Riello RS 70 VA Quick start guide

20074364 (11) - 07/2018
Installation, use and maintenance instructions
Instructions pour installation, utilisation et entretien
Burners in air duct
Brûleurs en veine d’air
Progressive two-stage or modulating operation
Fonctionnement à deux allures progressif ou modulant
CODE MODEL - MODELE
20019477 RS 70 VA
20017842 RS 100 VA
CODE
(A) CODE (B) HEAD ASSEMBLY - GROUPE TÊTE
- 20074339 5/250
20090684 20074340 5/500
20027307 20074341 5/750
20019476 20074344 5/1000
- 20093965 5/1500
20070118 20074351 6/250
20026012 20074352 6/500
20019475 20074353 - 20149278 6/750
20035615 20074354 6/1000
20081696 20074355 7/250
20077117 20074356 7/500
20020521 20074357 7/750
20081697 20074358 7/1000
GB
F

CONTENTS
DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . page 1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Gas category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Pilot burner - A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Pilot burner - B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fixing the purging structure to the head assembly . . . . . . . . . . . .12
Examples of assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
START-UP, CALIBRATION AND OPERATION OF
THE BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . .14
Adjustments prior to ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Burner ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Burner adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1 - Ignition output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2 - Maximum burner output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4 - Minimum gas pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . .18
5 - Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . .18
Flame presence check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Residual flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Final checks (with burner operating) . . . . . . . . . . . . . . . . . . . . . . .21
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Safety test - with gas ball valve closed. . . . . . . . . . . . . . . . . . . . . .22
Safety components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
FAULTS - PROBABLE CAUSES - SOLUTIONS . . . . . . . . . . . . .23
APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Layout of electric panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
N.B.
The figures mentioned in the text are identified as follows:
1)(A) = part 1 of figure A, same page as text;
1)(A)p.4 = part 1 of figure A, page number 4.

1
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Burners in air duct
Model: RS 70 VA
RS 100 VA
These products are in compliance with the following Technical Standards:
EN 676
EN 746-2
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 ISO 9001:2015.
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

2
TECHNICAL DATA
(1) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The
sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy,
as set out in EN ISO 3746.
(2) For head assembly code 20035615 only G20 fuel.
ELECTRICAL DATA
NOTA: for the application of the combustion head in depression, contact the manufacturer.
PURGING STRUCTURE MODEL RS 70 VA RS 100 VA
Fuel Natural gas: G20 - G25 and G31
G20 G25 G31
- Gross heat value kWh/Nm3
Mcal/Nm311.1
9.5 9.5 8.2 32.4 28
- Absolute density kg/Nm30.71 0.78 2.15
Operation Intermittent (min. 1 stop in 24 hours)
Standard applications Powder coating ovens. drying cereals. etc... (8/24h and 5/7days)
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (1) Sound pressure
Sound power dBA 75 86 78.5 89.5
PURGING STRUCTURE MODEL RS 70 VA RS 100 VA
Main electrical supply 3 ~ 230/400V 50 Hz
Control circuit power supply 1 ~ 230V 50 Hz
Motor IE3 rpm
W
V
A
2880
1100
230/400
4.3 - 2.5
2860
1500
230/400
5.5 - 3.2
Ignition transformer V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
Electrical power consumption kW max 1.5 1.8
Protection level IP 44
Combustion head
code Fuel type PMax (kW) Length (mm) Pressure in combustion chamber 3 mbar Pressure in combustion chamber 3 - 6 mbar
20074339 G31 (G20-G25)
720
5/250
RS 70 VA RS 100 VA
-
20074340 G31 5/500
20090684 G31 (G20-G25)
20074341 G31 5/750
20027307 G31 (G20-G25)
20074344 G31 5/1000
20019476 G31 (G20-G25)
-G31 5/1500
20093965 G20-G25
20074351 G31
900
6/250
20070118 G31 (G20-G25)
20074352 G31 6/500
20026012 G31 (G20-G25)
20074353 G31 6/750
20019475 G31 (G20-G25)
20149278 G20-G25
20074354 G31 6/1000
20035615 G20-G25
20074355 G31 (G20-G25)
1080
7/250
RS 100 VA RS 100 VA
20081696 G31 (G20-G25)
20074356 G31 7/500
20077117 G31 (G20-G25)
20074357 G31 7/750
20020521 G31 (G20-G25)
20074358 G31 7/1000
20081697 G31 (G20-G25)

3
GAS CATEGORY
ACCESSORIES (optional):
• KIT FOR MODULATING OPERATION
There are two components to order:
- the output power regulator to install on the burner;
- the probe to install on the heat generator
• CONTINUOUS VENTILATION KIT Code 3010094
• GROUND FAULT INTERRUPTER KIT Code 3010329
• GAS TRAINS ACCORDING TO EN 676 REGULATIONS (with valves, pressure adjuster and filter): see page 8.
COUNTRY CATEGORY
IT-AT-GR-DK-FI-SE II2H3B/P
ES-GB-IE-PT II2H3P
NL I2L - I2E - I2 (43.46 ÷ 45.3 MJ/m3(0°C))
FR II2Er3P
DE II2ELL3B/P
BE I2E(R)B, I3P
LU - PL II2E3B/P
Output power regulator kit RWF
Parameter to control Probe Output power regulator
Adjustment field Type Code Type Code
Temperature - 100...+500°C PT 100 3010110 RWF50
RWF55 20099869 20099905
Important:
The installer is responsible for the addition of any safety device not foreseen in this manual.
D8863

4
BURNER DESCRIPTION (A)
1 Combustion head
2 Servomotor, controls the gas butterfly valve
3 Gas pressure test point and head fixing
screw
4 Air pressure switch
5 Slide bars for opening the burner and
inspecting the combustion head
6 Air pressure test point
7 Air inlet to fan
8 Pipe coupling
9 Gas butterfly valve
10 Fixing plate
11 Motor contactor and thermal relay with reset
button
12 Switch for different operations:
automatic - manual - off
Button for:
power increase - power reduction
13 Flame inspection window
14 Control box with lockout pilot light and reset
button
15 Bracket for application of output power regu-
lator RWF (kit)
16 Terminal board for electrical wiring
17 Air gate valve
18 Gas to pilot flame connection
19 Ignition electrode
20 Ionisation probe S01 (pilot flame)
21 Ionisation probe S0 (main flame)
22 Valve VP1
23 Valve VP2
24 Pipe coupling
25 Ignition transformer
26 Filter to protect against radio disturbance
27 K1-K2 relay
28 Timer
29 Lifting rings
30 Elbow
31 Maximum gas pressure switch
Two types of burner lockout may occur:
•Control box lockout:
if the control box button lights up, it indicates
that the burner is in lockout.
To reset, press the button.
•Motor lockout:
release by pressing the button on thermal
relay.
PACKAGING - WEIGHT (B) - (C) - Approximate
measurements
• The purging structures are shipped in card-
board boxes with the maximum dimensions
shown in table (B).
• The weight of the purging structure complete
with packaging is indicated in table (B).
• The head assemblies are shipped on pallets
with the dimensions shown in table (C).
(B)
(C)
mm ABCkg
RS 70 VA 1405 740 692 70
RS 100 VA 1405 740 692 73
D88
20074868
20070515
(A)
mm ABC
5/250 2200 850 501
5/500 2200 850 501
5/750 2700 850 501
5/1000 2700 850 501
5/1500 3400 940 515
6/250 2200 850 501
6/500 2700 850 501
6/750 2700 850 501
6/1000 3400 940 515
7/250 2700 850 501
7/500 3400 940 515
7/750 3400 940 515
7/1000 3400 940 515
9/250 3400 940 515
10/250 3400 940 515

5
DIMENSIONS (A) -Approximatemeasurements
• The dimensions of the purging structure are
given in Fig. (A).
• The dimensions of the head assemblies are
given in Fig. (B).
STANDARD EQUIPMENT
4 Flange fixing screws M 8 x 25
1 Thermal insulation screen
1 Plugs for electrical connections with
4 - 5 - 6 - 7 poles
1 Instruction booklet
1 Spare parts list
1 Flexible piping for ignition pilot
1 Pilot gas train assembly
ADJUSTMENTS
Adjust the fan air delivery in order to obtain, at
maximum output, a blue flame with yellow tips
that is ~ 500 mm long.
At minimum modulation, the flame will shorten
and turn blue.
A
C
D
E
B
(B)
D8278
mm ABCDE
5/250 1750
800 572 472
1200
5/500 2000
5/750 2250
5/1000 2500
5/1500 3000
6/250 2050
1500
6/500 2300
6/750 2550
6/1000 2800
7/250 2350
1800
7/500 2600
7/750 2850
7/1000 3100
20077298
(A)
mm A
RS 70 VA 523.5
RS 100 VA 540.5

6
The maximum dimensions of the plate fixed to the oven, and the layout of the holes, are shown in (A).
Hole diameters and fuels for combustion heads
(*) Only for applications of agricultural dryer or oven baking or drying materials
DIMENSIONS L P
RS 70VA 800 350
RS 100 VA
HOLES X Y Ø
A20 330 10
B210 330 10
C400 330 10
D590 330 10
E780 330 10
F780 175 10
G780 20 10
H570 20 10
I400 20 10
L210 20 10
M20 20 10
N20 175 10
DESCRIPTION CODE GAS BORING MAIN FUEL OPTIONAL
FUEL (*) MATERIALS FOR GASKET IONISATION PROBE
5/250 20074339 1.5 LPG -AISI 321 4 mm reinforced
5/500 20074340 1.5 LPG - AISI 321 4 mm reinforced
5/500 20090684 2 LPG CH4 AISI 304 3 mm
5/750 20027307 2 LPG CH4 AISI 304 3 mm
5/750 20074341 1.5 LPG - AISI 321 4 mm reinforced
5/1000 20019476 2 LPG CH4 AISI 304 3 mm
5/1000 20074344 1.5 LPG - AISI 321 4 mm reinforced
5/1500 20093965 2 CH4 - AISI 321 4 mm reinforced
6/250 20070118 2 LPG CH4 AISI 304 3 mm
6/250 20074351 1.5 LPG - AISI 321 4 mm reinforced
6/500 20026012 2 LPG CH4 AISI 304 3 mm
6/500 20074352 1.5 LPG - AISI 321 4 mm reinforced
6/750 20019475 2 LPG CH4 AISI 304 3 mm
6/750 20074353 1.5 LPG - AISI 321 4 mm reinforced
6/750 20149278 2 CH4 - AISI 321 4 mm reinforced
6/1000 20035615 2.5 CH4 - AISI 304 3 mm
6/1000 20074354 1.5 LPG - AISI 321 4 mm reinforced
7/250 20081696 2 LPG CH4 AISI 304 3 mm
7/250 20074355 1.5 LPG - AISI 321 4 mm reinforced
7/500 20077117 2 LPG CH4 AISI 304 3 mm
7/500 20074356 1.5 LPG - AISI 321 4 mm reinforced
7/750 20020521 2 LPG CH4 AISI 304 3 mm
7/750 20074357 1.5 LPG - AISI 321 4 mm reinforced
7/1000 20081697 2 LPG CH4 AISI 304 3 mm
7/1000 20074358 1.5 LPG - AISI 321 4 mm reinforced
MLI
N
ABCD E
F
G
H
X
Y
00
L
P
D9693
(A)
(B)

7
INSTALLATION
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 environment, proceed
with the installation operations.
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 stand-
ards and regulations of the laws in force.
Handling (C)
Warning: The handling operations for the
burner can be highly dangerous if not carried
out with the greatest attention: keep any unau-
thorised people at a distance; check the integrity
and suitableness of the available means of han-
dling.
Check also that the area in which you are work-
ing is empty and that there is an adequate
escape area (i.e. a free, safe area to which you
can quickly move if the burner should fall).
During the handling, keep the load at not more
than 20-25 cm from the ground.
Caution: After positioning the burner near the
installation point, correctly dispose of all residual
packaging, separating the various types of
material.
Before proceeding with the installation opera-
tions, carefully clean all around the area where
the burner will be installed.
PRELIMINARY CHECKS
Checking the consignment
Caution: After removing all the packaging,
check the integrity of the contents. In the event
of doubt, do not use the burner; contact the sup-
plier.
The packaging elements (wooden cage or
cardboard 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.
Checking the characteristics of the burner
Check the identification labels of the burner (A)
and the head (B), showing:
• the model (A);
• the year of manufacture, in cryptographic
form (B);
• the serial number (C);
• the data for electrical supply and the protec-
tion level (D);
• the electrical input power (E);
• the combustion head output (F).
Warning: A label that has been tampered with,
removed or is missing, along with anything else
that prevents the definite identification of the
parts and makes any installation or maintenance
work difficult.
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.
During lifting, check that the burner
remains balanced and in a horizontal
position.
The manufacturer accepts no
responsibility in the event that lifting
is performed in a manner different to
that described in this manual.
(B)
(A)
AB
CF
D9696
AB
DCE
D9695
(C) S8962
WARNING

8
P
PILOT BURNER
Adjust the gas pressure measured when exiting
the valve VP 23)(A)p.4 for a value between:
It is advisable to select an output that will ensure
the best possible pilot flame stability.
Check the single pilot flame stability and meas-
ure the ionisation current.
Make sure the value is 20 µA.
For the first ignition proceed without purging in
the main piping system and then check combus-
tion stability in presence of air in the main piping
system.
OPERATION CHARACTERISTIC
See diagram (A). It is valid for natural gas oper-
ation (G20) and pressure in the combustion
chamber = 0 mbar.
• With G25 operation, the gas pressure values
need to be multiplied by 1.3.
• For G31 operation, the gas pressure values
are divided by 2.4.
These data are referred to the codes
of the head assembly (A)
Fuel mbar kW
G20 - G25 4 ÷ 9 9 ÷ 20
G31 1,5 ÷ 3 9 ÷ 20
0
5
10
15
20
25
100 200 300 400 500 600 700 800 900 1000 1100
0
1
2
3
4
5
6
7
8
9
10
100 200 300 400 500 600 700 800 900 1000 1100
S9195
S9196
Fuel G31
Burnt output [kW]
(A)
SIZE 5
SIZE 6
SIZE7
Fuel G20
Burnt output [kW]
Min. pressure at the burner input (mbar)
Drop to the comb. haed + gas butterfly valve
SIZE 5
SIZE 6
SIZE7
Min. pressure at the burner input (mbar)
Drop to the comb. haed + gas butterfly valve

9
P
GAS PRESSURE
The adjacent tables (A) show minimum pres-
sure losses along the gas supply line depending
on the maximum burner output operation.
Column 1
Combustion head load loss. See 30)(A)p.4.
(*) Combustion head load loss with standard
gas nozzles Ø = 2mm. See 30)(A)p.4.
Column 2
Load loss at gas butterfly valve with maximum
opening: 90°.
Column 3
Load loss at gas train including: adjustment
valve VR, safety valve VS (both fully open),
pressure adjuster R, filter F.
The values shown in the various tables refer to:
natural gas G 20 PCS 11.1kWh/Nm3
With:
natural gas G 25 multiply the values of the tables
by 1.3.
Calculate the approximate maximum output of
the burner in this way:
- subtract the combustion chamber pressure
from the gas pressure measured at test point
3)(A)p.5.
- Find the nearest pressure value to your
result in column 1 of the table for the
required burner.
- Read off the corresponding output on the left.
To calculate the required gas pressure at test
point 3)(A)p.5, set the MAX output required from
the burner operation:
- find the nearest output value in the table for
the burner in question.
- Read off the pressure at test point 3)(A)p.5
on the left in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
GAS FEEDING LINE
• The gas train is connected to the gas attach-
ment, by means of the elbow fixed to the cou-
pling 8)(A)p.4.
• Make sure that the calibration range of the
pressure adjuster included the pressure
needed for the burner (in models with differ-
ent springs, refer to their colour to change the
calibrations).
These data are referred to the codes
of the head assembly (A)
The data of thermal output and
combustion head gas pressure
are related to full open (90°) gas
butterfly valve.
Head size 5 p (mbar)
Head size 6 p (mbar)
(G31) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 0.4 0.1 3.1 1.6 \ \
300 1.2 0.1 9.1 4.5 2.4 \
400 2.0 0.3 14.7 7.1 3.5 2.2
450 2.5 0.4 18.1 8.7 4.0 2.6
500 3.0 0.5 21.7 10.3 4.6 3.0
550 3.5 0.6 25.7 12.1 5.2 3.4
600 4.1 0.7 \ 14.0 5.8 3.9
650 4.7 0.8 16.1 6.5 4.4
700 5.4 1.0 18.3 7.1 4.9
720 5.7 1.0 19.2 7.4 5.2
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 1.0 0.2 6.7 3.6 2.4 1.3
300 2.9 0.4 19.7 9.9 5.3 3.2
400 4.8 0.7 32.0 15.5 7.5 4.7
450 5.9 0.9 \ 18.8 8.7 5.6
500 7.1 1.1 \ 22.4 10.0 6.5
550 8.4 1.4 \ 26.3 11.3 7.5
600 9.8 1.6 \ 30.5 12.6 8.5
650 11.4 2.0 \ 35.0 14.0 9.6
700 13.0 2.3 \ 39.7 15.5 10.8
720 13.7 2.4 \ 41.7 16.1 11.2
(G31) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 0.3 0.1 3.1 1.6 \ \
300 0.9 0.1 9.1 4.5 2.4 \
400 1.5 0.3 14.7 7.1 3.5 2.2
450 1.8 0.4 18.1 8.7 4.0 2.6
500 2.1 0.5 21.7 10.3 4.6 3.0
550 2.5 0.6 25.7 12.1 5.2 3.4
600 2.9 0.7 \ 14.0 5.8 3.9
650 3.4 0.8 16.1 6.5 4.4
700 3.9 1.0 18.3 7.1 4.9
750 4.4 1.2 20.6 7.9 5.5
800 4.9 1.3 23.1 8.6 6.1
900 6.1 1.7 28.5 10.1 7.4
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 0.8 0.2 6.7 3.6 2.4 1.3
300 2.2 0.4 19.7 9.9 5.3 3.2
400 3.5 0.7 32.0 15.5 7.5 4.7
450 4.3 0.9 \ 18.8 8.7 5.6
500 5.1 1.1 \ 22.4 10.0 6.5
550 6.1 1.4 \ 26.3 11.3 7.5
600 7.1 1.6 \ 30.5 12.6 8.5
650 8.1 2.0 \ 35.0 14.0 9.6
700 9.3 2.3 \ 39.7 15.5 10.8
750 10.5 2.6 44.8 17.1 12.0
800 11.8 3.4 \ 18.7 13.3
900 14.6 3.7 \ 22.0 16.0
(A)

10
Head size 7 p (mbar)
(G31) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 0.2 0.1 3.1 1.6 \ \
300 0.6 0.1 9.1 4.5 2.4 \
400 1.0 0.3 14.7 7.1 3.5 2.2
450 1.3 0.4 18.1 8.7 4.0 2.6
500 1.5 0.5 21.7 10.3 4.6 3.0
550 1.8 0.6 25.7 12.1 5.2 3.4
600 2.1 0.7 \ 14.0 5.8 3.9
650 2.4 0.8 16.1 6.5 4.4
700 2.8 1.0 18.3 7.1 4.9
750 3.2 1.2 20.6 7.9 5.5
800 3.6 1.3 23.1 8.6 6.1
900 4.4 1.7 28.5 10.1 7.4
1000 5.4 2.1 34.4 11.8 8.7
1080 6.2 2.4 39.5 13.2 9.9
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263
mbar mbar 4÷50 4÷50 4÷33 4÷33
150 0.5 0.15 6.7 3.6 2.4 1.3
300 1.5 0.44 19.7 9.9 5.3 3.2
400 2.5 0.7 32.0 15.5 7.5 4.7
450 3.1 0.9 \ 18.8 8.7 5.6
500 3.7 1.1 \ 22.4 10.0 6.5
550 4.3 1.35 \ 26.3 11.3 7.5
600 5.1 1.6 \ 30.5 12.6 8.5
650 5.9 1.95 \ 35.0 14.0 9.6
700 6.7 2.25 \ 39.7 15.5 10.8
750 7.6 2.6 44.8 17.1 12.0
800 8.5 3.4 \ 18.7 13.3
900 10.6 3.7 \ 22.0 16.0
1000 12.9 4.6 \ 25.6 19.0
1080 14.8 5.35 \ 28.6 21.5
(A)

11
PILOT BURNER
Adjust the gas pressure measured when exiting
the valve VP 23)(A)p.4 for a value between:
It is advisable to select an output that will ensure
the best possible pilot flame stability.
Check the single pilot flame stability and meas-
ure the ionisation current.
Make sure the value is 20 µA.
For the first ignition proceed without purging in
the main piping system and then check combus-
tion stability in presence of air in the main piping
system.
OPERATION CHARACTERISTIC
See diagram (A). It is valid for natural gas oper-
ation (G20) and pressure in the combustion
chamber = 0 mbar or with LPG (G31).
• With G25 operation, the gas pressure values
of the diagram for G20 need to be multiplied
by 1.3.
FIXING THE PURGING STRUCTURE TO THE
HEAD ASSEMBLY (B)
Fix the flange 1) to the plate 3) interposing the
insulating gasket 2) supplied.
Fix the assembly using the four M8 screws sup-
plied.
The seal between purging structure and head
assembly seal must be airtight.
EXAMPLES OF ASSEMBLY (C)
The fan structure can be rotated by 90º.
It is necessary to select a solution in which the
fan motor is in horizontal position and the pilot
valve coil in vertical position, pointing upwards.
NOTE: make sure you leave a clearance of at
least 2000 mm between the front of the combus-
tion chamber and the first obstacle facing it from
the front. In addition, a clearance of at least
300 mm at the sides of the chamber is recom-
mended.
Give the bottom of the combustion head a clear-
ance of 1000 mm from the chamber that houses
the air fan so as to avoid uneven flows of input air
and ignition problems.
These data are referred to the codes
of the head assembly (B)
Fuel mbar kW
G20 - G25 7 ÷ 15 9 ÷ 20
G31 3 ÷ 6 9 ÷ 20
Do not install the burner near piping
curves or obstacles: apart from
causing overheating problems, this
increases the CO generated.
0
5
10
15
20
25
30
100 200 300 400 500 600 700 800 900 1000 1100
0
5
10
15
20
25
30
35
100 200 300 400 500 600 700 800 900 1000 1100
20077303
S9189
(A)
(B)
(C)
S9188
Fuel G31 - Holes 1.5 mm
Burnt output [kW]
SIZE 5
SIZE6
SIZE7
Fuel G20 - Holes 2.0 mm
Burnt output [kW]
SIZE 5
SIZE 6
SIZE7
Min. pressure at the burner input (mbar)
Drop to the comb. haed + gas butterfly valve
Min. pressure at the burner input (mbar)
Drop to the comb. haed + gas butterfly valve
WARNING

12
P
GAS PRESSURE
The adjacent tables (A) show minimum pres-
sure losses along the gas supply line depending
on the maximum burner output operation.
Column 1
Combustion head load loss. See 30)(A)p.4.
(*) Combustion head load loss with standard
gas nozzles Ø = 2mm. See 30)(A)p.4.
Column 2
Load loss at gas butterfly valve with maximum
opening: 90°.
Column 3
Load loss at gas train including: adjustment
valve VR, safety valve VS (both fully open),
pressure adjuster R, filter F.
The values shown in the various tables refer to:
natural gas G 20 PCS 11.1 kWh/Nm3 or G 31
PCS 28.1 kWh/Nm3
With:
natural gas G 25 multiply the values of the tables
by 1.3 for G 20.
Calculate the approximate maximum output of
the burner in this way:
- subtract the combustion chamber pressure
from the gas pressure measured at test point
3)(A)p.5.
- Find the nearest pressure value to your
result in column 1 of the table for the
required burner.
- Read off the corresponding output on the left.
To calculate the required gas pressure at test
point 3)(A)p.5, set the MAX output required from
the burner operation:
- find the nearest output value in the table for
the burner in question.
- Read off the pressure at test point 3)(A)p.5
on the left in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
GAS FEEDING LINE
• The gas train is connected to the gas attach-
ment, by means of the elbow fixed to the cou-
pling 8)(A)p.4.
Make sure that the calibration range of the pres-
sure adjuster included the pressure needed for
the burner (in models with different springs, refer
to their colour to change the calibrations).
These data are referred to the codes
of the head assembly (B)
The data of thermal output and
combustion head gas pressure
are related to full open (90°) gas
butterfly valve.
Head size 5 p (mbar)
Head size 6 p (mbar)
(G31) holes 1.5 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
150 1.6 0.05 3.1 1.6 \ \ \ \
300 5.3 0.1 9.1 4.5 2.4 \ \ \
400 9.0 0.3 14.7 7.1 3.5 2.2 \ \
450 11.3 0.37 18.1 8.7 4.0 2.6 \ \
500 13.8 0.46 21.7 10.3 4.6 3.0 \ \
550 16.5 0.57 25.7 12.1 5.2 3.4 5.2 3.4
600 19.5 0.68 \ 14.0 5.8 3.9 5.8 3.9
650 22.7 0.82 16.1 6.5 4.4 6.5 4.4
700 26.1 1 18.3 7.1 4.9 7.1 4.9
720 27.6 1 19.2 7.4 5.2 7.4 5.2
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
150 1.4 0.2 6.7 3.6 2.4 1.3 \ \
300 4.5 0.4 19.7 9.9 5.3 3.2 \ \
400 7.5 0.7 32.0 15.5 7.5 4.7 \ \
450 9.4 0.9 \ 18.8 8.7 5.6 \ \
500 11.4 1.1 \ 22.4 10.0 6.5 \ \
550 13.6 1.4 \ 26.3 11.3 7.5 \ \
600 16.0 1.6 \ 30.5 12.6 8.5 12.6 8.5
650 18.6 2.0 \ 35.0 14.0 9.6 14.0 9.6
700 21.4 2.3 \ 39.7 15.5 10.8 15.5 10.8
720 22.6 2.4 \ 41.7 16.1 11.2 16.1 11.2
(G31) holes 1.5 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
150 1.1 0.1 3.1 1.6 \ \ \ \
300 3.5 0.1 9.1 4.5 2.4 \ \ \
400 5.9 0.3 14.7 7.1 3.5 2.2 \ \
450 7.4 0.4 18.1 8.7 4.0 2.6 \ \
500 9.0 0.5 21.7 10.3 4.6 3.0 \ \
550 10.8 0.6 25.7 12.1 5.2 3.4 \ \
600 12.7 0.7 \ 14.0 5.8 3.9 \ \
650 14.8 0.8 16.1 6.5 4.4 \ \
700 17.0 1.0 18.3 7.1 4.9 7.1 4.9
750 19.4 1.2 20.6 7.9 5.5 7.9 5.5
800 22.0 1.3 23.1 8.6 6.1 8.6 6.1
900 27.6 1.7 28.5 10.1 7.4 10.1 7.4
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
150 1.0 0.2 6.7 3.6 2.4 1.3 \ \
300 3.0 0.4 19.7 9.9 5.3 3.2 \ \
400 5.0 0.7 32.0 15.5 7.5 4.7 \ \
450 6.2 0.9 \18.8 8.7 5.6 \ \
500 7.6 1.1 \22.4 10.0 6.5 \ \
550 9.0 1.4 \26.3 11.3 7.5 \ \
600 10.6 1.6 \30.5 12.6 8.5 \ \
650 12.3 2.0 \35.0 14.0 9.6 \ \
700 14.1 2.3 \39.7 15.5 10.8 \ \
750 16.0 2.6 44.8 17.1 12.0 \ \
800 18.1 3.4 \18.7 13.3 18.7 13.3
900 22.6 3.7 \22.0 16.0 22.0 16.0
(A)

13
GAS TRAIN (B)
It is type-approved according to EN 676 Regula-
tions.
KEY (B)
FFilter
PG Minimum gas pressure switch
R Main pressure regulator
Rp Pilot pressure regulator (*)
VF Butterfly valve
VP Pilot solenoids
VR Adjustment solenoid
VS Safety solenoid
(*) By adjusting the spring it is possible to
change the range from 10 to 30 mbar.
KEY (C)
Gas train/burner adaptor.
Supplied separately from the optional gas train.
(*) Adapter 1-1/4” ---> 1-1/2” as equipment
The data of thermal output and
combustion head gas pressure
are related to full open (90°) gas
butterfly valve.
Gas train Outlet
pressure Size Adaptor
Ø net Ø burner Code Model mbar 5 6 7 Code
1” 3/4” 3970600 MB 410/1 - RT 52 (*)(1) 4 ÷ 50 • • / 3000824 +
3000843
1-1/4” 1-1/4” 3970144 MB 412/1 - RT 20 (*) 4 ÷ 20 • • • 3000843
1-1/4” 1-1/4” 3970256 MB 412/1 - RT 52 (*)(1) 4 ÷ 50 • • • 3000843
1-1/2” 1-1/2” 3970180 MB 415/1 - RT 30 4 ÷ 33 • • • 3000843
1-1/2” 1-1/2” 3970262 MB 415/1 - RT 22 (1) 4 ÷ 33 • • • 3000843
1-1/2” 1-1/2” 3970250 MB 415/1 - RT 52 (1) 20 ÷ 50 • • • 3000843
2” 2” 3970181 MB 420/1 - RT 30 4 ÷ 33 • • • -
2” 2” 3970263 MB 420/1 - RT 22 (1) 4 ÷ 33 • • • -
2” 2” 3970257 MB 420/1 - RT 52 (1) 20 ÷ 50 • • • -
20050723
(B)
(C)
(1) Separate control of the valves
Head size 7 p (mbar)
(G31) holes 1.5 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
1500.80.13.11.6\\\\
300 2.5 0.1 9.1 4.5 2.4 \ \ \
400 4.2 0.3 14.7 7.1 3.5 2.2 \ \
450 5.2 0.4 18.1 8.7 4.0 2.6 \ \
500 6.4 0.5 21.7 10.3 4.6 3.0 \ \
550 7.6 0.6 25.7 12.1 5.2 3.4 \ \
600 9.0 0.7 \ 14.0 5.8 3.9 \ \
650 10.4 0.8 16.1 6.5 4.4 \ \
700 12.0 1.0 18.3 7.1 4.9 \ \
750 13.7 1.2 20.6 7.9 5.5 \ \
800 15.5 1.3 23.1 8.6 6.1 8.6 6.1
900 19.4 1.7 28.5 10.1 7.4 10.1 7.4
1000 23.8 2.1 34.4 11.8 8.7 11.8 8.7
1080 27.6 2.4 39.5 13.2 9.9 13.2 9.9
(G20) holes 2.0 mm 3
1" 1 1/4" 1 1/2" 2" 1 1/2" 2"
kW 1 2 3970600 3970256 3970262 3970263 3970250 3970257
mbar mbar 4÷50 4÷50 4÷33 4÷33 20÷50 20÷50
150 0.7 0.2 6.7 3.6 2.4 1.3 \ \
300 2.2 0.4 19.7 9.9 5.3 3.2 \ \
400 3.6 0.7 32.0 15.5 7.5 4.7 \ \
450 4.4 0.9 \ 18.8 8.7 5.6 \ \
500 5.3 1.1 \ 22.4 10.0 6.5 \ \
550 6.3 1.4 \ 26.3 11.3 7.5 \ \
600 7.4 1.6 \ 30.5 12.6 8.5 \ \
650 8.6 2.0 \ 35.0 14.0 9.6 \ \
700 9.8 2.3 \ 39.7 15.5 10.8 \ \
750 11.2 2.6 44.8 17.1 12.0 \ \
800 12.6 3.4 \ 18.7 13.3 \ \
900 15.7 3.7 \ 22.0 16.0 \ \
1000 19.2 4.6 \ 25.6 19.0 25.6 19.0
1080 22.2 5.4 \ 28.6 21.5 28.6 21.5
(A)

14
START-UP, CALIBRATION AND OPERA-
TION OF THE BURNER
NOTES ON SAFETY FOR THE FIRST START-
UP
ADJUSTMENTS PRIOR TO IGNITION
• Ensure that the gas supply company has car-
ried out the supply line vent operations, elimi-
nating air or inert gases from the piping.
• Slowly open the manual valves situated
upstream of the gas train.
• Adjust the minimum gas pressure switch (A)
to the start of the scale.
• Adjust the maximum gas pressure switch (B)
to the end of the scale.
• Adjust the air pressure switch (C) to the start
of the scale.
• Check the gas supply pressure by connecting
a pressure gauge to the pressure test point
(E) of the minimum gas pressure switch: it
must be lower than the maximum allowed
pressure of the gas train, as shown on the
characteristics label.
• Bleed the air from the piping of the gas train,
connecting a plastic tube to the pressure test
point 1) (D) of the minimum gas pressure
switch.
Take the vent tube outside the building so you
can notice the smell of gas.
• Connect two lamps or testers to the two gas
line solenoids to check the exact moment in
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.
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
regulations of the laws in force.
Check the correct working of the
adjustment, command and safety
devices.
Refer to paragraph “Safety test -
with gas ball valve closed” on
page 22 before the first start-up.
Excessive gas pressure can damage
the components of the gas train and
lead to a risk of explosion.
Before starting 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 deliv-
ery at the minimum.
D3855
(A)
(B)
(C)
D3856
(D) 20078114
D3854
1
(E) 20078041
WARNING
CAUTION
WARNING

15
SERVOMOTOR (A)
The servomotor manages the position of the gas
butterfly valve. The servomotor rotation time
from 0º to 90º is 30 seconds.
The full opening, full closure and ignition posi-
tions in the butterfly valve 2nd stage are estab-
lished by setting the 4 servomotor cams:
•Red cam (I)
fully open at 90°
•Blue cam (II)
fully closed at 0°
•Orange cam (III)
ignition at 20°
•Black cam (IV)
not used
BURNER START-UP
Switch off the remote controls and place the
switch 1)(B) in position “MAN”.
BURNER IGNITION
Having completed the checks indicated in the
previous heading, ignition of the burner should
be achieved. If the motor starts up but the flame
does not appear and the control box goes into
lockout, reset and wait for a new ignition
attempt. If ignition is still not achieved, it may be
that gas is not reaching the combustion head
within the safety time period of 5 seconds.
Increase the gas delivery at ignition therefore,
using the pilot valve delivery adjuster. If there
are still problems during ignition, increase the
position of the orange cam by 5°.
The arrival of gas at the pipe coupling is indi-
cated by the U-type pressure gauge (E)p. 11.
Once the ignition has been achieved, proceed
with global adjustment operations.
At maximum output, the middle of the flame
should be light blue, and the edges yellow.
A compact light blue flame indicates excess cali-
bration air; this produces CO emission levels that
are far from satisfactory.
During the start-up and the adjustments, it is
vital to monitor the state of the ionisation cur-
rent.
Given its state button and given the characteris-
tics of the burner, it is very important that the
value returned is higher than 20 µA.
For further details, see the section “FLAME
PRESENT CHECK” page 16.
Normally the ionisation current can fluctuate
also by 10 ÷ 15 µA.
For this reason, we recommend that a minimum
value of 20 µA be maintained.
As soon as the burner starts, check
that the rotation direction of the fan
corresponds to the rotation arrow
indicated in the diagram (C).
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 immedi-
ately stop the burner and check the
electrical wiring.
These operations increase the mod-
ulation minimum.
12
D791
RED CAM
(A)
(B)
D2266
BLUE CAM
BLACK CAM
ORANGE CAM
20078046
(C)
WARNING
DANGER
WARNING

16
BURNER ADJUSTMENT
The optimum adjustment of the burner requires
an analysis of the flue gases at the boiler outlet.
Adjust successively:
1 - First ignition output
2 - Maximum burner output
3 - Air pressure switch
4 - Minimum gas pressure switch
5 - Maximum gas pressure switch
1 - IGNITION OUTPUT
Burners with MAX. output up to 120 kW
Ignition can be performed at the maximum oper-
ation output level. Example:
• Max. operation output: 120 kW
• Max. ignition output: 120 kW
Burners with MAX. output above 120 kW
Ignition must be performed at a lower output
than the max. operation output.
If the ignition output does not exceed 120 kW,
no calculations are required. If ignition output
exceeds 120 kW, the regulations prescribe that
the value be defined according to the control
box safety time "ts":
• For "ts" = 2s, ignition output must be equal to
or lower than 1/2 of max. operation output.
• For "ts" = 3s, ignition output must be equal to
or lower than 1/3 of max. operation output.
• Direct ignition with reduced output using a by-
pass valve: possible if the ignition output does
not exceed 120 kW.
Under these conditions, no calculation is
required. If the output is greater than 120 kW,
regulations prescribe that its maximum value
be defined in accordance with the safety time
and the percentage on the maximum load
representing the ignition output.
With ts = 3s the ignition output should not be
greater than 33% of the maximum load.
• Ignition with pilot burner, with maximum pilot
output equal to 10% of the maximum load.
With a pilot burner output less than 70 kW the
first safety time should be 5 seconds at the
most.
With a pilot burner output greater than 70 kW
(but less than 10% of the burner's maximum
output) the first safety time should be 3 sec-
onds at the most.
If the main burner’s ignition output falls within
the limit of 180 kW nothing further is required.
If greater than 180 kW, the maximum permis-
sible output is related to the second safety
time and the percentage of the maximum out-
put made up of the ignition output.
With a second safety time of 3 seconds the
maximum ignition output is 50% of the maxi-
mum burner output.
According to EN 676 Regulation
According to EN 746-2 Regulation

17
Example (according to EN 676)
MAX operation output of 600 kW.
Ignition output must be equal to or lower than:
• 300 kW with ts = 2 s;
• 200 kW with ts = 3 s.
In order to measure the ignition output:
- Disconnect the plug-socket 7)(A)p.5 on the
ionisation probe cable (the burner starts up
and then go into lockout after the safety time
has elapsed).
- Perform 10 ignitions 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 (according to EN 676)
For G 20 gas (10 kWh/Nm3):
Max. operation output: 600 kW corresponding to
60 Nm3/h.
After 10 ignitions with lockouts, the delivery read
on the meter must be equal to or lower than:
60 : 360 = 0.166 Nm3.
2 - MAXIMUM BURNER OUTPUT
The maximum output values are included in the
table on page 3.
Gas adjustment
Measure the gas delivery at the meter.
A guideline indication can be calculated from the
tables on page 9, simply read off the gas pres-
sure on the U-type pressure gauge, see fig.
(E)p. 11, and follow the instructions on page 9.
- 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
Adjust the fan air gate valve by using the gradu-
ated sector 1)(A) after having loosened the nut
2)(A).
BURNER CALIBRATION
The calibration - to be performed with an appro-
priate analyser to measure the CO in the heated
room - is a compromise between the need to
minimise the emissions, to keep an acceptable
flame length, and to obtain stable ionisation cur-
rent values.
As a rule of thumb, by reducing the maximum
opening of the air damper you can obtain bene-
ficial effects for both the reduction of CO pro-
duced and the shift towards higher emission
peak outputs.
On the other hand, the flame lengthens and the
flame root rises; beyond a certain limit, this
could cause detection problems and, conse-
quentially, burner lockouts due to flame failure.
This is particularly possible when the burner
reaches maximum output.
During the calibration phase therefore, you are
strongly advised to monitor the levels of ionisa-
tion current generated with the various outputs.
D593
(A)
10 20 30 40 50 60 70 80 90
D9683
Gas butterfly valve opening angle [°]
CO formation [ppm]
(B)
Effects of the excess air reduction
Positive Negative
Reduction of CO produced at
all output levels The flame tends to lengthen; if it comes into contact with cold surfaces, combustion is interrupted and
there is an increase in the overall level of CO pro-
duced.
CO formation peak shifts to
higher output levels The flame root rises from the base of the chamber "V".
At a high output level, there may be flame detection
problems because of the rising flame root.
Nm3/h (max. burner delivery)
360