D. interminal diameter of the oil pipes
NOTE:
The Tab. D shows the maximum approximate lengths for the sup-
ply line, depending on the difference in level, length, and the di-
ameter of the fuel conduit.
5.9 Pump pressure
The pump is factory set to the values indicated in Tab. E on
page 16.
CAUTION
Youareadvisedtouse additionalfilters on the fuel
supply line.
Riello recommends a good quality fuel filter at the
tank (Fig. 11) and a secondary filter (15 µfor ker-
osene) are used to protect the burner pump and
nozzle from contamination.
WARNING
Before starting the burner make sure that the re-
turn pipe-line is not clogged: any obstruction
would cause the pump seals to break.
WARNING
The pump vacuum should not exceed a maximum
of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil.
H (meters) L (meters)
I.D. (8 mm) I.D. (10 mm)
0 35 100
0.5 30 100
1 25 100
1.5 20 90
2 15 70
3 8 30
3.5 6 20
Fig. 11
H
max. 4 m
H
D10011

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Installation
5.10 Electrical wiring
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 incompliance with the EN60 335-1 standard.
5.10.1 Control box
To remove the active block, follow these instructions;
➤loosen the screws 1)(Fig. 12) and remove protection 6) of
the coil 4);
➤remove the coil 4) and unplug the connections;
➤loosen screws 2), open the protection 3) and remove all
components;
➤loosen the two screws 5), lightly move the control box and
disconnect the wires from the electrodes.
As a spare part, the housing is delivered with the bridge 7)
(Fig. 13) 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 cables of the heater and thermostat must also be connected.
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 electrical diagrams.
➤The manufacturer declines all responsibility for modifications or connections different from those shown in the
electrical 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 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.
➤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
Disconnect the electrical supply from the burner
by means of the main system switch.
DANGER
Close the fuel interception tap.
Condensation, water infiltration and formation of
ice are not permitted!
Perform all maintenance, cleaning or inspection
operations and mount the cover again.
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. 13) into the safety housing so that the
burner can operate without the heater until the
heater is replaced.
Fig. 12
D9938
5
1 23
65
4
Fig. 13
7
S8824

15
20063165
GB
Installation
TESTING:
Check the shut-down of the burner by opening the thermostats
and the lock-out by darkening the photoresistance.
Key to layout (Fig. 14)
C Capacitor
FM Fan motor
h Hour counter
HT Heat demand
ID Ignition device
K Thermostat of start-up
PH Heater oil
SB External signal lock-out (230V~ -0.5A max)
RS Remote reset
TR Regulation on demand
TS Safety thermostat
V1 One stage oil valve
V2 Two stage oil valve
F Flame detector
Fig. 14
~50Hz - 230V
CONTROL BOX
Fuse
Main switch
NLPE
BURNER
MO535-BRSPHF
BOILER
20067494
DANGER
➤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 1mm
2
(unless requested otherwise by
local standards and legislation).
WARNING
This control box contains a post-purging function.
Do not replace it with other versions!

20063165
16
GB
Start-up, calibration and operation of the burner
6.1 Notes on safety for the first start-up
6.2 Combustion adjustment
In accordance with Efficiency Directive 92/42/EEC, follow the in-
structions in the boiler manual to assemble the burner, perform
the adjustment and testing, and to check the concentration of
CO
2
in the flue gases, as well as their temperature and the aver-
age water temperature from the boiler.
According to the flow required for the boiler, the nozzle, pump
pressure and the adjustment of the air dampers must be deter-
mined according to the following values.
ADJUSTMENTS MADE IN THE FACTORY
The values in Tab. E refer to 12.50% CO
2
, at sea level, with am-
bient temperature and oil temperature of 20° C.
Tab. E
6.3 Combustion check
Consider air temperature and Fig. 15.
Tab. F
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
Check the correct working of the adjustment, com-
mand and safety devices.
WARNING
The combustion air is drawn from outside, there-
fore there may be sensitive temperature varia-
tions, which can affect the CO
2
percentage value.
It is recommended to adjust the CO
2
based on the
graph indicated.
For example: external air temperature equal to
20° C, set the CO
2
at 12% (± 0.2%).
External air temperature (°C)
% CO
2
D7052
Fig. 15
Nozzle Pump
pressure Burner output Combustion head adjustment
One stage air damper
adjustment
12)(Fig. 2 on page 8)
Two stage air damper
adjustment
13)(Fig. 2 on page 8)
GPH Angle bar kg/h ± 4% Notch (Fig. 18) Notch Notch
0.50 60° H 10 - 16 1.75 - 2.2 2 1.5 0.75
Case CO
2
Smoke Remedies
0 12 to 13.5 ST = 0 No modification.
1 12 to 13.5 ST > 1 Check the calibration settings Check the seal between the nozzle, the boiler and the flue and the tightening of the boiler door
Check the penetration of the nozzle in the furnace. If the settings are correct, change the nozzle
2 CO
2
> 13.5
Turn the button (notch V) to open the delivery air damper half a graduation or three notches
(e.g. 3 to 3.5 to obtain CO
2
between 12 and 13)
Check the blackening index (if blackening index > 1 return case No. 1)
Check the cold start-up
3 CO
2
< 12 Close the air damper
Check the blackening index (if blackening index > 1 return case No. 1)
Check the cold start-up
Observations Remedies
Good cold start-up No modification
Rumble during cold start ignition Check head electrodes and adjustment (measure the head pressure)

17
20063165
GB
Start-up, calibration and operation of the burner
6.4 Accessing the nozzle, diffuser disc and electrodes
Proceed as follows to access the nozzle, the diffuser disc-holder
assembly and the electrodes:
➤Unscrew and remove the fixing nut to the flange and remove
the burner from the boiler.
➤Loosen the screws 1)(Fig. 16) then extract the blast tube
unit 2).
➤Loosen the screw 4) to remove the diffuser disc-holder
assembly 6) from the nozzle-holder assembly 7).
➤Fully unscrew the fixing screw to extract the optical fibre 4)
from the diffuser disc-holder assembly 6).
➤Remove the wires 5) from the electrodes.
➤Replace and correctly screw in the nozzle 8), tightening it as
shown in Fig. 16.
➤Refit following the procedure in the reverse order to the one
described above.
6.5 Electrodes setting
To access the electrodes, performthe operation described in par-
agraph “Accessing the nozzle, diffuser disc and electrodes”.
To adjust, proceed as follows:
➤Rest the diffuser disc-holder assembly 3)(Fig. 16) on the
nozzle-holder 2) and lock it with the screw 4).
➤For any adjustments to the electrode assembly 5), loosen
the screw 6).
1
2
3
4
5
6
7
8
Fig. 16
D10582
WARNING
Measures must be respected.

20063165
18
GB
Start-up, calibration and operation of the burner
6.6 Positionning the optical fibre
To position the optical fibre, carry out the following procedure
(Fig. 17):
➤Insert the optical fibre 1) into the diffuser disc-holder assem-
bly 3) making sure it fits snugly.
➤Carefully tighten the screw 4) to lock the optical fibre 1).
6.7 Combustion head adjustment
The combustion head is factory set.
Check that these settings are consistent with the value indicated
in Tab. E on page 16.
The adjustments according to the power required (Fig. 18) can
be adjusted by turning the adjustment screw 9)(Fig. 2 on page 8).
– Distance between two notches = 3 mm
– One full turn = 1 mm
Fig. 17
D4222
4,5 – 0,5 mm
0
3 ± 0,3 mm
5,5 ± 0,3 mm
41
2
5 6
3
Fig. 18
0
0
1
2
3
mm
3
D9873