Riello RG4S Quick start guide

20136874 (2) - 05/2018
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Light oil burner
Quemador de gasóleo
One stage operation
Funcionamiento a 1 llama
CODE - CÓDIGO MODEL - MODELO
3739654 RG4S
GB
E

Original instructions
Instructions originales

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Contents
1 Declaration..................................................................................................................................................................................3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Technical data............................................................................................................................................................. 8
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Burner equipment........................................................................................................................................................ 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Burner description ....................................................................................................................................................... 9
4.8 Firing rate .................................................................................................................................................................. 10
4.8.1 Commercial boilers.................................................................................................................................................... 10
4.8.2 Test boiler.................................................................................................................................................................. 10
4.9 Electrical control box ................................................................................................................................................. 11
5 Installation ................................................................................................................................................................................ 12
5.1 Notes on safety for the installation ............................................................................................................................ 12
5.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 12
5.3 Handling .................................................................................................................................................................... 12
5.4 Preliminary checks .................................................................................................................................................... 13
5.5 Operating position ..................................................................................................................................................... 13
5.6 Securing the burner to the boiler............................................................................................................................... 14
5.7 Maintenance position ................................................................................................................................................ 15
5.8 Combustion head adjustment.................................................................................................................................... 15
5.9 Pump pressure and air output................................................................................................................................... 16
5.9.1 Adjusting the low ignition flame................................................................................................................................. 16
5.9.2 Adjusting the high ignition flame................................................................................................................................ 16
5.10 Electrodes setting...................................................................................................................................................... 16
5.11 Hydraulic systems ..................................................................................................................................................... 17
5.11.1 Combustion supply.................................................................................................................................................... 17
5.11.2 Pump ..............................................................................................................................................................................................................................................................................................17
5.11.3 Pressure adjustment ................................................................................................................................................. 17
5.11.4 Pressurised one-pipe systems .................................................................................................................................. 18
5.11.5 Priming pump ............................................................................................................................................................ 18
5.11.6 Vacuum systems ....................................................................................................................................................... 18
6 Start-up, calibration and operation of the burner ................................................................................................................. 19
6.1 Notes on safety for the first start-up .......................................................................................................................... 19
6.2 Combustion adjustment............................................................................................................................................. 19
6.3 Recommended nozzles............................................................................................................................................. 19
6.4 Electrical system ....................................................................................................................................................... 20
6.5 Electrical diagram...................................................................................................................................................... 21
6.6 Operating programme ............................................................................................................................................... 22
6.7 Table of times............................................................................................................................................................ 23

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Contents
6.7.1 Operating status indication ........................................................................................................................................23
6.7.2 Fault diagnostics - lockouts........................................................................................................................................24
6.7.3 Shutdown test ............................................................................................................................................................24
6.7.4 Intermittent operation.................................................................................................................................................24
6.7.5 Recycle and limit of repetitions ..................................................................................................................................24
6.7.6 Presence of an extraneous light or parasite flame.....................................................................................................25
6.7.7 Pre and post-ignition of the discharge of the ignition transformer..............................................................................25
6.7.8 Reset by button and remotely of the burner...............................................................................................................25
6.7.9 Protection reset..........................................................................................................................................................25
6.7.10 Reset button/Remote reset fault ................................................................................................................................25
6.7.11 External lockout signal (S3) .......................................................................................................................................25
6.7.12 Hour counter function (B4).........................................................................................................................................25
6.7.13 Monitoring the power supply voltage .........................................................................................................................25
6.7.14 Frequency supply error ..............................................................................................................................................26
6.7.15 Internal voltage fault...................................................................................................................................................26
6.7.16 Checking the fan motor..............................................................................................................................................26
6.7.17 Checking the electronic control circuit of the 1st stage valve ....................................................................................26
6.7.18 Checking the short-circuit of the 1st stage valve .......................................................................................................26
6.7.19 EEprom check............................................................................................................................................................26
6.7.20 Post-purging...............................................................................................................................................................26
6.7.21 Continuous purging....................................................................................................................................................26
6.7.22 Lockout log.................................................................................................................................................................27
6.7.23 Logging of burner operating parameters....................................................................................................................27
6.7.24 Admissible lengths of the external connections to the burner....................................................................................27
6.7.25 Long pre-purging........................................................................................................................................................27
6.8 Programming menu ...................................................................................................................................................28
6.8.1 General notes ............................................................................................................................................................28
6.8.2 Block diagram for entering the menu .........................................................................................................................28
6.8.3 Shutdown test ............................................................................................................................................................29
6.8.4 Post-purging and continuous purging ........................................................................................................................29
6.8.5 Intermittent operation.................................................................................................................................................29
6.8.6 Setting a long pre-purging..........................................................................................................................................29
6.8.7 Displaying the lockout log ..........................................................................................................................................29
6.8.8 Resetting the programming menu parameters and the lockout log ..........................................................................30
6.9 Lockout types.............................................................................................................................................................30
7 Maintenance ..............................................................................................................................................................................31
7.1 Notes on safety for the maintenance .........................................................................................................................31
7.2 Maintenance programme ...........................................................................................................................................31
7.2.1 Maintenance frequency..............................................................................................................................................31
7.2.2 Checking and cleaning...............................................................................................................................................31
8 Faults / Solutions ......................................................................................................................................................................32
9 Appendix - Accessories ...........................................................................................................................................................33

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Declaration
1 Declaration
Declaration of Conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Light oil burner
Model: RG4S
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
Quality is ensured by means of an ISO 9001:2015 certified quality and management system.
Legnago, 01.12.2015 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini

20136874 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Cen-
tre of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates 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 date of
installation, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

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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 ambient temperature must all be within the values in-
dicated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties;
Personnel must follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to inform their superiors of every
problem or dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Designation Combustion head Voltage Code
RG4S TC 1/230/50 3739654
Range:
Size
Fuel: Natural gas
Light oil
Variations:
Electrical supply 1/230/50
1/220/60
R G 4 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
1/230V/50Hz
1/220V/60Hz
K Conical head
M Ignition with reduced flow rate
F Light industrial process
S
G
Head : TC Standard head
TL Extended head
of the system :
Standard Emission
Low NOx
R
B
D Two-stage
S
R Light oil pre-heater
S Ignition with reduced output

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Technical description of the burner
4.3 Technical data
Tab. B
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l. (Hi = 11.86 kWh/kg)
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output. The sound power
is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3” measurement, as described in
EN ISO 3746.
4.4 Electrical data
Tab. C
4.5 Burner equipment
Flange with insulating gasket ............................................. No. 1
Screw and nuts for flange .................................................. No. 1
Remote reset connection ................................................... No. 1
Screws and nuts for fixing the flange to the boiler ............. No. 4
Flexible hoses with nipples ................................................ No. 2
Installer booklet................................................................... No. 1
Spare Parts List................................................................... No. 1
Remote reset kit
The burner has a remote reset kit (RS) consisting of a connec-
tion and a push-button operating at a distance of 20 metres max.
In order to install it, remove the safety lockout device installed at
the factory and insert the lockout supplied with the burner (see
electrical diagram).
Model RG4S
Delivery (1)
Thermal power(1)
kg/h
kW 10 20 119 237
Fuel Light oil, viscosity 4 6 mm2/s at 20°C
Operation Intermittent (FS1)
Use Boilers: water and diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 40
Pump bar Pressure: 8  15
Noise levels (2) Sound pressure
Sound power dB (A) 64 75
Burner weight kg 18
Model RG4S
Electrical power Single-phase, ~ 50Hz 230V ± 10%
Motor A
rpm
rad/s
2
2730
286
Capacitor F6.3
Ignition transformer Secondary 18 kV - 25 mA
Absorbed electrical power kW 0.39
Protection level IP 40

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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the flange and burner are given in Fig. 1.
4.7 Burner description
1 Oil pump
2 Control box
3 Reset button with lock-out signal
4 Flange with insulating gasket
5 Air damper adjustment assembly
6 Nozzle-holder assembly
7 Flame sensor
8 Hydraulic jack
9 Delaying device
Fig. 1
228 142 300 213
160
190
12
36
285
345
11
9999
127
45°
45°
D5353
ø 123
Fig. 2
4
6
3
2
18
5
9
7
D7821
WARNING
To meet the required standards, the burner must
be protected by a pane or by the boiler door.
This protection must be removed only with a tool.

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Technical description of the burner
4.8 Firing rate
The burner output is chosen from within the diagram area (Fig. 3).
4.8.1 Commercial boilers
The burner-boiler combination poses no problems if the boiler
conforms to EN 303 and its combustion chamber dimensions are
similar to those provided in EN 267.
If, on the other hand, the burner is combined with a commercial
boiler that does not conform to EN 303, or where the combustion
chamber is much smaller than the dimensions set out in EN 267,
please contact the manufacturers.
4.8.2 Test boiler
The firing rate has been defined on test boilers according to EN
267 standard.
WARNING
To ensure the burner works correctly, start-ups
should always occur within the relative firing rate.
WARNING
The firing rate (Fig. 3) was obtained at an ambient
temperature of 20 °C, at a barometric pressure of
1013 mbar (about 0 m a.s.l.) and with the combus-
tion head regulated as indicated on page 19.
Fig. 3
0
Light oil output – kg/h
120 140 160 Heat output – kW
2.5
2.0
1.5
1.0
0.5
Pressure in the combustion
chamber – mbar
D5543
10
180 200
11 12 13 14 15 16
240
17 18 19 20
220

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Technical description of the burner
4.9 Electrical control box
The control box is a control and supervision system for forced
draught burners, for intermittent operation (at least one controlled
shutdown every 24 hours).
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following instruc-
tions:
- avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure the control box is perfectly dry.
- Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Installation notes
• Check the electrical wiring inside the boiler complies with the
national and local safety regulations.
• Install switches, fuses, earth connection etc. in compliance
with local regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit, make sure the 230V AC mains voltage
cables are run strictly separate from extra low-voltage cables,
to avoid the risk of electrocution.
To remove the control box from the burner it is necessary to (Fig. 4):
disconnect all the connectors connected to it, all the plugs,
the high voltage cables and the earth wire (TB);
unscrew the screw (A) and pull the control box in the direc-
tion of the arrow.
To install the control box it is necessary to:
tighten the screw (A) with a tightening torque of 1 - 1.2 Nm;
reconnect all previously disconnected connectors, making
sure to connect the 7 pin plug as the final step.
NOTE:
The burners have been approved for intermittent operation.
This means that they must stop once every twenty four
hours to permit the electrical control box to check its effi-
ciency at start up. The boiler limit thermostat (TL) normally
ensures the stopping of the burner. If this is not the case, it
is necessary to apply a timer switch in series to the limit
thermostat (TL) that turns off the burner at least once every
24 hours.
Electrical wiring of the flame sensor
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• Always separate the flame sensor cables from the other ca-
bles:
- the line capacity reduces the magnitude of the flame sig-
nal.
Technical data
Tab. D
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. The Man-
ufacturer cannot assume any responsibility for
damage resulting from unauthorised work!
Mains voltage AC 210...230 V -15 % / +10 %
Mains frequency 50/60 Hz ±6 %
Built-in fuse T4A 250V
Energy consumption 40 VA
Protection level IP00
Fig. 4
E9275
A

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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Instructions to avoid burnout or bad combustion of the burner
1 The burner can not be installed outside as it is suitable for
operation in closed rooms only.
2 The premises the burner operates in must have openings
for the air need for the combustion.
To be sure about this, you have to control CO2 and CO in
the exhaust gases with all the windows and doors closed.
3 If there are air extractors in the premises the burner works,
make sure that there are openings for air to be taken in that
are big enough to ensure the required air change; In any
case, check that when the burner stops the extractors do
not draw hot fumes from pipes through the burner.
4 When the burner is stopped, the flue must be kept open and
a natural draft created in the combustion chamber.
If the smoke pipe is closed, the burner must be drawn back
till the extraction of blast tube from the furnace. Before oper-
ating in this way take the voltage off.
5.3 Handling
The transport weight is given in chapter 4.3 page 8.
Observe the permissible ambient temperatures for storage and
transport: - 20... + 70 °C, with max. relative air humidity 80%.
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.
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.
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.
The operator must use the required equipment
during installation.

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Installation
5.4 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 power consumption 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).
5.5 Operating position
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
D9370
WARNING
The burner is designed to work only in positions 1
and 2 (Fig. 6).
Installation 1 (Fig. 6) is preferable, as it is the only
one that allows the maintenance operations as
described later in this manual.
Installation 2 (Fig. 6) allows it to operate but not
maintenance with hooking to the boiler.
Any other position could compromise the correct
operation of the appliance.
WARNING
Any other positioning could compromise the cor-
rect operation of the appliance.
Installations 3, 4 and 5 (Fig. 6) are prohibited for
safety reasons.
Fig. 6
D7088
1 2 3 4 5

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Installation
5.6 Securing the burner to the boiler
To install the burner on the boiler, do the following:
put on the flange 1)(Fig. 9) the screw 5) and the two nuts 2).
if necessary, widen the holes of the insulating gasket
5) Fig. 7).
To the door of the boiler 3)(Fig. 9) fix the flange 1) using the
screws 5) and (if necessary) the nuts 2) placing the insulat-
ing gasket 4)(Fig. 9) in-between.
Provide an adequate lifting system of the burner.
WARNING
With some boilers it is possible that the CO values
exceed those stated in this manual. To lower
these emissions it is necessary to use the recircu-
lating pipe supplied.
WARNING
When the installation is complete, check the burn-
er is slightly tilted, as shown in Fig. 8.
WARNING
In any event, make sure that the combustion head
crosses the entire thickness of the boiler door.
WARNING
The seal between burner and boiler must be
airtight.
Fig. 7
D5012
5
Fig. 8
D5025
Fig. 9
S7071

15 20136874
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Installation
5.7 Maintenance position
For accessing the nozzle, the diffuser disc and the electrodes, fol-
low the instructions below:
take out the nozzle-holder assembly 1)(Fig. 11) after loosen-
ing the screws 2)(Fig. 11), having unscrews the nuts 3)(Fig.
11), removed the wires 4)(Fig. 11) from the control box and
the flame sensor 5)(Fig. 11).
Take out the wires 4)(Fig. 11) from the electrodes, remove
the nozzle-holder assembly 1)(Fig. 11) the diffuser disc-
holder assembly 8)(Fig. 11) after loosening the screw
3)(Fig. 13).
Screw in the nozzle 9)(Fig. 11) tightening it correctly as
shown in Fig. 11.
5.8 Combustion head adjustment
The adjustment of the combustion head varies depending on the
burner output.
Do the following to adjust it:
turn the adjustment screw 6)(Fig. 11) clockwise or anti-clock-
wise until the notch on the regulating rod 7)(Fig. 11) lines up
with the outer surface of the nozzle-holder assembly 1)(Fig.
11).
Example: the head is set for an output of 3.5 GPH at 12 bar.
The notch 2.5 of the regulating rod lines up with the outer surface
of the nozzle-holder assembly as shown in the Tab. G.
WARNING
Having put back the nozzle-holder assembly,
screw in the nut 9), as shown in Fig. 10.
Fig. 10
D5684
9
Tighten without
bringing right to
the end stop
D7916
Fig. 11

20136874 16
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Installation
5.9 Pump pressure and air output
In order to ensure a regular start up with any type of boiler, the
burner has a hydraulic device, independent of the control box,
that reduces the flow rate of the fuel and the air. At ignition, the
pressure at the nozzle is 9 bar.
After 3 - 9 seconds it automatically passes to 12 bar.
The air flow rate, initially calibrated on the low flame, automatical-
ly goes with the change of pressure to the rate required for the
high flame.
5.9.1 Adjusting the low ignition flame
Air damper adjustment
Unscrew the screw 8)(Fig. 12) by about 1 turn, in this way the
burner remains permanently with the low flame. Loosen the nut
5)(Fig. 12), adjust the screw 4)(Fig. 12), and bring the indicator
6)Fig. 12) to the required position.
Then lock the nut 5)(Fig. 12) and tighten the screw 8)(Fig. 12).
Delaying device adjustment
It is set in the factory at 9 bar. The pressure gauge for checking
pressure should be fitted in place of the plug 4)(Fig. 15).
If necessary recalibrate the pressure, or if you prefer change it,
just turn the screw 7)Fig. 12), always after first unscrewing the
screw 8)(Fig. 12).
5.9.2 Adjusting the high ignition flame
Air damper adjustment
Loosen the nut 3)(Fig. 12), turn the screw 1)(Fig. 12) until the in-
dicator 2)(Fig. 12) is at the required position.
Then lock the nut 3)(Fig. 12).
Pump adjustment
It leaves the factory set at 12 bar. The pressure gauge for check-
ing pressure should be fitted in place of the plug 4)(Fig. 15).
If necessary recalibrate the pressure, or if you prefer change it,
just turn the screw 5)(Fig. 15).
When the burner stops, the air damper automatically closes, up
to a max. flue depression of 0.5 mbar.
5.10 Electrodes setting
To access the electrodes carry out the operation described, see
paragraph “Maintenance position” on page 15.
To adjust, proceed as follows:
rest the diffuser disc-holder assembly 3)(Fig. 13) against the
nozzle holder 2)(Fig. 13) and lock it in place with the screw
4)(Fig. 13).
For any adjustments of the electrodes assembly 5),
loosen screw 6)(Fig. 13).
Fig. 12
S7161
WARNING
These dimensions Fig. 13 must be respected.
Model A (mm) ± 0 B (mm)
RG4S 4.5 - 0.5 6 7
Fig. 13
D5085
2
4
31
5
AB

17 20136874
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Installation
5.11 Hydraulic systems
5.11.1 Combustion supply
The burner is designed to allow entry of the flexible oil lines on
either side of the burner.
Depending on whether the pipe outlet is to the right or left of the
burner, it will be necessary to invert both the fixing plate 1) and
the closing bracket 2)(Fig. 16).
5.11.2 Pump
The pump is designed to allow working with two pipes.
Before starting up the burner, make sure that the return pipeline
is not clogged.
An excessive back pressure ( 1 bar) would cause the damage
of the pump seal, with subsequent fuel leaks inside the burner.
The pump has a delivery pressure regulation device 4)(Fig. 15).
Pressure increases if turned in a clockwise direction, and de-
creases if turned in the other direction.
An indication of sensitivity is 1 bar per turn.
The pressure can be regulated in a range of 8 - 15 bar.
Key
1Suction line
2Return line
3By-pass screw
4Gauge connection
5Pressure adjuster
6Vacuum gauge connection
7Valve
8Auxiliary pressure test point
5.11.3 Pressure adjustment
The pump leaves the factory set at 12 bar.
If necessary, recalibrate the pressure using the screw 5)(Fig.
15).
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
WARNING
It is necessary to install a filter on the fuel feed
line.
Fig. 14
D5530
2
11
WARNING
The suction line plug 1)(Fig. 15) is made of plastic.
Once removed, it must not be used again.
In single-pipe installations, the plug in the return
line 2) must be totally in steel.
Fig. 15
3
2
7
6
5
4
1
D5527

20136874 18
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Installation
5.11.4 Pressurised one-pipe systems
Pressurised one-pipe systems (Fig. 16) 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.
In order to obtain one pipe working it is necessary to unscrew the
return line plug 2)(Fig. 15), remove the by-pass screw 3)(Fig. 15)
and then screw the plug 2)(Fig. 15) in again at a tightening torque
of 0.5 Nm.
Tab. E
H= Difference of level
L= Maximum suction line length
Ø= Inner diameter of the pipe
In the systems in Fig. 16 and Fig. 17, the table shows the maxi-
mum approximate lengths for the supply line, depending on the
difference in level, length, and the diameter of the fuel conduit.
5.11.5 Priming pump
In the system of Fig. 16 just loosen the connection of the vacuom-
eter 5) (Fig. 15) and wait for the fuel to come out.
In the systems A and B of Fig. 17 start the burner and wait for the
priming. Should lockout occur prior to the arrival of the fuel, await
at least 20 seconds before repeating the operation.
The pump vacuum should not exceed a maximum of 0.4 bar (30
cm Hg).
Beyond this limit gas is released from the oil.
5.11.6 Vacuum systems
Depressurised systems (Fig. 17) have a negative fuel pressure
(depression) at the burner intake.
Usually the tank is lower than the burner.
Tab. F
H= Difference of level
L= Maximum suction line length
Ø= Inner diameter of the pipe
H
metres
L metres
Ø (8 mm) Ø (10 mm)
0.5 10 20
120 40
1.5 40 80
260 100
Fig. 16
D5338
H
WARNING
The installer must ensure that the power supply
pressure never exceeds 0.4 bar (30 cm Hg).
Above that level, the pump seal is subject to too
much stress.
WARNING
The pipes must all be perfectly sealed.
Fig. 17
H
max. 4 m
max. 4 m
H
H
H
D5337
H
metres
L metres
Øi
8 mm
Øi
10 mm
035 100
0.5 30 100
125 100
1.5 20 90
215 70
3 8 30
3.5 620
WARNING
The installer must ensure that the supply de-
pression never exceeds 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil.
The pipes must all be perfectly sealed.