Riello RLS 190/M MZ Quick start guide

20079226 (2) - 03/2014
Installation, use and maintenance instructions
安装、使用和维护手册
Dual fuel light oil/gas burners
双燃料轻油 / 燃气燃烧器
Two-stage progressive or modulating operation gas side / two-stage light oil side
平滑两段火或比例调节燃气运行 / 两段火轻油运行
CODE - 代码 MODEL - 型号 TYPE - 类型
20079219 RLS 190/M MZ 784T
GB
CN

Original instructions
说明书原文翻译

1
CONTENTS
DECLARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Choice of nozzles for the 1st and 2nd stage . . . . . . . . . . . . . . . . . .6
Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Adjustments before first firing (light oil operation) . . . . . . . . . . . . . .8
Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Burner calibration (light oil operation). . . . . . . . . . . . . . . . . . . . . . .11
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Adjustment before firing (gas operation) . . . . . . . . . . . . . . . . . . . .14
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Gas combustion checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
FAULTS - POSSIBLE CAUSES - SOLUTIONS . . . . . . . . . . . . . .21
ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Layout of electric panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
GB

2
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Dual fuel light oil/gas burner
Model: RLS 190/M MZ
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BImSchV release
26.01.2010”.
Product Type Model Power
Dual fuel light oil/gas burner 784 T RLS 190/M MZ 550 - 2150 kW
Legnago, 10.10.2013 Executive Director
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. G. Conticini Mr. R. Cattaneo

3
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m s.l.m.
(2 Upstream pressure of the gas train 1)(A)p.12 as indicated by EN676 Standard, with 0 mbar in the combustion chamber and at the maximum
burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The
sound power is evaluated, in line with the regulations, on a spherical surface centred on the burner and with a radius of 1 metre.
ELECTRICAL DATA
BURNER CATEGORIES
MODEL RLS 190/M MZ
Output (1)
Delivery (1)
2nd stage kW
kg/h 1100 - 2150 93 - 181
min. 1st stage kW
kg/h 550 46
Fuel LIGHT OIL, viscosity at 20 °C: 6 mm2/s max (1,5 °E - 6 cSt)
NATURAL GAS: G20 (methane) - G21 - G22 - G23 - G25
Gas pressure at maximum delivery (2)
Gas: G20/G25 mbar 39.5/55.7
Operation - Intermittent (min. 1 stop in 24 hours)
- Light oil: Two-stage (high and low flame) and single-stage (all - nothing)
- Gas: Progressive two-stage or modulating by kit (see ACCESSOIRES)
Nozzles number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperatur °C 0 - 40
Combustion air temperature °C max 60
Pump delivery (at 12 bar)
pressure range
fuel temperatur
kg/h
bar
° C max
230
10 - 21
90
Noise levels (3) Sound pressure
Sound power dBA 85 96
MODEL RLS 190/M MZ
Main electrical supply
Control circuit power supply 3 ~ 400V 50Hz 1N ~ 230V 50Hz
Fan motor IE2 rpm
Hz
V
W
A
2900
50
230 / 400
4500
15.1/8.7
Pump motor
Pump motor capacitor
rpm
Hz
V
W
A
µF
2700
50
230
550
3.6
25
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 5 kV 1,9 A - 35 mA
Absorbed electrical power W max 6000
Protection level IP 44
COUNTRY CATEGORY
IT - AT - GR - DK - FI - SE II2H3B / P
ES - GB - IE - PT II2H3P
NL II2L3B / P
FR II2Er3P
DE II2ELL3B /P
BE I2E(R)B, I3P
LU - PL II2E3B/P

4
BURNER DESCRIPTION (A)
1 Flame stability disk
2 Ignition electrodes
3 Combustion head
4 Gas pressure test point and head fixing
screw
5 Screw securing fan to sleeve
6 OIL/GAS selector
7 Relay
8 Slide bars for opening the burner and
inspecting the combustion head
9 Control box with lock-out pilot light and lock-
out reset button
10 Air gate valve
11 Air inlet to fan
12 Gas input pipework
13 Gas butterfly valve
14 Screw for combustion head adjustment
15 Sleeve with flange for securing the burner to
the boiler
16 Max. gas pressure switch
17 Cell UV
18 Servomotor controlling the gas butterfly
valve and of air gate valve (by means of a
variable profile cam mechanism).
When the burner is not operating the air gate
valve is fully closed in order to reduce heat
dispersion from the boiler due to the flue
draught which draws air from the fan suction
inlet.
19 Fan motor
20 Extensions for slide bars 8)
21 Power switch for different operations:
automatic - manual - off
Button for:
Power increase - power reduction
22 Motor contactor and thermal cut-out with
reset button
23 Bracket for mounting the power regulator
RWF40
24 Terminal strip
25 Fairleads for electrical connections by
installer
26 Flame inspection window
27 Minimum air pressure switch
(differential operating type)
28 Pump motor
29 Pump
30 Safety solenoid valve
31 1st and 2nd stage valves
32 Air pressure test point
Two types of burner failure may occur:
Control Box Lock-out: if the control box 9)(A)
pushbutton lights up, it indicates that the burner
is in lock-out.
To reset, press the pushbutton.
Motor trip: release by pressing the pushbutton
on thermal relay 22)(A).
PACKAGING - WEIGHT (B) - Approximate
measurements
• The burners stands on a wooden base which
can be lifted by fork-lifts. Outer dimensions of
packaging are indicated in (B).
• The weight of the burner complete with pack-
aging is indicated in Table (B).
MAX. DIMENSIONS (C) -Approximate meas-
urements
The maximum dimensions of the burner are
given in (C).
Bear in mind that inspection of the combustion
head requires the burner to be opened and the
rear part withdrawn on the slide bars.
The maximum dimension of the burnerwhen
open, without casing, is give in measurement I.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws M 10 x 40 to the but-
terfly valve
1 - Thermal insulation screen
4 - Screws to secure the burner sleeve with
flange to the boiler: M 16 x 40
2 - Flexible hoses
2 - Nipples for flexible hoses with gasket
1 - Instruction booklet
1 - Spare parts list
(A)
mm A B C kg
RLS 190/M MZ 1400 750 900 160
D3168
D36
D3169
mm ABCDEFGH I LMNO
RLS 190/M MZ 843 366 477 555 863 412 222 430 1442 237 141 186 Rp2
(B)
(C)

5
FIRING RATE (A)
During operation, burner output varies between:
•aMAXIMUM OUTPUT, selected within area A,
•and a MINIMUM OUTPUT, which must not be
lower than the minimum limit in the diagram.
RLS 190/M MZ = 550 kW
Important:
The FIRING RATE area values have been
obtained considering a surrounding temperature
of 20 °C, and an atmospheric pressure of 1000
mbar (approx. 100 m above sea level) and with
the combustion head adjusted as shown on
page 8.
MODULATION RATIO
The modulation ratio, determined using test boil-
ers according to standard (EN 676 for gas, EN
267 for light oil), is:
- 3 : 1 (gas);
- 2 : 1 (light oil).
In case of gas operation the burner can be used
with a different modulation ratio depending on
the application - contact the manufacturer for
further information.
TEST BOILER (B)
The firing rates were set in relation to special
test boilers, according to EN 676 regulations.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example:
Output 650 Mcal/h:
diameter = 60 cm; length = 2 m.
COMMERCIAL BOILERS (C) - IMPORTANT
The burner is suitable for operation on boilers
with combustion chambers featuring flow from
the base (three flue passes) on which the best
results are obtained in terms of low NOx emis-
sions.
The maximum thickness of the boiler’s front door
must not exceed 250 mm (see fig. C).
The burner-boiler match is assured where the
boiler is EC type-approved; for boilers and fur-
naces with combustion chambers featuring di-
mensions differing considerably from those
given in the diagram (B), it is advisable to per-
form preliminary tests.
(A) D3170
D715
(B)
Combustion chamber
lenght - m
A
Combustion chamber
pressure - mbar
D1079
(C)
250 mm MAX

6
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling. The range of
lengths available, L (mm), is as follows:
Blast tube 12): RLS 190/M MZ
• short 418
• long 548
For boilers with front flue passes 15) or flame
inversion chambers, protective fettling in refrac-
tory material 13) must be inserted between the
boiler fettling 14) and the blast tube 12).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the
refractory fettling 13)-14)(B) is not required
unless it is expressly requested by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER
(B)
Detach the combustion head from the burner,
fig. (B):
-Disconnect the oil pipes by unscrewing the two
connectors 6)
- Disengage the articulated coupling 7) from the
graduated sector 8).
- Loosen the 4 screws 3) and remove the cover 1)
- Remove the screws 2) from the slide bars 5)
- Remove the 2 screws 4) and pull the burner
back on slide bars 5) by about 100 mm.
- Disconnect the electrode wires and then pull
the burner completely off the slide bars.
Secure the sleeve with flange 11)(B) to the
boiler plate, interposing the thermal insulating
screen 9)(B) supplied with the burner. Use the 4
screws, also supplied with the unit, after first
protecting the thread with an anti-locking prod-
uct. The seal between burner and boiler must be
airtight.
CHOICE OF NOZZLES FOR 1ST AND 2ND
STAGE
The burner complies with the emission require-
ments of the EN 267 standard.
In order to guarantee that emissions do not vary,
recommended and/or alternative nozzles speci-
fied by Riello in the Instruction and warning
booklet should be used.
Both nozzles must be chosen from among those
listed in Table (C).
The first nozzle determines the delivery of the
burner in the 1st stage.
The second nozzle works together with the 1st
nozzle to determine the delivery of the burner in
the 2nd stage.
It is advisable to replace the nozzle
once a year during periodical mainte-
nance.
The use of nozzles other than those
specified by Riello S.p.A. and inade-
quate regular maintenance may re-
sult into emission limits non-
conforming to the values set forth by
the regulations in force, and in ex-
tremely serious cases, into potential
hazards to people and objects.
The manufacturing company shall not
be liable for any such damage arising
from nonobservance of the require-
ments contained in this manual.
mm A B C
RLS 190/M MZ 230 325-368 M 16
(A)
(B)
(C)
D455
D3171
D3172
GPH kg/h kW
12 bar
10 bar 12 bar 14 bar
11.0
12.0
13.0
13.5
14.0
15.0
15.5
16.0
17.0
17.5
18.0
19.0
19.5
20.0
21.5
22.0
24.0
26.0
28.0
42.3
46.1
50.0
51.7
53.8
57.7
59.3
61.5
65.4
67.3
69.2
73.0
75.0
76.9
82.7
84.6
92.2
99.9
107.6
46.7
50.9
55.1
57.0
59.4
63.6
65.5
67.9
72.1
74.2
76.4
80.6
82.7
84.8
91.2
93.3
101.8
110.3
118.8
50.7
55.3
59.9
62.0
64.5
69.2
71.1
73.8
78.4
80.7
83.0
87.6
89.9
92.2
99.1
101.4
110.6
119.9
129.1
553.9
603.7
653.5
681.4
704.5
754.3
782.3
805.3
855.1
880.0
906.1
956.0
980.9
1005.8
1081.7
1106.6
1207.3
1308.2
1409.0
(D)
WARNING
CAUTION

7
The deliveries of the 1st and 2nd stages must
be contained within the value range indicated on
page 3.
Use nozzles with a 60° spray angle at the rec-
ommended pressure of 12 bar.
As a rule the two nozzles have equal deliveries
but the 1st stage nozzle may have a delivery
less than 50% of the total delivery when a
reduction of the counter-pressure peak is
desired at the moment of starting (the burner
allows good combustion rates also with a 40 -
100 % ratio between the 1st and 2nd stage).
Example
Boiler output = 1630 kW - efficiency 90 %
Output required by the burner =
1630 : 0,9 = 1812 kW;
1812 : 2 = 906 KW per nozzle;
therefore, two equal, 60°, 12 bar nozzles are
required:
1° = 18 GPH - 2° = 18 GPH,
or the following two different nozzles:
1° = 16 GPH - 2° = 20 GPH.
NOZZLE ASSEMBLY
Remove screw 1)(D)p.6 and extract the internal
part 2)(D).
Fit two nozzles with the box spanner 1)(A) (16
mm), after having removed the plastic plugs
2)(A), fitting the spanner through the central
hole in the flame stability disk or loosen screws
1)(B), remove disk 2)(B) and replace the noz-
zles using the wrench 3)(B).
Do not use any sealing products such as gas-
kets, sealing compound, or tape. Be careful to
avoid damaging the nozzle sealing seat. The
nozzles must be screwed into place tightly but
not to the maximum torque value provided by
the wrench.
The nozzle for the 1st stage of operation is the
one lying beneath the firing electrodes Fig. (C).
Refit the burner to the slide bars 3)(D) at
approximately 100 mm from the sleeve 4) -
burner positioned as shown in fig. (B)p.6 - insert
the ignition electrode cables and then slide the
burner up to the sleeve so that it is positioned as
shown in fig. (D).
Refit screws 2)(D) on slide bars 3).
Secure the burner to the sleeve by tightening
screws 1).
Connect the oil pipes again by screwing on the
two connectors 6)(B)p.6.
Reconnect the articulation 7) to the graduated
sector 8).
Make sure that the electrodes are
positioned as shown in figure (C).
When fitting the burner on the two
slide bars, it is advisable to gently
draw out the high tension cables
until they are slightly stretched.
(A) (B)
D1146 D1147
(C) D1124
(D) D3174
WARNING
WARNING

8
ADJUSTMENTS BEFORE FIRST FIRING
(light oil operation)
• Combustion head setting
The setting of the combustion head depends
exclusively on the maximum burner output.
Turn screw 5)(A) until the notch shown in dia-
gram (B) is level with the front surface of flange
6)(B).
Example:
Maximum burner output = 1500 kW.
If diagram (B) is consulted it is clear that for this
delivery, the combustion head must be adjusted
using notch 5, as shown in fig. (B).
• Pump adjustment
No settings are required for the pump, which is
set to 12 bar by the manufacturer. This pressure
must be checked and adjusted (if required) after
the burner has been ignited.
The only operation required in this phase is the
application of a pressure gauge on the appropri-
ate pump attachment.
• Fan gate adjustment
The first time the burner is fired leave the factory
setting unchanged for both 1st stage and 2nd
stage operation.
In order to facilitate adjustment,
loosen screw 1)(D)p.6, adjust and
then tighten.
Burner output
SETTING THE COMBUSTION HEAD
(B)
D1149
D3173
(A)
No. notches
WARNING

9
LIGHT OIL SUPPLY (A)
The burner is equipped with a self-priming pump
which is capable of feeding itself within the limits
listed in the table at the side.
The tank higher than the burner A
The distance "P" must not exceed 10 meters in
order to avoid subjecting the pump's seal to
excessive strain; the distance "V" must not
exceed 4 meters in order to permit pump self-
priming even when the tank is almost com-
pletely empty.
The tank lower than the burner B
Pump depression values higher than 0.45 bar
(35 cm Hg) must not be exceeded because at
higher levels gas is released from the fuel, the
pump starts making noise and its working life-
span decreases.
It is good practice to ensure that the return and
suction lines enter the burner from the same
height; in this way it will be more improbable that
the suction line fails to prime or stops priming.
Key (A)
H =Pump/Foot valve height difference
L =Piping length
Ø =Inside pipe diameter
1 =Burner
2=Pump
3=Filter
4 =Manual on/off valve
5 =Suction line
6 =Foot valve
7 =Rapid closing manual valve
remote controlled (only Italy)
8 =On/off solenoid valve (only Italy)
9 =Return line
10 =Check valve (only Italy)
HYDRAULIC CONNECTIONS (B)
The pumps are equipped with a by-pass that
connects return line and suction line. The
pumps are installed on the burner with the by-
pass closed by screw 6)(A)p.10.
It is therefore necessary to connect both hoses
to the pump.
The pump will break immediately if it is run with
the return line closed and the by-pass screw
inserted.
Remove the plugs from the suction and return
connections of the pump.
Insert the hose connections with the supplied
seals into the connections and screw them
down.
Take care that the hoses are not stretched or
twisted during installation.
Install the hoses where they cannot be stepped
on or come into contact with hot surfaces of the
boiler and where they do not hamper the open-
ing of the burner.
Now connect the other end of the hoses to the
suction and return lines by using the supplied
nipples.
(A)
+/- H
mL m
Ø 12 mm Ø 14 mm Ø 16 mm
+ 4
+ 3
+ 2
+ 1
+ 0,5
71
62
53
44
40
138
122
106
90
82
150
150
150
150
150
0 36 74 137
- 0,5
- 1
- 2
- 3
- 4
32
28
19
10
-
66
58
42
26
10
123
109
81
53
25
(B)
D3175
D3176
6
7
9
53
4
8
- H
10 cm
+ H V
P
5
9
10
7
A
B
6

10
HYDRAULIC SYSTEM
Key (A)
1 Pump suction
2Filter
3Pump
4 Pressure governor
5 Return pipe
6 By-pass screw
7 Pump return
8 Safety solenoid
9 1st stage valve
10 2nd stage valve
11 Filter
M Pressure gauge
V Vacuometer
PUMP (B)
1 - Suction G 1/2"
2 - Return G 1/2"
3 - Pressure gauge attachment G 1/8"
4 - Vacuum meter attachment G 1/8"
5 - Pressure adjustment screw
6 - By-pass screw
A - Min. delivery rate at 12 bar pressure
B - Delivery pressure range
C - Max. suction depression
D - Viscosity range
E - Max light oil temperature
F - Max. suction and return pressure
G - Pressure calibration in the factory
H-Filtermeshwidth
PUMP PRIMING
-Before starting the burner, make sure that
the tank return line is not clogged.
Obstructions in the line could cause the
sealing organ located on the pump shaft
to break. (The pump leaves the factory with
the by-pass closed).
- Also check to make sure that the valves
located on the suction line are open and that
there is sufficient fuel in the tank.
- For self-priming to take place, the screw
3)(B) of the pump must be loosened in order
to bleed off the air contained in the suction
line.
- Start the burner by closing the control
devices, with switch 1)(C) in the "MAN" posi-
tion and with switch 6)(A)p.4 in the "OIL"
position.
- The pump can be considered to be primed
when the light oil starts coming out of the
screw 3)(B).
- Stop the burner: switch 1)(C) set to "OFF"
and tighten the screw 3)(B).
The time required for this operation depends
upon the diameter and length of the suction tub-
ing. If the pump fails to prime at the first starting
of the burner and the burner locks out, wait
approx. 15 seconds, reset the burner, and then
repeat the starting operation as often as
required.
After 5 or 6 starting operations allow 2 or 3 min-
utes for the transformer to cool.
Do not illuminate the UV cell or the burner will
lock out; the burner should lock out anyway
about 10 seconds after it starts.
Important: the a.m. operation is possible
because the pump is already full of fuel when it
leaves the factory. If the pump has been
drained, fill it with fuel through the opening on
the vacuum meter prior to starting; otherwise,
the pump will seize. Whenever the length of the
suction piping exceeds 20-30 meters, the supply
line must be filled using a separate pump.
(A) D3006
(C) D791
(B)
PUMP - SUNTEC J7 C
J7 C
A
B
C
D
E
F
G
H
kg/h
bar
bar
cSt
°C
bar
bar
mm
230
10 - 21
0,45
2.8 - 200
90
1.5
12
0.17
D1251
12

11
BURNER CALIBRATION (light-oil operation)
N.B.
It is advisable to first set the burner for operating
on oil and then for gas.
WARNING
Execute the fuel exchange when the burner
is off.
FIRING
Set switch 1)(C)p.10 to "MAN".
During the first firing, during the passage from
the 1st to the 2nd stage, there is a momentary
lowering of the fuel pressure caused by the fill-
ing of the 2nd stage nozzle tubing. This lowering
of the fuel pressure can cause the burner to
lock-out and can sometimes give rise to pulsa-
tions.
Once the following adjustments have been
made, the firing of the burner must generate a
noise similar to the noise generated during oper-
ation.
OPERATION
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet
and interventions on the following points.
• 1st and 2nd stage nozzles
See the information listed on page 6 and 7.
• Combustion head
The adjustment of the combustion head already
carried out (page 8) need not be altered unless
the 2nd stage delivery of the burner is changed.
• Pump pressure
12 bar: This is the pressure calibrated in the fac-
tory which is usually sufficient for most pur-
poses. Sometimes, this pressure must be
adjusted to:
10 bar in order to reduce fuel delivery. This
adjustment is possible only if the surrounding
temperature remains above 0 °C;
14 bar in order to increase fuel delivery or to
ensure firings even at temperatures of less than
0 °C.
In order to adjust pump pressure, use the screw
5)(B)p.10.
• 1st and 2nd stage fan air gate valve
See adjustments of servomotor.
SERVOMOTOR (A)
The servomotor provides simultaneous adjust-
ment of the air gate valve, by means of the
variable profile cam, and the gas butterfly valve.
The servomotor rotates through 130 degrees in
33 seconds.
Do not alter the factory setting for the 5 cams;
simply check that they are set as indicated
below:
Cam I : 130°
Limits rotation toward maximum position.
When the burner is at max output the gas butter-
fly valve must be fully open: 90°.
Cam II : 0°
Limits rotation toward the minimum position.
When the burner is shut down the air gate valve
and the gas butterfly valve must be closed: 0°.
Cam III : 30° (gas)
Adjusts the ignition position and the MIN output.
Cam IV : 30° (oil)
Adjusts the ignition position and the 1st stage
output.
Cam V : 90°
Determines when the 2nd-stage diesel oil valve
opens.
(A)
SERVOMOTOR
D887

12
GAS FEEDING
KEY (A)
1 Gas input pipe
2 Manual valve
3 Vibration damping joint
4 Pressure gauge with pushbutton cock
5Filter
6A Includes:
–Filter
– working valve
–safetyvalve
– pressure adjuster
6C Includes
–safetyvalve
– working valve
6D Includes:
–safetyvalve
– working valve
– pressure adjuster
–filter
7 Minimum gas pressure switch
8 Leak detection device, supplied as an ac-
cessory or incorporated, based on the gas
train code. In compliance with the EN 676
standard, the leak detection control is com-
pulsory for burners with maximum outputs
over 1200 kW.
9 Gasket, for “flanged” versions only
10 Pressure adjuster
11 Train-burner adaptor, supplied separately
P2 Upstream pressure of valves/adjuster
P3 Upstream pressure of the filter
L Gas train supplied separately
L1 The responsibility of the installer
GAS TRAIN
Type-approved in accordance with EN 676 and
supplied separately from the burner.
To select the correct model of the gas train, refer
to the “burner-gas train combination” manual
supplied.
See the accompanying instructions for the ad-
justment of the gas train.
GAS TRAIN INSTALLATION
• The gas train must be connected to the gas
attachment 1)(B), using flange 2), gasket 3)
and screws 4) supplied with the burner.
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient.
• Make sure that the pressure governor calibra-
tion range (colour of the spring) comprises the
pressure required by the burner.
Explosion danger due to fuel leaks in
the presence of a flammable source.
Precautions: avoid knocking, attri-
tion, sparks and heat.
Make sure that the fuel interception
tap is closed before performing any
operation on the burner.
The fuel supply line must be installed
by qualified personnel, in compliance
with current standards and laws.
The gas solenoids must be as close
as possible to the burner, to ensure
that the gas reaches the combustion
head within the safety time of 3s.
(A)
20057264
MB
20062223
MBC
20062227
DMV
20062228
CB
(B) D3002
WARNING
WARNING

13
GAS PRESSURE
The adjacent table shows minimum pressure
losses along the gas supply line depending on
the maximum burner output operation.
The values shown in the table refer to:
- Natural gas G20 PCI 9.45 kWh/Sm3
(8.2 Mcal/Sm3)
- natural gas G 25 PCI 8,6 kWh/Nm3 (7,4 Mcal/
Nm3)
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0 mbar;
• Combustion head adjusted as indicated in
diagram (C)p. 18.
Column 2
Pressure loss at gas butterfly valve 2)(B) with
maximum opening: 90°.
Calculate the approximate maximum output of
the burner thus:
- subtract the combustion chamber pressure
from the gas pressure measured at test point
1)(B).
- Find the nearest pressure value to your result
in column 1 of the table (A).
- Read off the corresponding output on the left.
Example:
• Maximum output operation
• Natural gas G 20 PCI 10 kWh/Nm3
• Gas pressure at test
point 1)(B) = 16.4 mbar
• Pressure in combustion
chamber = 3.0 mbar
16.0 - 3.4 = 13.4 mbar
A maximum output of 1600 kW shown in Table (A)
corresponds to 13.4 mbar pressure, column 1.
This value serves as a rough guide, the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B), set the maximim output required
from the burner operation:
- Find the nearest output value in the table (A).
- Read off the pressure at test point 1)(B) on
the right in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
Example:
• Required burner maximum output operation:
1600 kW
• Natural gas G 20 PCI 10 kWh/Nm3
• Gas pressure at burner
output of 1600 kW, taken
from table (A), column 1 = 13.4 mbar
• Pressure in combustion
chamber = 3.0 mbar
13.4 + 3 = 16.4 mbar
pressure required at test point 1)(B).
kW 1 p (mbar) 2 p (mbar)
1100 7.0 1.1
1200 8.3 1.4
1300 9.6 1.7
1400 10.8 2.0
1500 12.1 2.2
1600 13.4 2.5
1700 14.6 2.8
1800 16.0 3.0
1900 17.0 3.2
2000 18.3 3.4
2150 21.2 3.9
(A)
S9002
(B)

14
ADJUSTMENTS BEFORE FIRST FIRING (gas
operation)
Adjustment of the combustion head has been
illustrated on page 8.
In addition, the following adjustments must also
be made:
- Open manual valves up-line from the gas
train.
- Adjust the minimum gas pressure switch to
the start of the scale (A).
- Adjust the maximum gas pressure switch to
the start of the scale (B).
- Adjust the air pressure switch to the zero
position of the scale (C).
- Purge the air from the gas line.
Continue to purge the air (we recommend
using a plastic tube routed outside the buil-
ding) until gas is smelt.
- Fit a U-type manometer (D) to the gas pres-
sure test point on the sleeve.
The manometer readings are used to calcu-
late the MAX. burner power using the table
(A)p.13.
- Connect two lamps or testers to the two gas
line solenoid valves VR and VS to check the
exact moment at which voltage is supplied.
This operation is unnecessary if each of the
two solenoid valves is equipped with a pilot
light that signals voltage passing through.
Before starting up the burner it is good practice
to adjust the gas train so that ignition takes
place in conditions of maximum safety, i.e. with
gas delivery at the minimum.
BURNER STARTING (gas operation)
N.B.: It is advisable to first set the burner for
operating on oil and then for gas.
WARNING
Execute the fuel exchange when the burner
is off.
Close the control devices and set switch 1)(E) to
“MAN” position.
As soon as the burner starts check the direction
of rotation of the fan blade, looking through the
flame inspection window 26)(A)p.4.
Make sure that the lamps or testers connected
to the solenoids, or pilot lights on the solenoids
themselves, indicate that no voltage is present.
If voltage is present, then immediately stop the
burner and check electrical connections.
BURNER FIRING (gas operation)
Having completed the checks indicated in the
previous heading, the burner should fire. If the
motor starts but the flame does not appear and
the control box goes into lock-out, reset and wait
for a new firing attempt.
If firing is still not achieved, it may be that gas is
not reaching the combustion head within the
safety time period of 3 seconds.
In this case increase gas firing delivery.
The arrival of gas at the sleeve is indicated by
the U-type manometer (D).
Once the burner has fired, now proceed with
global calibration operations.
BURNER CALIBRATION (gas operation)
The optimum calibration of the burner requires
an analysis of the flue gases at the boiler outlet.
Adjust successively:
1 - First firing output;
2 - MAX burner output;
3 - MIN burner output;
4 - Intermediate outputs;
5 - Air pressure switch;
6 - Maximum gas pressure switch;
7 - Minimum gas pressure switch.
(A)
(D)
MIN GAS PRESSURE SWITCH AIR PRESSURE SWITCH
(B) (C)
MAX GAS PRESSURE SWITCH
D896 D66 D521
D3178
(E) D791
12

15
1 - FIRING OUTPUT
According to EN 676 Regulations:
Burners with MAX output up to 120 kW
Firing can be performed at the maximum opera-
tion output level. Example:
• Max. operation output : 120 kW
• Max. firing output : 120 kW
Burners with MAX output above 120 kW
Firing must be performed at a lower output than
the max. operation output. If the firing output
does not exceed 120 kW, no calculations are
required. If firing output exceeds 120 kW, the
regulations prescribe that the value be defined
according to the control box safety time "ts":
- For ts = 2s, firing output must be equal to or
lower than 1/2 of max. operation output.
- For ts = 3s, firing output must be equal to or
lower than 1/3 of max. operation output.
Example: MAX operation output of 600 kW.
Firing output must be equal to or lower than:
• 300 kW con ts = 2s
• 200 kW con ts = 3s
In order to measure the firing output:
- Extract the UV cell 17)(A)p.4 (the burner will
ignite and lock-out at the end of a safety
period).
- Perform 10 firings with consecutive lock-outs.
On the meter read the quantity of gas burned.
- This quantity must be equal to or lower than
the quantity given by the formula:
Example: for gas G 20 (10 kWh/Sm3):
Max. operation output: 600 kW corresponding to
60 Sm3/h
After 10 firings with lock-outs, the delivery read
on the meter must be equal to or lower than:
60 : 360 = 0,166 Sm3
2 - MAX. OUTPUT
Max. output of the burner must be set within the
firing rate range shown on page 5.
In the above instructions we left the burner run-
ning in MIN. output operation. Now press button
2)(A) “increase output” and keep it pressed until
the servomotor has opened the air gate valve
and the gas butterfly valve.
Gas calibration
Measure the gas delivery at the meter.
A guideline indication can be calculated from the
table (A)p.13, simply read off the gas pressure
on the U-type manometer, see fig. (D)p.14, and
follow the instructions on page 13.
- If delivery needs to be reduced, diminish out-
let gas pressure and, if it is already very low,
slightly close adjustment valve VR.
- If delivery needs to be increased, increase
outlet gas pressure.
Adjusting air delivery
Progressively adjust the end profile of cam 4)(B)
by turning the screws 7)(B).
- Turn the screws clockwise to increase air
delivery.
- Turn the screws counter-clockwise to reduce
air delivery.
(A) D791
12
(B) D1710
1Servomotor
2 Servomotor 1) - Cam 4): engaged
3 Servomotor 1) - Cam 4): disengaged
4 Adjustable profile cam
5 Cam starting profile adjustment screws
6 Adjustment fixing screws
7 Cam end profile adjustment screws
8 Graduated sector for gas butterfly
valve
9 Index for graduated sector 8
10 Key for cam III adjustment
Sm3/h (max. burner delivery)
360

16
3 - MIN OUTPUT
Min output must be selected within the firing rate
range shown on page 5.
Press button 2)(A)p.15 “output reduction” until
the servomotor has closed the air gate valve
and the gas butterflu valve to 30° (factory set
adjustment).
Adjusting gas delivery
Measure the delivery of gas from the gas meter.
- If this value is to be reduced, decrease the
angle of cam III (A) slightly by proceeding a
little at a time until the angle is changed from
30° to 28° - 26°....
- If it has to be increased press the button “out-
put increase” 2)(A)p.15 (i.e. open the gas but-
terfly valve by 10-15°), increase the cam III
angle (A) with small successive movements,
i.e. take it from angle 30° to 32° - 34°....
Then press the button “output decrease” until
the servomotor is taken to the minimum open-
ing position and measure the gas delivery.
Note
The servomotor follows the adjustment of cam
III only when the cam angle is reduced. If it is
necessary to increase the cam angle, first
increase the servomotor angle with the key “out-
put increase”, then increase the cam III angle,
and finally bring the servomotor back to the MIN
output position with the key ”output decrease”.
In order to adjust cam III, especially for fine
movements, the key 10)(A), held by a magnet
under the servomotor, can be used.
Adjustment of air delivery
Progressively adjust the starting profile of cam
4)(B)p.15 by turning the screws 5).
It is preferable not to turn the first screw since
this is used to set the air gate valve to its fully-
closed position.
4 - INTERMEDIATE OUTPUTS
Adjustment of gas delivery
No adjustment of gas delivery is required.
Adjustment of air delivery
Press the button 2)(A)p.15 “output increase” a
little so that the servomotor turns by about 15°.
Adjust the screws until optimal combustion is
obtained. Proceed in the same way with the
other screws.
Take care that the cam profile variation is pro-
gressive.
Switch off the burner using switch 1)(A)p.15, at
“OFF” position, disengage the cam 4)(B)p.15
from the servomotor, by pressing the button
3)(A) and moving it to the right, and check more
than once that the movement is soft and
smooth, and does not grip, by rotating the cam
4) forward and backward by hand.
Engage the cam 4) to the servomotor again by
moving the button 2)(A) to the left.
As far as is possible, try not to move those
screws at the ends of the cam that were previ-
ously adjusted for the opening of the air gate to
MAX and MIN output.
Finally fix the adjustment by turning the screws
6)(B)p.15.
N.B.
Once you have finished adjusting outputs MAX -
MIN - INTERMEDIATE, check ignition once
again: noise emission at this stage must be
identical to the following stage of operation. If
you notice any sign of pulsations, reduce the
ignition stage delivery.
(A) D889

17
5 - AIR PRESSURE SWITCH (A)
Adjust the air pressure switch after having per-
formed all other burner adjustments with the air
pressure switch set to the start of the scale (A).
With the burner operating at min. output,
increase adjustment pressure by slowly turning
the relative knob clockwise until the burner locks
out.
Then turn the knob anti-clockwise by about 20%
of the set point and repeat burner starting to
ensure it is correct.
If the burner locks out again, turn the knob anti-
clockwise a little bit more.
Attention: as a rule, the air pressure switch
must prevent the air pressure from lowering
below 80% of the adjustment value as well as
preventing the CO in the fumes from exceeding
1% (10,000 ppm).
To check this, insert a combustion analyser into
the chimney, slowly close the fan suction inlet
(for example with cardboard) and check that the
burner locks out, before the CO in the fumes
exceeds 1%.
The air pressure switch is of the differential type.
If a negative pressure in the combustion cham-
ber during pre-purging prevents the air pressure
switch from closing, fit a tube between the air
pressure switch and the suction inlet of the fan.
Attention: the use of the air pressure switch
with differential operation is allowed only in
industrial applications and in places where
national rules enable the air pressure switch to
control only fan operation.
6 - MAXIMUM GAS PRESSURE SWITCH (B)
Adjust the maximum gas pressure switch after
having performed all the other burner adjust-
ments with the maximum gas pressure switch
set at the end of the scale (B).
With the burner operating at MAX output,
reduce the adjustment pressure by slowly turn-
ing the relative knob anticlockwise until the
burner locks out.
Then turn the knob clockwise by 2 mbar and
repeat burner firing.
If the burner locks out again, turn the knob again
clockwise by 1 mbar.
7 - MINIMUM GAS PRESSURE SWITCH (C)
Adjust the minimum gas pressure switch after
having performed all the other burner adjust-
ments with the pressure switch set at the start of
the scale (C).
With the burner operating at MAX output,
increase adjustment pressure by slowly turning
the relative knob clockwise until the burner
locks out.
Then turn the knob anti-clockwise by 2 mbar
and repeat burner starting to ensure it is uni-
form.
If the burner locks out again, turn the knob anti-
clockwise again by 1 mbar.
(A)
(C)
AIR PRESSURE SWITCH
MIN. GAS PRESSURE SWITCH
MAX. GAS PRESSURE SWITCH
D521
D66
D896
(B)

18
BURNER OPERATION
Key (A) - (B)
1- Thermostat
2- Motor
3- Air gate valve
4- Ignition transformer
5- First valve
6- First flame
7- Second valve
8- Second flame
9- Lock-out
BURNER FLAME GOES OUT DURING OPER-
ATION
If the flame should accidentally go out during
operation, the burner will lock out within 1s.
(B)
NORMAL FIRING
(n° = seconds from instant 0)
NO FIRING
D3202
D3203
(A)