Riello RX 180 S/PV Quick start guide

2903357 (11) - 01/2015
Istruzioni per installazione, uso e manutenzione
Instructions pour installation, utilisation et entretien
Installation, use and maintenance instructions
Bruciatori di gas premiscelato
Brûleurs de gaz prémélangé
Premixed gas burners
Funzionamento bistadio progressivo o modulante
Fonctionnement à deux allures progressif ou modulant
Progressive two-stage or modulating operation
CODICE - CODE MODELLO - MODEL
MODELE
TIPO
TYPE
3790310 - 3790330 RX 180 S/PV 908 T
3790300 - 3790320 RX 250 S/PV 903 T
I
F
GB
RX

Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Premixed gas burners
Model: RX 180 S/PV
RX 250 S/PV
These products are in compliance with the following Technical Standards:
EN 12100
EN 676
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Producer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.riello.com
Distributed by: RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE conformity declaration and they
are produced and placed in circulation in conformity with the provisions defined in L.D. dated January 8, 2004 and July 17, 2009.
Product type: Premixed gas burners
Model: RX 180 S/PV
RX 250 S/PV
Standard applied: EN 676 and A.R. dated January 8, 2004 - July 17, 2009
Measured value: RX 180 S/PV CO max: 11 mg/kWh
NOx max: 45 mg/kWh
RX 250 S/PV CO max: 22 mg/kWh
NOx max: 44 mg/kWh
Controlling organisation: TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
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
Premixed gas burners 908T RX 180 S/PV 30 - 180 kW
903T RX 250 S/PV 42 - 250 kW
Legnago, 03.09.2014 Executive General Manager
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. R. Cattaneo
CE-0085BT0104 Classe 3 (EN 676)

The following symbols are used in this manual:
ATTENTION = for actions requiring special care and adequate preparation.
FORBIDDEN = for actions THAT MUST NOT be performed.
!
IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and perfor-
mance data. If the Identification Plate is tampered with, removed or missing, the product cannot be
clearly identified, thus making any installation or maintenance work potentially dangerous.
GENERAL WARNINGS
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guaran-
tee a combustion with the lowest polluting emissions rate.
You are therefore advised to consult the Technical Assistance Department before choosing this type of
burner for the combination with a boiler.
Qualified personnel are those with the professional and technical requirements indicated by Law no.
46 dated 5 March 1990. The commercial organisation has a widespread network of agencies and tech-
nical offices whose personnel participates periodically in instructional and refresher courses at the
company training centre.
This burner must only be used for the application it was designed for.
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to
errors in installation or in the burner adjustment, or due to improper or unreasonable use or non-obser-
vance of the technical instructions enclosed with the burner, or due to the intervention of unqualified
personnel.
USER INFORMATION
If faults arise in ignition or operations, the burner performs a "safety stop", which is signalled by the
red burner lock out LED. To rearm start-up conditions, press the release button. When the burner
starts up again, the red LED goes out.
This operation can be repeated for a maximum of 3 times. If the "safety stop" recurs, then the
Technical Assistance Centre must be contacted.
BASIC SAFETY RULES
Children or inexpert persons must not use the appliance.
Under no circumstances must the intake grids, dissipation grids and ventilation vents in the installa-
tion room be covered up with cloths, paper or any other material.
Unauthorised persons must not attempt to repair the appliance
It is dangerous to pull or twist the electric leads.
Cleaning operations must not be performed if the appliance is not disconnected from the main power
supply.
Do not clean the burner or its parts with inflammable substances (e.g. petrol, alcohol, etc.).
The cover must be cleaned with soapy water.
Do not place anything on the burner.
Do not leave containers and inflammable products in the installation room.

1
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Output supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Working position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Head length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fixing the burner to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Burner star-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas valve adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Burner adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ionisation current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Appendix1 Combustion manager CM222 . . . . . . . . . . . . . . . . . . .13
Appendix2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ionisation Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Switchboard layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
N.B.
Figures mentioned in the text are identified as follows:
1)(A) =part 1 of figure A, same page as text;
1)(A)p.3 =part 1 of figure A, shown on page 3.
INFORMATION ABOUT THE INSTRUCTION
MANUAL
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 neces-
sary 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 Service of the area;
- is designed for use by qualified personnel;
- offers important indications and instructions relating to the installa-
tion safety, start-up, use and maintenance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUCTION
MANUAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the system man-
ufacturer, 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 Assistance
Centre;
- The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system is
started up,
- maintenance and the need to have the system checked at least
once a year by the manufacturer or another specialised techni-
cian.
To ensure a periodic check, recommends the drawing
up of a Maintenance Contract.
..................................................................................
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2
TECHNICAL DATA
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0m above sea level.
(2) Socket pressure 6)(A)p.3 with zero pressure in the combustion chamber.
(3) Sound pressure measured in the manufacturer's combustion laboratory, with burner operating on the test boiler at maximum output and measured from one metre
away and at a frequency of 50Hz.
ACCESSORIE (optional):
KIT FOR MODULATING OPERATION
NOTE: The installer is responsible for the addition of any safety device not foreseen in this manual.
MODEL RX 180 S/PV RX 250 S/PV
TYPE 908 T 903 T
OUTPUT (1) MAX. kW 180
155 250 215
Mcal/h
MIN. kW
Mcal/h 30 26 42 36
FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25
G20 G25 G20 G25
- net calorific value kWh/Sm3
Mcal/Sm39.45
8.2 8.13 7.0 9.45 8.2 8.13 7.0
- absolute density kg/Sm30.71 0.78 0.71 0.78
- max. delivery Sm3/h 19.0 22.1 26.5 30.8
- pressure at max. delivery (2) mbar 7.1 10.7 9 13.5
OPERATION • On-Off (1 stop min each 24 hours).
• Progressive two-stage or modulating
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATURE °C 0 - 40
COMBUSTION AIR TEMPERATURE °C max 60
ELECTRICAL SUPPLY V
Hz 230 ~ +/-10% 50/60 - single-phase
ELECTRIC MOTOR (Rating plate) rpm
W
V
5830
360
220 - 240
5830
360
220 - 240
WORKING CURRENT A - -
IGNITION TRANSFORMER V1 - V2
I1 - I2 230 V - 2 x 5 kV 1.45 A - 50 Hz - 30 mA
ELECTRICAL POWER CONSUMPTION W max 340 -
ELECTRICAL PROTECTION IP40
NOISE (3) dBA - -
GAS CATEGORIES
COUNTRY CATEGORY
IT - AT - GR - DK - FI - SE
ES - GB - IE - PT
NL
FR
DE
BE
LU
II2H3B/P
II2H3P
II2L3B/P
II2Er3P
II2ELL3B/P
I2E(R)B, I3P
II2E 3B/P
OUTPUT POWER REGULATOR KIT RWF50.2
Two components should be ordered:
• the Output power regulator to install on the burner;
• the Probe to install on the heat generator
Parameter to control Probe Output power regulator
Adjustment field Type Code Type Code
Temperature - 100...+500°C PT 100 3010110
RWF50.2 20086840
Pressure 0...2.5 bar
0...16 bar Output probe 4...20 mA 3010213 3010214

3
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Flame sensor probe
4Gasvalve
5 Air/gas mixer in the suction line circuit
6 Gas pressure test point
7 Gas valve conduit - Venturi
8 Gas input
9 Boiler mounting flange
10 Fan
11 Air passage in fan
12 Control box with lockout pilot light
13 Reset button
14 Plug-socket on ionisation probe cable
15 Sockets for electrical connection
16 Transformer
17 Plate pre-arranged to obtain 4 holes for the
passage of the electric cables
18 Suppressor
Two types of burner failure may occur:
• CONTROL BOX LOCKOUT:
if the 13)(A) pushbutton lights up, it indicates that
the burner is in lockout.
To reset, press the push button.
PACKAGING - WEIGHT (B) - Approximate
measurements
• The burners are shipped in cardboard boxes
with the maximum dimensions shown in tab.
(B).
• The weight of the burner complete with pack-
aging is indicated in tab. (B).
MAX. DIMENSIONS (C) -approximate meas-
urements
The maximum dimensions of the burner are
given in (C).
Bear in mind that, in order to inspect the com-
bustion head, the burner must be pulled back.
STANDARD EQUIPMENT
1 - Gas train flange
4 - Valve fixing screws M 5 x 16
1 - Insulating screen
1 - Combustion head with gasket and screws
1 - Gas valve
1 - 4 pole plug
1 - 7 pole plug
1 - Instruction manual
1 - Spare parts list
Small parts for fixing burners
4 - 8x40 galvanised nuts (with or without tip)
4 - 8x16 galvanised washers
4 - 8-type galvanised notched washers
4 - M8 galvanised nuts
1-M4nut
(A)
L F
G
I
E
H
C
A
D
mm A B C kg
RX 180 S/PV 1000 500 485 30
RX 250 S/PV 1000 500 485 30
mm A D C E F G H I L
RX 180 S/PV 443 417 637 371 465 320 119 306 134
RX 250 S/PV 443 417 637 371 465 320 119 306 134
D88
(B)
20077519
D7787
(C)

4
FIRING RATES (A)
During operation, burner output varies between:
•aMAXIMUM OUTPUT, which must not be
greater than the maximum limit given on the
diagram:
RX 180 S/PV = 180 KW
RX 250 S/PV = 250 KW
•and a MINIMUM OUTPUT, which must not be
lower than the minimum limit in the diagram:
RX 180 S/PV = 30 KW
RX 250 S/PV = 42 KW
•and a FIRING POWER, which must be cho-
sen within:
- area A for gas G20 - G25:
- area B for gas G30 - G31.
Important
The FIRING RATE values have been obtained
considering an ambient temperature of 20°C, an
atmospheric pressure of 1013 mbar (approx.0m
above sea level), and with the combustion head
adjusted as shown on page 5.
TEST BOILER (B)
The firing rates were set in relation to special
test boilers, according to EN 676 regulations.
COMMERCIAL BOILERS
The burner/boiler combination does not pose
any problems if the boiler is CE approved.
If the burner must be combined with a commer-
cial boiler that has not been CE approved and/or
its combustion chamber dimensions are clearly
smaller, consult the manufacturer.
You are advised to use this burner for boilers
with a frontal circulation of the flue gases.
(A) D7813
A
A
B
B
Firing rate G20 - G25 Firing rate G30 - G31
Firing rate G20 - G25 Firing rate G30 - G31

5
OUTPUT SUPPLIED
The charts alongside will allow you to determine
the output supplied either by reading the num-
ber of rotations or by reading the downstream
pressure of the gas valve (point 1).
Example:
• Operation with PREMIX RX 250 S/PV
• Natural gas G31 PCI 9.45 kWh/Sm3;
• Pressure on point 1 = -21 mbar.
The burnt power corresponds to 200 kW.
The burnt power corresponds to 200 kW.
Going back in vertical in the diagram, until inter-
crossing the outlined straight line, you can esti-
mate the value of the number of rotation on the
scale of the left-hand ordinates: in this case
4750 turns/min.
For an exact reading of the number of rotations,
it is available a control box interface kit.
VS VR
R
21
F
D7789
RX180S/ PV G20- G25
RX180S/ PV G30- G31
RX250S/ PV G20- G25
RX250S/ PV G30- G31
(A)
Motor rpm
Thermal power - kW
Gas valve output pressure - mbar
RX 180 S/PV G20 - G25
RX 180 S/PV G30 - G31
RX 250 S/PV G20 - G25
RX 250 S/PV G30 - G31
D7814
(B)
Motor rpmMotor rpmMotor rpm
Gas valve output pressure - mbarGas valve output pressure - mbarGas valve output pressure - mbar
Thermal power - kW
Thermal power - kW
Thermal power - kW
rpm
Pressure

6
INSTALLATION
THE BURNER MUST BE INSTALLED
IN CONFORMITY WITH LEGISLATION
AND LOCAL STANDARDS.
WORKING POSITION (A)
The burner is designed to work only in
the positions 1, 2, 4 and 5.
Installation 1is preferable, as it is the only one
that allows the maintenance operations as de-
scribed in this manual.
Installations 2, 4 and 5 allow the working, but
make the operations of maintenance.
Any other position could compromise
the correct working of the appliance.
Installation 5is forbidden, for safety
reasons.
All the positions require the installation of the
gas valve with coils pointing upwards, or hori-
zontal (Fig.A). Installation with the coils point-
ing downwards is absolutely forbidden.
BOILER PLATE (B)
Pierce the closing plate of the combustion
chamber, as in (B). The position of the threaded
holes can be marked using the thermal screen
supplied with the burner.
HEAD LENGTH (C)
The length of the head must be selected accord-
ing to the indications provided by the manufac-
turer 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 fol-
lows:
The burners cannot be used on
flame inversion boilers.
It is possible to insert a protection made of
refractory material between the combustion
head 6)(B) and the boiler refractory 8)(B).
This protection must allow the blast tube to be
taken out.
Do not insert the protection in line
with the electrode unit, as this
would compromise its good opera-
tion.
LNon combu-
stion zone
RX 180 S/PV RX 250 S/PV
160 mm 160 mm
(C)
2 3 4 51
(A) D7796
4
11
12
10
5
mm A B C D E
RX 180 S/PV
RX 250 S/PV
163
163
224
224
M 8
M 8
94
94
68
68
D3367
(B)
D7792
!
!
WARNING
WARNING

7
FIXING THE BURNER TO THE BOILER
Fasten the combustion head 6) to flange 4) by
means of the three screws 10) supplied.
Make sure you have the seal 11) fit on flange 4).
Fasten the electrode unit 17)(A) on flange 4)
with the two nuts and screws 16.
Make sure seal 15) is fitted and in the right
position.
Insert the connections 21)(A) in the holes 22).
Connect the high voltage cables to the trans-
former 23), and the ionisation probe lead to the
appropriate cable emerging from the control
box.
Before installing the burner on the boiler, check
through the blast tube opening to make sure
that the flame sensor probe and the ignition
electrodes are correctly set in position, as
shown in fig. (C).
Use the screws 1)(E) to obtain the correct dis-
tances.
Fix the train assembly 20)(B) by using the 4
screws 18)(B) supplied.
Pay attention to the presence of the gasket
19)(B) and the gas seal.
• Tighten the studs 2)(D) on the plate 1)(D).
• Position the refractory gasket 3)(D).
• Position the silicone rubber gasket 4)(D).
• Fix the flange 4)(A) to the boiler plate and
tighten the nuts 5)(D).
During this operation, take care not to touch
the electrode unit.
• Tighten the nuts 5)(D).
The seal between burner and boiler and elec-
trode unit must be airtight.
Fit the gas train as instructed on page 8.
1
2
3
4
5
D9776
(A)
(B) D9777
(D) D8666
(C) 20084006
17
15
6
10
11
4
16
22
21
19
18
20
23
PROBE
ELECTRODE
(E)
20084009

8
FUEL SUPPLY
The burners are teamed with one-piece pneu-
matic proportioning gas valves, via which the
amount of gas delivered, and hence the output
produced, can be modulated.
A signal reporting pressure detected in the air
circuit is carried to the pneumatic gas valve,
which delivers an amount of gas in proportion to
the airflow produced by the fan.
The gas train, in order to render the dimensions
efficent is assembledd directly onto the burner
body.
Air/gas mixer
Gas and combustive air are mixed inside the
purging circuit (mixer), starting from the intake
inlet. Through the gas train, fuel is introduced
into the intake air current and optimal mixing
commences with the aid of a mixer.
Note
The pipe (T) between Venturi-valve, accidental
blocking of the intake can be compensated by
reducing the amount of gas delivered.
After connecting the compensation pipe (T),
with the valve coat it with a rubber protection.
GAS TRAIN (B)
Approved, together with the burner, according to
the regulation EN 676, and supplied.
LEGENDA (B)
1 - Gas input pipe
2 - Manual valve
3 - Vibration damping joint
4 - Pressure gauge with pushbutton cock
5 - Valve, including:
- filter (replaceable)
- working valve
- pressure adjuster
P1 - Pressure up-line from the filter
P2 - Downstream pressure of valve
L - Gas train supplied
L1 - The responsibility of the installer
(A) D7803
Gas valve
Compensation pipe (T)
Metal protection
Wiring loom fitting
Compensation pipe (T)
Maximum flow adjustment (V1)
Downstream pressure test point (P2)
+
-
+
-
Air/gas mixer
(Venturi)
in the suction
circuit
Gas
pressure
test point
upline (P1)
Minimum gas flow
adjustment on the stabiliser (V2)
D8668
(B)
L1 L
VS VR
R
F
12 3
45
P2
P1

9
BURNER OPERATION
ADJUSTMENT BEFORE FIRST FIRING
The following to be made are:
- open the manual valves located upline from
the gas train;
- bleed the air from the gas pipes using the
screw on the socket (page 8).
BURNER START-UP
Close the thermostat and switch on the burner's
power. The burner starts in pre-purging mode at
top speed.
Speed subsequently decreases to the START
value and the burner fires. If however the fan
starts up but no flame has appeared at the end
of the safety period, the burner goes into lock-
out. Reset and wait for a new start-up attempt. If
the burner still does not fire, the problem may be
that gas is not reaching the combustion head
within the 3-second safety time.
Turn screw V1 on the gas valve mixer anticlock-
wise slightly (page 8).
Once the burner has fired, the next step is to
complete the burner's other adjustments.
FAN ADJUSTMENT
Modulation is based on variable-speed technol-
ogy. Combustion air delivery can be adjusted by
varying the motor's speed (rpm).
The proportioning gas train, depending on the
pressure detected in the purging circuit, delivers
the right amount of fuel.
Hence the output delivered is adjusted by vary-
ing the motor's speed of rotation.
Motor speed can be adjusted by means of the
three Trimmers (see figure A).
GAS VALVE ADJUSTMENT
The regulation of the gas delivery is achieved
using the two screws V1 and V2.
To vary the maximum gas delivery turn screw
V1:
- to increase the delivery: turn the screw in an
anticlockwise direction (unscrew);
- to reduce the delivery: turn the screw in a
clockwise direction (screw up).
To vary the minimum gas delivery act on the
screw V2 on the gas valve.
Remove the protective screws and turn the
screw inside with an allen spanner:
- to increase the delivery: turn the screw in
clockwise direction (screw);
- to reduce the delivery: turn the screw in anti-
clockwise direction (unscrew).
Definition of the fan adjustments:
The adjustments are made by adjusting the
three potentiometers on the control box:
START: determines the air in the start phase;
MIN: determines the modulation minimum;
MAX: determines the modulation maximum.
D7802
(A)
MAX
START
MIN
Reset button
Maximum output Start
Minimum output

10
BURNER ADJUSTMENT
To achieve optimal burner adjustment, the flue
gases produced by combustion must be ana-
lysed as they leave the generator. In conformity
with Efficiency Directive 92/42/EEC, the burner
must be applied to the generator, adjusted and
tested in compliance with the instruction manual
of the generator in question, including checking
of CO and CO2concentration in flue gases and
their temperature.
Check in this order:
- MAX output;
- MIN output;
- firing output.
The maximum output must correspond with the
the output required by the boiler used.
To increase or decrease its value, adjust trim-
mer MAX on the control box (Fig. 9).
Measure the gas delivery on the contactor to
precisely establish the burnt output.
Using a smoke analyser measure the value of
the CO2or the O2in order to optimise the
burner calibration.
The correct values are: CO28.2 - 9%.
To correct these values act on the gas valve in
the following way:
- to increase the gas delivery and the CO2: turn
the screw V1 in anticlockwise direction
(unscrew);
- to reduce the gas delivery and the CO2:
turn the screw V1 in a clockwise direction
(screw up).
The minimum output must correspond with the
the output required by the boiler used.
To increase or decrease its value, adjust trim-
mer MIN on the control box (Fig. 9).
Measure the gas delivery on the contactor to
precisely establish the burnt output.
Using a smoke analyser, measure the value of
the CO2or the O2in order to optimise the
burner calibration. The correct values are: CO2
7.8 - 8.5%. To correct these values act on thee
gas valve in the following way:
- to increase the gas delivery and the CO2:
turn the screw V2 in a clockwise direction
(screw up);
- to reduce the gas delivery and the CO2: turn
the screw V2 in an anticlockwise direction
(unscrew).
Firing power is inside area A highlighted inside
the operating range (A, page 4).
To increase or decrease its value, adjust trim-
mer START on the control box (Fig. 9).
COMBUSTION HEAD (A)
The combustion head comprises a highly heat
resistant cylinder whose surface features nu-
merous holes, encased in a metal "mesh". The
air-gas mixture is pushed inside the cylinder and
out of the head through the holes in the perime-
ter. Combustion starts when the air-gas mixture
is ignited by a spark generated by the electrode.
The metal "mesh" is the combustion head's
most essential element since it improves burner
performance considerably.
The flame developed on the surface of the head
is perfectly retained and adheres to the mesh
when operating at the maximum setting. This al-
lows modulating ratios as high as 6:1, avoiding
the danger of flashback when modulating is at
its minimum. The flame features an extremely
compact geometry, meaning that there is no risk
of contact between the flame and parts of the
boiler, consequently eliminating the possible
problem of poor combustion. The flame's struc-
ture means that smaller combustion chambers
can be developed, designed to exploit this par-
ticular feature.
OPTIMUM CALIBRATION VALUES
MIN output MAX output
CO2(%) O2(%) CO2(%) O2(%)
METHANE 8 6.6 8.5 5.7
LPG 9.5 6.4 10 5.6
(A) D9714

11
EMISSION
The burners' emission values (according to
EN 676) prove much lower than the limits laid
down by the strictest standards.
The flame's distribution and its spread over a
large surface means that the burner manages
to limit the formation of thermal NOx, the main
causes of pollutant emission.
(A)
Class Limit 3 = 80 mg/kWh
D9715
Modulation min.
25 kW Modulation max. 145 kW

12
FINAL CHECKS (with the burner working):
• disconnect a wire of the minimum gas pres-
sure switch;
• switch on the thermostat/pressure switch TL;
• switch on the thermostat/pressure switch TS;
the burner must stop.
• Disconnect the wire of the ionisation probe;
the burner must stop in lockout.
Make sure that the mechanical locking systems
on the various adjustment devices are fully tight-
ened.
MAINTENANCE
The burner requires periodic maintenance
carried out by a qualified and authorised
technician in conformity with legislation and
local standards.
Periodic maintenance is essential for the
reliability of the burner, avoiding the
excessive consumption of fuel and consequent
pollution.
Before carrying out any cleaning or con-
trol, always switch off the electrical supply
to the burner, using the main switch of the sys-
tem and close the gas shutoff valve.
Make sure the air intake areas and ducts
taking the flue gases away do not feature
any obstructions or restrictions.
Electrical wiring
Check that the burner and gas train electrical
connections are correct.
Gas leaks
Make sure there are no gas leaks in the following
areas:
- on the meter-burner pipework
- on the mixer/valve connection
- on the burner fastening flange where the seal
is fitted.
Combustion head
Inspect the combustion head and make sure
the fabric is undamaged and does not features
large or deep holes or corroded areas. Also
make sure that no parts have warped as a re-
sult of high temperature.
Electrode unit
Make sure neither the electrodes nor probe fea-
ture marked warping or oxidation on surfaces.
Make sure distances are still in line with those in-
dicated in Fig. (D) page 6, readjusting to the right
values where necessary.
Where necessary, remove oxide from the sur-
face of the probe with abrasive paper.
Gas train
Check valve setting and proportionality of opera-
tion by analysing flue gases. Check the valve/
manifold compensation pipe.
Combustion
Leave the burner operating in steady state for
approx. ten minutes, ensuring that all compo-
nents indicated herein have the proper settings.
Then analyse combustion by checking:
- Percentage of CO2(%);
- CO content (ppm);
- NOx content (ppm);
- Ionization current (µA);
- Flue gases temperature at stack.
Adjust burner if combustion values encountered
at the beginning of operation do not meet the
standards in force or, whatever the case, do not
indicate satisfactory combustion.
Note the new combustion values down on a
suitable sheet: they will come in handy when
next checking.
!
!
!
!

13
APPENDIX 1 - COMBUSTION MANAGER CM222
The Combustion Manager CM222 is a microprocessor-controlled gas burner safety control system designed for use with forced draught modu-
lating gas burners.
OPERATION
The range-limits of the potentiometer are expert parameters. Adjustments of the potentiometers are immediately active in all program steps.
To deactivate the potentiometers set the minimum limit and the maximum limit of each potentiometer equal.
Then these equal values are the active setpoints.
The values of the min. capacity potentiometer and the max. capacity potentiometer are the limits for the modulation of the burner capacity.
These limits are used during program step ‘Burner operation’.
The value of the max. capacity potentiometer is also the setpoint for the prepurge speed.
The value of the start capacity potentiometer is the setpoint for the burner capacity during program step ‘Ignition’ and ‘Flame stabilization’.
ERROR CODE
If the burner control is in lockout the error code is shown in the display as a blinking number. The following error codes will be displayed as a
blinking number:
PROGRAM STEPS
No. Error code Explanation Buner off Lockout
1Failure fan Fan speed check. Deviation too high x x
2Failure gas pressure No signal from the gas pressure switch x -
3Failure flame No flame signal after burner start-up / Flame loss during burner operation /
Flame signal without burner operation xx
4Failure BCC Wrong BCC connected / BCC lost /
BCC parameter block is not valid xx
5Failure Remote Reset More than 5 remote resets in 15 minutes /
Permanent remote reset (> 10 sec) x / - x / -
6Failure gas valve circuit Gas valve V1/V2 leak x x
7Failure air pressure No signal from the air pressure switch x x
8Failure CRC The parameter block is not valid x x
9Failure power supply The power supply is not sufficient (lower than
185VAC or higher than 270VAC). x-
ESafety shut down The safety operating system has done a safety
shut down. xx
No. Program step Explanation
0Standby Waiting for heat demand;
All actors off
1Standstill check Fan standstill check; APS-Off-Check
2Prepurge check Fan speed check; APS-On-Check
3Prepurge Fan: prepurge speed; Time is parameter
4Waiting for ignition speed Waiting until fan reached ignition speed
5Safety time Ignition and gas valves on; Fan: ignition speed; Time is parameter
6Flame stabilization time Fan: ignition speed for flame stabilization; Time is parameter
7Burner operation Fan: Modulation speed
8Gas valve circuit V1/V2 check Checking gas valves tightness with flame signal
9Postpurge Fan: postpurge speed; Time is parameter
POTENZIOMETER MAX
POTENZIOMETER START
DISPLAY AND RESET BUTTON
POTENZIOMETER DI MINIMUM

14
BCC (CHIP CARD)
The Burner Chip Card (BCC) is a card to update the parameters of a burner control easily without a PC.
N. Safety parameters Min. Max. OEM-preset Value
1 Prepurge time 0.2 51.0 51 Seconds
2 Safety time 0.1 10.0 3 Seconds
3 Flame stabilization time 0.1 25.5 20 Seconds
4 Start-up attempts 1 5 3 Number
5 Postpurge time 0.2 51.0 0 Seconds
6 Pre-Ignition time 0.1 25.5 3 Seconds
7 Ignition reduction time 0.1 25.5 3 Seconds
8 Postpurge speed 780 9960 1980 R/min
9 Maximum speed 780 9960 6660 R/min
10 Checktime V1 0.1 25.5 1 Seconds
11 Pulsetime V1 0.1 25.5 2 Seconds
12 Checktime V2 0.1 25.5 2.5 Seconds
13 Pulsetime V2 0.1 25.5 2 Seconds
14 Min. limit max. fan speed 780 9960 4020 Rot/min
15 Max. limit max. fan speed 780 9960 2280 Rot/min
16 Fan speed feed back 1 4 3 Impulses/Rot
17 Sample rate speed control 1 2 2 Hz
18 No APS 0 1 - -
19 Permanent APS check 0 1 - -
20 No fan speed feedback 0 1 -
21 No GPS 0 1 - -
22 Restart 0 1 - -
23 Gas valve check 0 1 -
24 Tightness control 0 1 - -
SAFETY PARAMETERS

15
START-UP AND SHUT DOWN
BURNER CONTROL PROGRAMM
APS-Supervision: No APS GPS-Supervision: Active
Valve-Supervision: Tightness control Behaviour after flame loss: Restart
Heat demand
Flame signal
Air pressure switch
Gas pressure switch
Ignition device
Gas valve V1
Gas valve V2
Fan
Operation
Fault signal
Fan speed
12 456 7
Standstill check
Prepurge check
Pulsetime V1 Checktime V2
Prepurge
Waiting for
ignition speed
ignition
Flame
stabilization
Pulsetime V2 Checktime V1
Postpurge
APS-Supervision: No APS GPS-Supervision: Active
Valve-Supervision: Gas valve circuit check Behaviour after flame loss: Restart
Heat demand
Flame signal
Air pressure switch
Gas pressure switch
Ignition device
Gas valve V1
Gas valve V2
Fan
Operation
Fault signal
Fan speed
123456 8
Standstill check
Prepurge check
Prepurge
Waiting for
ignition speed
ignition
Flame
stabilization
Gas valve circuit
check
On Off Must disappear Must appear Don´t care Alternately on
InputsOutputs
Standby
9
InputsOutputs
Postpurge
Program step /
Message
Standby
0
Normal operation: Start-up and shut down
3
Burner operation
Normal operation: Start-up and shut down
0
Stop StopIgnition *Prepurge Min. - Max.
Stop Prepurge Ignition *
790
Min. - Max.
Program step /
Message
Standby Burner operation
Postpurge
Standby
Postpurge Stop
0
Head demand
Flame signal
Air prssure switch
Gas pressure switch
Ignition device
Gas valve V1
Gas valve V2
Fan
Operation
Fault signal
Fan speed
Program step/
Stop Prepurge Ignition Min. - Max. Postpurge Stop
Standstil l check
Prepurge Waiting for igintion speed Ignition Flame stabilization
Burner operation
Pulsetime V2 Checktime V1 Postpurge
Standby Standby
Head demand
Flame signal
Air prssure switch
Gas pressure switch
Ignition device
Gas valve V1
Gas valve V2
Fan
Operation
Fault signal
Fan speed
Stop Prepurge Ignition Min. - Max. Postpurge Stop
Prepurge Ignition Flame stabilization
Burner operation
Standby Standby
Gas valve Postpurge
On Off Must disappear Must appear Don’t care Alternately on
circuit check
Message
Prepurge check
Pulsetime V1 Checktime V2
Program step/
Message
Standstill check
Prepurge check
Waiting for igintion speed

16
DRAWINGS
Fan Ignition Gas-valves Flame Gas-min. Air min. Reset
Failure
Chip
Card
(optional)
Air prssure
switch
Gas pressure
switch
Reset
remoto
(min.) (min.)
3 Stage
Power
Thermostat
Combustion
Manager
Ignition Flame Safety
Valves Operation
Failure
Fusibile
Operation
3-Stage-Controller
Fan
Analog-
Power-
Control Control