Riello RX35 S/PV H Quick start guide

20037916 (4) - 05/2011
Instructions pour installation, utilisation et entretien
Installation, use and maintenance instructions
Brûleurs de gaz pré-mélangé
Premixed gas burners
Fonctionnement à une allure ou modulant
One stage or modulating operation
CODE MODEL - MODELE TYPE
20037660 RX35 S/PV H 906T1
20038336 RX35 S/PV H 906T1
F
GB

1 20037916
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Contents
1 Declaration.................................................................................................................................................................................. 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual........................................................................................................................ 4
2.1.1 General dangers............................................................................................................................................................. 4
2.1.2 Danger: live components ................................................................................................................................................ 4
2.2 Guarantee and responsibility .......................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction..................................................................................................................................................................... 6
3.2 Personnel training........................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Models available............................................................................................................................................................. 7
4.2 Destination country - Gas category ................................................................................................................................ 7
4.3 Technical data ................................................................................................................................................................ 7
4.4 Maximum dimensions..................................................................................................................................................... 8
4.5 Description of the burner ................................................................................................................................................ 9
4.6 Burner equipment ........................................................................................................................................................... 9
4.7 Accessories .................................................................................................................................................................... 9
4.7.1 Kit diaphragm (LPG operation)....................................................................................................................................... 9
5 Installation ................................................................................................................................................................................ 10
5.1 Notes on safety for the installation................................................................................................................................ 10
5.2 Handling........................................................................................................................................................................ 10
5.3 Preliminary checks........................................................................................................................................................ 10
5.4 Generator plate............................................................................................................................................................. 10
5.5 Securing the burner to the boiler .................................................................................................................................. 11
5.6 Positioning the probe - electrode.................................................................................................................................. 11
5.7 Fuel supply ................................................................................................................................................................... 12
5.7.1 Gas train assembly....................................................................................................................................................... 12
5.7.2 Gas valve...................................................................................................................................................................... 12
5.7.3 Testing.......................................................................................................................................................................... 13
5.7.4 Ionisation current .......................................................................................................................................................... 13
6 Operation .................................................................................................................................................................................. 14
6.1 Notes on safety for the first start-up.............................................................................................................................. 14
6.2 Adjustments prior to ignition ......................................................................................................................................... 14
6.3 Burner start-up.............................................................................................................................................................. 14
6.4 Fan adjustment............................................................................................................................................................. 14
6.5 Gas valve adjustment ................................................................................................................................................... 14
6.6 Burner adjustment ........................................................................................................................................................ 15
6.7 Combustion head.......................................................................................................................................................... 16
6.8 Emissions ..................................................................................................................................................................... 16
6.9 Operating programme................................................................................................................................................... 17
6.9.1 Normal operation .......................................................................................................................................................... 17
6.9.2 Lockout due to ignition failure ....................................................................................................................................... 18
6.9.3 Lockout due to a flame or flame simulation detected during pre-purging ..................................................................... 18
6.10 Recycle function if flame goes out during operation ..................................................................................................... 18
6.11 Restart function following firing failure.......................................................................................................................... 19
6.12 Control of the motor rpm............................................................................................................................................... 19
6.13 Control box reset (using built-in button)........................................................................................................................ 19
6.14 Control box reset (using remote connection)................................................................................................................ 19
7 Maintenance.............................................................................................................................................................................. 20
7.1 Notes on safety for the maintenance............................................................................................................................ 20
7.2 Maintenance programme.............................................................................................................................................. 20

20037916 2
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Contents
7.2.1 Maintenance frequency .................................................................................................................................................20
7.2.2 Checking and cleaning ..................................................................................................................................................20
8 Faults / Solutions......................................................................................................................................................................21
8.1 Start-up problems..........................................................................................................................................................21
8.2 Operating faults .............................................................................................................................................................22
9 Electrical wiring ........................................................................................................................................................................23
9.1 Electrical panel layout ...................................................................................................................................................23

3 20037916
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Declaration
1Declaration
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Pre-mixed gas burner
Model: RX35 S/PV H
These products are in compliance with the following Technical Standards:
EN 292
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
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.rielloburners.com
Distributed by: RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration of Conformity and
has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of January 8th 2004 and July 17th
2009.
Type of product: Pre-mixed gas burner
Model: RX35 S/PV H
Regulation applied: EN 676 e A.R. of January 8th 2004 - July 17th 2009
Values measured: CO max: 2 mg/kWh
NOx max: 72 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
Pre-mixed gas burner 906T1 RX35 S/PV H 15 - 30 kW
Legnago, 11.05.2011 Ing. G. Conticini
Burners Division Department
RIELLO S.p.A.
CE - 0085BR0101

20037916 4
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Information and general warnings
2.1 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 necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance
Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.1 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.2 Danger: live components
Other symbols
This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assist-
ance Centre.
The system supplier must carefully inform the user about:
- how to use the system,
- any further tests that may be required before activating
the system,
- maintenance, and the fact that the system should be
checked at least once a year by a representative of the
manufacturer or another specialised technician.
To ensure a periodic check, recommends the
drawing up of a Maintenance Contract.
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
........................................................................................
........................................................................................
........................................................................................
........................................................................................

5 20037916
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Information and general warnings
2.2 Guarantee and responsibility
guarantees its new products from the installation date, in
accordance with the regulations in force and/or the sales con-
tract. At the moment of the first start-up, check that the burner is
integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
the use of non-original components, including spare
parts, kits, accessories and optional;
force majeure.
furthermore declines any and every responsibility
for the failure to observe the contents of this manual.
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by of the
guarantee that it supplies with the burner.

20037916 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance
with current regulations and directives, applying the known tech-
nical rules of safety and envisaging all the potential danger situ-
ations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the man-
ufacturer;
the type and pressure of the fuel, the voltage and frequency
of the electrical power supply, the minimum and maximum
deliveries for which the burner has been regulated, the pres-
surisation of the combustion chamber, the dimensions of the
combustion chamber and the room temperature must all be
within the values indicated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
must inform the manufacturer if faults or malfunctioning of
the accident prevention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications
given in this manual.
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
3 Safety and prevention

7 20037916
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Technical description of the burner
4.1 Models available
4.2 Destination country - Gas category
4.3 Technical data
4 Technical description of the burner
Designation Voltage Code
RX70 S/PV H 230V/50-60Hz 20038510 - 20038512
Destination country Gas category Gas pressure
(mbar)
AT - CH - CZ - DK - EE - ES - FI - GB - GR - HU - IE - IT - LT - LV
NO - PT - SE - SK I2H 20
AT - BE - CH - CZ - DE - ES - FR - GB - GR - HU - IE - IT - PT - SI I3P 29
CZ - DE - DK - EE - ES - FI - FR - GB - GR - IE - IT - LU - NO - PT
SE - SI - SK I2R 20/25
FR I2Er 20/25
BE I2E(R) 20/25
LU - PL I2E 20
DE I2ELL 20
Model RX35 S/PV H
Thermal power kW
Kcal/h 15 -30
12.900 -25.800
Natural gas - (Family 2) G20 Ncv: 9.45 kWh/Sm3 = 8.100 kcal/Sm3- Pressure 10 - 30 mbar
G25 Ncv: 8.125 kWh/Sm3 = 7.000 kcal/Sm3- Pressure 10 - 30 mbar
LPG - (Family 3) G31 Ncv: 24.44 kWh/Sm3 = 21.000 kcal/Sm3- Pressure 10 - 30 mbar
Electrical supply Single-phase, 220/230V ~±10%, 50/60 Hz
Motor Max 7.000 rpm - 50/60 Hz
Ignition transformer Primary 220V/240 - 50/60Hz– Secondary 15 kV - 25 mA
(1) Reference conditions:
Air temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

20037916 8
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Technical description of the burner
4.4 Maximum dimensions
The maximum dimensions of the burner and flange are shown in Fig. 1.
Fig. 1
54
233
108
455
283
266
54
108
455
233
280
290
D11391
D11432
20037660
20038336

9 20037916
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Technical description of the burner
4.5 Description of the burner
1 Reset button with lockout signal
2 Control box
3 Gas valve
4 Air/gas mixer in intake circuit
5 Flange
6 Motor/Fan
7 Combustion head with metal mesh
8 Ignition transformer
9 Adjustment No. of fan turns
10 7 pole socket
11 Terminal board
12 Manifold
4.6 Burner equipment
Gas valve fitting + screws. . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Insulating gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws and nuts for fixing the flange to the boiler . . . . . . . No. 4
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
4.7 Accessories
4.7.1 Kit diaphragm (LPG operation)
The burner is supplied to operate with methane gas (G20)
A diaphragm is available 4)(Fig. 3), allows burners to operate on
LPG (G31) if fitted to the gas valve 1).
The diaphragm must be installed in compliance with local laws
and regulations. .
To carry out the modification:
cut off the electrical supply;
close the fuel interception tap;
disassemble the gas valve 1) from the Venturi unit 2) by
removing the screws 3);
house the diaphragm 4) supplied with the kit in the
gasket 5);
reassemble the gas valve and carry out all the adjustment
operations described above.
RESET
ALARM
1
2
3
5
78911
2
4
6
10
12
Fig. 2
D10486
1
2
3
4
5
D8564 Fig. 3

20037916 10
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model A)(Fig. 4) and type of burner B);
the year of manufacture, in cryptographic form C);
the serial number D);
the electrical supply data E);
the electrical power consumption F);
the types of fuel used and the relative supply pressures G);
the data of the burner's minimum and maximum output pos-
sibilities H) (see Firing rate).
5.4 Generator plate
Pierce the closing plate of the combustion chamber, as in Fig. 5.
The position of the threaded holes may be marked using the gas-
ket joint supplied with the burner.
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 cm from the ground.
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 operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected
and disposed of in the appropriate places.
WARNING
The burner output must be within the boiler's firing
rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
and makes any installation or maintenance work
difficult.
Fig. 4
GAS
GAZ
....
I2R
I3P
D11539
ABC
DE
G
GHF
H
Fig. 5
140
160
11
45
150
110
D7582

11 20037916
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Installation
5.5 Securing the burner to the boiler
For the installation proceed as follows:
Fix the burner 1)(Fig. 6) to the boiler door 2) using the 4
screws and (if necessary) the 4 nuts supplied to the stand-
ard equipment, interposing the insulating gasket 3).
5.6 Positioning the probe - electrode
Before installing the burner on the boiler, make sure the probe
and electrode are placed correctly as in Fig. 7.
1
23
Fig. 6
D10488
WARNING
Do not turn the electrode: position it as illustrated.
Placing the electrode near the ionisation probe
may result in the control box amplifier being dam-
aged.
Fig. 7
54
11
±1
4.5
+0.5
0
D11393

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Installation
5.7 Fuel supply
The burners are teamed with one-piece pneumatic 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 pro-
portion to the airflow produced by the fan.
To optimise the bulk, the gas train is assembled directly on the
body of the burner.
5.7.1 Gas train assembly
The connection valve-manifold allows compensating the acci-
dental occlusion of the suction line through the distributed gas re-
duction.
Air/gas mixer
Gas and combustive air are mixed inside the purging circuit (mix-
er), 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.
5.7.2 Gas valve
Tab. A
GAS TRAIN ASSEMBLY
D7375
D7155 D7380
Air/gas mixer
in the suction line circuit
Gas supply
Gas pressure downline
test point (P1)
Gas pressure downline
test point (P2)
Flange Gas valve
Minimum gas flow
adjustment (V1)
Minimum gas flow
adjustment on the stabiliser (V2)
D7376
Gas compensation pipe
Fig. 8
Valve model Honeywell VK4125V 2003 4
Mixer model Honeywell 45.900.446-253B
Gas line connection 1/2" inlet
Working temperature -15°C/70°C
Max. working pressure 30 mbar
Min. working pressure 15 mbar
Max. inlet pressure 60 mbar
Valve class B + B
Electrical supply 220-240 V
Protection level IP 40 according to IEC 529

13 20037916
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Installation
5.7.3 Testing
Check the standby of the burner by opening the thermostats (TL);
check that the burner is blocked while is working by opening
the connector (CN)inserted in the probe red wire and located out-
side the control box.
5.7.4 Ionisation current
The minimum current necessary for the control box operation is
5 µA. The burner normally supplies a higher current value, so that
no check is needed.
Anyway, if you want to measure the ionisation current, you need
to open the connector (CN1) fitted on the red wire and insert a
microammeter.
Optimum calibration values
MIN. output MAX. output
CO2(%) O2(%) CO2(%) O2(%)
METHANE86.694.9
LPG 9.5 6.4 10 5.6
Probe
Connector
Control box
D5006
Fig. 9

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Operation
6.1 Notes on safety for the first start-up
6.2 Adjustments prior to ignition
The following adjustments must be carried out:
Open manual valves upline from the gas train.
Bleed the air from the gas line using the screw on the socket
START.
Check the trimmer settings on the control box (Fig. 11).
6.3 Burner start-up
Close the thermostat and switch on the burner's power.
The burner starts up under pre-purging conditions to the START
and the ignition occurs.
If the fan starts up, but no flame appears by the end of the safety
time, the control box allows the start-up programme to be
repeated up to 2 times.
If ignition does not occur upon the third attempt, the burner goes
into lockout mode. Reset and wait for a new start-up 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.
Turn the screw V1 on the gas valve mixer slightly anticlockwise.
Once the burner has ignited, proceed with the global adjustment
of the burner.
6.4 Fan adjustment
Modulation is based on variable-speed technology. Combustion
air delivery can be adjusted by varying the motor's speed (rpm).
The proportioning gas train delivers the right amount of fuel, de-
pending on the pressure detected in the purging circuit. Hence
the output delivered is adjusted by varying the motor's speed of
rotation. The speed of the motor can be adjusted by means of
three “Trimmers” (Fig. 11).
6.5 Gas valve adjustment
The adjustment of the output of gas is achieved by using the two
screws V1 and V2.
To alter the maximum output of gas act on the screw V1.
– To increase the output: turn the screw V1 anticlockwise (un-
screw).
– To reduce the output: turn the screw clockwise (tighten).
To alter the minimum output of gas act on the screw V2 on the
gas valve. Remove the protection screw and act on the intern
screws with a hex key.
– To increase the output: turn the screw clockwise (tighten)
– To reduce the output: turn the screw anticlockwise (unscrew)
Definition of the adjustment for the fan:
The adjustments are carried out means on three potentiometers
on board of the motor control box.
START Determine the air during the start
MIN Determine the minimum modulation
MAX Determine the maximum modulation
The adjustment of “MIN” takes place outright at finishing the pre-
purging outlined by the valve opening and by the presence of the
discharge. The authorisation to the maximum modulation with
“MAX” occurs about 10 sec by the valve opening.
6Operation
WARNING
The first start-up of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
WARNING
Check the correct working of the adjustment, com-
mand and safety devices.
Fig. 10
D7375
Minimum gas flow adjustment
on the stabiliser (V2)
Maximum gas flow
adjustment (V1)
Fig. 11
D10505

15 20037916
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Operation
6.6 Burner adjustment
The optimum adjustment of the burner requires an analysis of
flue gases at the boiler outlet. The burner application at the gen-
erator, the adjustment and the testing must be carried out in com-
pliance with the instruction manual of the generator itself,
including the control of the CO and CO2concentration in the flue
gases and of their temperature.
Check in sequence:
Maximum output
Minimum output
Ignition output
Maximum output should match the value required by the boiler
that is used. To increase or decrease its value, adjust the trimmer
MAX located on the control box (Fig. 11).
Measure the gas delivery on the counter to precisely establish the
burnt output.
Using a smoke analyser, measure the value of the CO2 or the O2
in order to optimise the burner calibration.
The correct values are: CO28.5 ÷ 9% or O25÷5.5%.
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
anticlockwise (unscrew).
– To reduce the gas delivery and the CO2: turn the screw V1
clockwise (tighten).
Minimum output should match the value required by the boiler
that is used. To increase or decrease its value, adjust the trimmer
MIN located on the control box (Fig. 11).
Measure the gas delivery on the counter to precisely establish the
burnt output.
Using a smoke analyser, measure the value of the CO2 or the O2
in order to optimise the burner calibration.
The correct values are: CO28.5÷9% or O25÷5.5%.
To correct these values act on the gas valve in the following way:
– To increase the gas delivery and the CO2: turn the screw V2
clockwise (tighten).
– To reduce the gas delivery and the CO2: turn the screw V2
anticlockwise (unscrew).
The ignition output can be varied by acting on the Trimmer
START located on the control box (Fig. 11).
The burner is installed in two generators - model HG 24-25.
The installation of the diaphragm is not needed for correct opera-
tion, but the valve must be adjusted.
The tables suggest the adjustments for the electronics of the mo-
dels indicated below, and for operation with methane.
These values are approximate.
Maximum output
Minimum output
Starting output
D11289
Fig. 12
Generator model HG 24
Work phase
Electronic adjustment
trimmer position Fan velocity Gas valve pressure P2 Output CO2
Notch Turns mbar kW %
Maximum output Trimmer Max 33900 - 0.35 23 9.1
Starting output Trimmer Start 10 3700 - 0.30 21 9
Minimum output Trimmer Min 42700 - 0.20 15 8.9
Generator model HG 25
Work phase
Electronic adjustment
trimmer position Fan velocity Gas valve pressure P2 Output CO2
Notch Turns mbar kW %
Maximum output Trimmer Max 55100 - 0.50 30 9.1
Starting output Trimmer Start 6.5 4200 - 0.36 25 9
Minimum output Trimmer Min 42700 - 0.20 15 8.9

20037916 16
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Operation
6.7 Combustion head
The combustion head comprises a highly thermal resistant cylin-
der whose surface features numerous holes, encased in a metal
"mesh" (Fig. 13).
The air-gas mixture is pushed inside the cylinder and out of the
head through the holes in the perimeter.
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 ele-
ment since it improves burner performance considerably.
The flame developed on the surface of the head is perfectly re-
tained and adheres to the mesh when operating at the maximum
setting. This allows 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
generator, consequently eliminating the possible problem of poor
combustion.
The flame's structure means that smaller combustion chambers
can be developed, designed to exploit this particular feature.
6.8 Emissions
The emission values of the burners are 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 ther-
mal NOx, the main causes of pollutant emission.
Fig. 13
D9714

17 20037916
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Operation
6.9 Operating programme
6.9.1 Normal operation
Operating times
Time expressed in seconds
ts
t3t2
tw t1 tm
TL
M
I
V
SO
LED
P
M
SO
.
tf
D10632
Red (LED signalling)
No signal needs to be received
Fig. 14
Key
I– Ignition transformer
LED – Reset button LED indicating operating status
M–Fanmotor
SO – Ionisation probe
TL – Limit thermostat
V– Gas valve
Lockout
Flame loss during the operation
and lockout due to ignition failure
ta tf tl tm ts tw t1 t2 t3 t8
20140105 -403 510
ta Time for checking motor turns:
if the number of turns is lower than 900 rpm, after ta will be
carried out a lockout. tw Stabilisation time motor turns.
tf Response time after the flame disappearance. t1 Pre-purging time:
by the signal of heat request to the end of the ignition.
tl Flame or flame simulation detected during pre-purging:
immediate lockout. t2 Transformer pre-ignition time: ignition before the valve closing.
tm Stabilisation time:
the modulation occurs after this time. t3 Transformer ignition time: the transformer remains on during the safety time.
ts Safety time:
if at the end of the time ts a flame is not present, tpp is car-
ried out. After 3 times follows a lockout. t8
Post-purging time:
Additional purging when the heat request is completed, or
in case of flame failure during the operation or in case of
ignition failure.

20037916 18
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Operation
6.9.2 Lockout due to ignition failure
6.9.3 Lockout due to a flame or flame simulation detected during pre-purging
Lockout types and triggering times in case of burner mal-
function
6.10 Recycle function if flame goes out during operation
The control box allows recycling, i.e. the complete repetition of
the start/up program.
If after the safety time since the last recycle the flame does not
appear, the burner carries out a lockout.
D7253
ts
t3
t1
t2
tw
TL
M
I
V
SO
LED
P
M
.
D10631
Lockout at 3th
re-ignition
Red (LED signalling)
ts
t1tw
TL
M
I
V
SO
LED
P
M
.
Key
I– Ignition transformer
LED – Reset button LED indicating operating
status
M–Fanmotor
SO – Ionisation probe
TL – Limit thermostat
V– Gas valve
Red (LED signalling)
D10633
Lockout
Description of types of faults Lockout
Presence of flame in pre-purging “t1” At the end of the time of “t1”
No ignition at end of safety time “ts” After max. 3 repeats, within 1 second
Flame goes out during operation After max. 1 repetition, if there is no flame at the end of ts
Not correct No. of turns of the fan motor (< 900 rpm) After max. 20 seconds
Fault at the valve circuit At the end of the time of “t1”

19 20037916
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Operation
6.11 Restart function following firing failure
The control box allows the start-up programme to be repeated,
making up to 3 attempts, if no flame is formed by the end of the
safety time.
If the flame still fails to appear after the fourth ignition attempt, the
burner locks out at the end of the safety time.
6.12 Control of the motor rpm
Check of the motor operation if the rotation number per minimum
minute exceeds (900 rpm).
If the motor does not exceed the number of minimum turns, it
stops after 20 seconds.
6.13 Control box reset (using built-in button)
To carry out the control box reset, proceed as follows:
Press and hold the reset button for 1-2 seconds.
In case the burner does not restart it is necessary to check if the
limit thermostat (TL) is closed.
6.14 Control box reset (using remote connection)
The terminal board X1 has an input RS provided for the remote
resetting of the control box.