Riello RS 34/1 MZ Installation and operating instructions

Installation, use and maintenance instructions
安装，使用和维护说明书
20033803 (2) - 08/2011
Forced draught gas burners
强制通风燃气燃烧器
CODE - 编码 MODEL - 型号 TYPE - 类型
20033785 RS 34/1 MZ 886 T
20033725 RS 44/1 MZ 873 T
GB
CN
One-stage operation
一段火运行

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 performance
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 guarantee a
combustion with the lowest polluting emissions rate.
You are thereforeadvised to consult the Technical Assistance Department beforechoosing thistype of burn-
er 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 technical of-
fices whose personnel participates periodically in instructional and refresher courses at the company train-
ing 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-observance of the
technical instructions enclosed with the burner, or due to the intervention of unqualified personnel.
USER INFORMATION
If faults arise in firing or operation, the burner performs a "safety stop", which is signalled by the red burner
lockout LED. To rearm start-up conditions, press the reset 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 MEASURES
Children or inexpert persons must not use the appliance.
Under no circumstances must the intake grids, dissipation grids and ventilation vents in the installation
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 sup-
ply.
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
INDEX
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Structural versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Max dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blast tube length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fixing the burner to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 - Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 - Minimum gas pressure switch. . . . . . . . . . . . . . . . . . . . . . . . 13
Flame presence check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 16
Reset of the control box and using diagnostics . . . . . . . . . . . . . 16
Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 17
Normal operation / flame detection time. . . . . . . . . . . . . . . . . . . 18
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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, page number 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 nec-
essary 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 instal-
lation 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
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 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
technician.
To ensure a periodic check, recommends the draw-
ing up of a Maintenance Contract.
GB
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2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the socket 8)(A)p.4 with zero pressure in the combustion chamber, at the maximum output of the burner.
(3) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ = ± 1.5 dB, in the manufacturer's combustion
chamber with burner operating on test boiler at maximum output.
MODEL RS 34/1 MZ RS 44/1 MZ
TYPE 886 T 873 T
OUTPUT (1) kW 70 - 390
60 - 336 100 - 550 86 - 473Mcal/h
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 35 40 49 57
- pressure at maximum delivery (2) mbar 13,1 18,4 16,7 23,2
OPERATION • On-Off (1 stop min each 24 hours).
• One stage (all - nothing)
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 rpm
W
V
A
2800/3400
300
220 - 240
2.4
2820/3400
420
220 - 240
3
ACCELERATION CURRENT A15 17
WORKING CURRENT A3.2 3.5
MOTOR CAPACITOR F/V 12.5/400 12.5/450
IGNITION TRANSFORMER V1 - V2
I1 - I2 230 V - 1 x 15kV 1 A - 25mA
ELECTRICAL OUTPUT CONSUMPTION W max 600 700
PROTECTION LEVEL IP 40
IN CONFORMITY WITH EEC DIRECTIVES 90/396 - 2004/108 - 2006/95 - 2006/42
NOISE (3) SOUND PRESSURE
SOUND POWER dBA 68 79 70 81
APPROVAL CE 0085BR0380 0085BR0380
STRUCTURAL VERSIONS GAS CATEGORIES
Model Blast tube
length mm COUNTRY CATEGORY
RS 34/1 MZ 216
351 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
RS 44/1 MZ 216
351

3
ACCESSORIES (optional):
• RADIO DISTURBANCE PROTECTION KIT
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10 V/m) owing to the presence of an
INVERTER, or in applications where the length of the thermostat connections exceeds 20 metres, a protection kit is available as an interface
between the control box and the burner.
• KIT LONG HEAD
• KIT FOR LPG OPERATION: the kit allows the RS 34-44/1 MZ burners to burn LPG.
• GAS TRAIN ACCORDING TO EN 676 (with valves, pressure governor and filter): see page 10.
NOTE: The installer is responsible for the addition of any safety device not foreseen in this manual.
BURNER RS 34/1 MZ - RS 44/1 MZ
Code 3010386
BURNER RS 34/1 MZ RS 44/1 MZ
Code 3010428 3010429
BURNER RS 34/1 MZ RS 44/1 MZ
Output kW 80 - 390 kW 120 - 530 kW
Blast tube length mm 216 - 351 216 - 351
Code 3010423 3010424
• KIT MAXIMUM GAS PRESSURE SWITCH Cod. 3010418
• KIT CLEAN CONTACTS Cod. 3010419
• KIT POST-PURGING Cod. 3010452
• KIT GROUND FAULT INTERRUPTER Cod. 3010448
• KIT CONTINUOUS PURGING Cod. 3010449
• KIT HOURCOUNTER Cod. 3010450
• KIT INTERFACE ADAPTER RMG TO PC Cod. 3002719

4
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4Sleeve
5 Minimum air pressure switch
(differential operating type)
6 Flame sensor probe
7 Air pressure test point
8 Gas pressure test point and head fixing
screw
9 Screw securing fan to pipe coupling
10 Slide bars for opening the burner and
inspecting the combustion head
11 Indexed selector.
Opens the fan gate to the value needed by
the burner delivery.
12 Pressure test point of
13 Air inlet to fan
14 Gas input pipework
15 Gas train connection flange
16 Boiler fixing flange
17 Flame stability disc
18 Flame inspection window
19 Motor capacitor (RS 34/1 MZ)
20 Control box with lockout pilot light and lock-
out reset button
21 Plugs for electrical wiring
22 Air damper
23 Plug-socket on ionisation probe cable
Note
If the control box 20)(A) pushbutton (red led)
lights up, it indicates that the burner is in lock-
out.
To reset, hold the pushbutton down for between
1 and 3 seconds.
PACKAGING - WEIGHT (B) - approximate
measurements
• The burner are shipped in cardboard boxes
with the maximum dimensions shown in
Table (B).
• The weight of the burner complete with pack-
aging is indicated in Table (B).
MAX. DIMENSIONS (C) -approximate meas-
urements
The maximum dimensions of the burner are
given in fig. (C).
Note that if you need to examine the combustion
head, the burner must be pulled backward on
the slide bars.
The maximum dimension of the burner,
without the cover, when open is given by meas-
urement H.
BURNER EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws M 8 x 25
4 - Screws to secure the burner flange to the
boiler: M 8 x 25
1 - Thermal insulation screen
3 - Plugs for electrical connection
1-Instruction
1 - Spare parts list
(A)
mm ABCkg
RS 34/1 MZ 1000 500 485 -
RS 44/1 MZ 1000 500 485 -
(B)
(1) Blast tube: short-long
mm A D E F (1) HILONVM
RS 34/1 MZ 442 422 508 216-351 140 305 138 780 84 177 1”1/2
RS 44/1 MZ 442 422 508 216-351 152 305 138 780 84 177 1”1/2
(C)
D88
D3831
D11831
D7561
D11832

5
FIRING RATES (A)
The burner output must be selected within the
area of the adjacent diagrams.
Attention
the FIRING RATE value range has been
obtained considering an ambient temperature of
20 °C, and an atmospheric pressure of
1013 mbar (approx. 0 m a.s.l.) and with the
combustion head adjusted as shown on page 9.
TEST BOILER (B)
The firing rates were set in relation to special
test boilers, according to EN 676 regulations.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example: Output 350 Mcal/h:
diameter = 50 cm - length 1.5 m.
COMMERCIAL BOILERS
The burner/boiler combination does not pose
any problems if the boiler is CE approved and its
combustion chamber dimensions are similar to
those indicated in diagram (B).
If the burner must be combined with a commer-
cial boiler that has not been CE type-approved
and/or its combustion chamber dimensions are
clearly smaller than those indicated in diagram
(B), consult the manufacturer.
(B) D497
Mcal/h
kW
length of comb. chamber m
comb. chamber pressure mbarcomb. chamber pressure mbar
(A) D8589

6
GAS PRESSURE
The adjacent tables show minimum pressure
losses along the gas supply line depending on
the burner output.
Column 1
Pressure loss at combustion head.
Pressure of the gas at the socket 1)(B)p.7, with
combustion chamber at 0 mbar.
Column 2
Pressure loss of gas train 2)(B)p.7 includes: one
stage or two stage adjustment valve VR, safety
valve VS (both fully open), pressure governor R,
filter F.
The values shown in the various tables refer to:
natural gas G 20 PCI 9.45 kWh/Sm3
(8.2 Mcal/Sm3)
With:
natural gas G 25 PCI 8.13 kWh/Sm3
(7.0 Mcal/Sm3)
multiply the values of the table:
- column 1: by 1.5;
- column 2: by 1.35.
Calculate the approximate maximum output of
the burner in this way:
- subtract the combustion chamber pressure
from the gas pressure measured at test
point 1)(B)p.7.
- Find, in the table relating to the burner con-
cerned, the pressure value closest to the
result of the subtraction.
- Read the corresponding output on the left.
Example - RS 34/1/M MZ:
• Maximum output operation
• Natural gas G 20 PCI 9.45 kWh/Sm3
• Gas pressure at test point 1)(B)p.7 =8.9 mbar
• Pressure in combustion chamber = 2 mbar
8.9 - 2 =6.9 mbar
An output of 250 kW shown in table RS 34/1
corresponds to 6.9 mbar pressure, column 1.
This value serves as a rough guide; the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B)p.7, set the output required from the
burner:
- Find the nearest output value in the table for
the burner in question.
- Read, on the right (column 1) the socket
pressure 1)(B)p.7.
- Add this value to the estimated pressure in
the combustion chamber.
Example - RS 34/1 MZ:
• Required burner output: 250 kW
• Natural gas G 20 PCI 9.45 kWh/Sm3
• Pressure of the gas at an output of 250 kW, from
the table RS 34/1 MZ, column 1 =6.9 mbar
• Pressure in combustion chamber = 2 mbar
6.9 + 2 =8.9 mbar
pressure required at test point 1)(B)p.7.
RS 34/1 MZ One-stage gas train p (mbar)
RS 44/1 MZ One-stage gas train p (mbar)
RS 34/1 MZ Two-stage gas train p (mbar)
kW 1 2
MBC-DLE-120
(Rp 3/4") MB 407 S2 (Rp 3/4") MB 410 S2 (Rp 1.1/4") MB 412 S2 (Rp 1.1/4") MB 415 S2 (Rp 1.1/2") MB 420 S2 (Rp 2")
70 0,6 5,2 3,0 -- -- -- --
75 0,6 5,6 3,4 2,1 -- -- --
100 1,0 8,2 5,6 2,9 -- -- --
125 1,4 11,1 8,0 4,2 2,1 -- --
150 2,4 15,7 11,0 5,6 2,8 -- --
175 3,5 21,1 14,4 7,2 3,6 -- --
200 4,6 27,2 18,1 9,0 4,5 -- --
225 5,8 33,9 22,1 11,0 5,5 3,2 --
250 6,9 41,3 26,4 13,2 6,5 3,3 --
275 8,0 49,4 31,3 15,5 7,6 3,8 --
300 9,1 58,0 36,6 18,0 8,7 4,3 --
325 10,2 67,2 42,2 20,5 9,9 4,8 3,2
350 11,3 76,7 47,8 22,9 11,2 5,4 3,4
375 12,4 86,7 53,7 25,4 12,7 5,9 3,8
390 13,1 57,4 27,0 13,5 6,3 4,0
kW 1 2
MB 407 S5
(Rp 3/4") MB 410 S5 (Rp 1.1/4") MB 412 S2 (Rp 1.1/4") MB 415 S2 (Rp 1.1/2") MB 420 S2 (Rp 2")
100 0,2 5,6 2,9 2,1 3,2 3,2
150 1,6 11,0 5,6 2,8 3,2 3,2
200 3,0 18,1 9,0 4,5 3,2 3,2
250 4,9 26,4 13,2 6,5 3,3 3,2
300 6,9 36,6 18,0 8,7 4,3 3,2
350 8,9 47,8 22,9 11,2 5,4 3,4
400 10,8 59,9 28,1 14,0 6,5 4,1
450 12,8 73,2 33,6 16,8 7,7 4,9
500 14,7 87,6 39,5 19,8 9,0 5,7
550 16,7 103,0 45,8 23,1 10,2 6,6
kW 1 2
MB-ZR 407 S2
(Rp 3/4") MB-ZR 410 S2 (Rp 1") MB-ZR 412 S2 (Rp 1.1/4") MB-ZR 415 S2 (Rp 1.1/2") MB-ZR 420 S2 (Rp 2")
70 0,6 3,0 2,1 2,1 -- --
75 0,6 3,4 2,1 2,1 -- --
100 1,0 5,6 2,9 2,1 -- --
125 1,4 8,0 4,2 2,1 -- --
150 2,4 11,0 5,6 2,8 -- --
175 3,5 14,4 7,2 3,6 -- --
200 4,6 18,1 9,0 4,5 -- --
225 5,8 22,1 11,0 5,5 3,2 --
250 6,9 26,4 13,2 6,5 3,3 --
275 8,0 31,3 15,5 7,6 3,8 --
300 9,1 36,6 18,0 8,7 4,3 --
325 10,2 42,2 20,5 9,9 4,8 3,2
350 11,3 47,8 22,9 11,2 5,4 3,4
375 12,4 53,7 25,4 12,7 5,9 3,8
390 13,1 57,4 27,0 13,5 6,3 4,0
(A)

7
2
VS VR
R
3
1
F
D8065
RS 44/1 MZ Two-stage gas train p (mbar)
kW 1 2
MB-ZR 410 S2
(Rp 1") MB-ZR 412 S2 (Rp 1.1/4") MB-ZR 415 S2 (Rp 1.1/2") MB-ZR 420 S2 (Rp 2")
100 0,2 2,9 2,1 -- --
150 1,6 5,6 2,8 -- --
200 3,0 9,0 4,5 3,2 --
250 4,9 13,2 6,5 3,3 --
300 6,9 18,0 8,7 4,3 3,2
350 8,9 22,9 11,2 5,4 3,4
400 10,8 28,1 14,0 6,5 4,1
450 12,8 33,6 16,8 7,7 4,9
500 14,7 39,5 19,8 9,0 5,7
550 16,7 45,8 23,1 10,2 6,6
(A)
(B)

8
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, 3 and 4.
Installation 1is preferable, as it is the only one
that allows the maintenance operations as de-
scribed in this manual. Installations 2, 3 and 4
allow the working, but make the operations of
maintenance and checking of the combustion
head more difficult page 15.
Any other position could compromise
the correct working of the appliance.
Installation 5is forbidden, for safety
reasons.
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.
BLAST TUBE LENGTH (C)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling.
The range of lengths available, L (mm), is as fol-
lows:
Blast tube 9) RS 34/1 MZ RS 44/1 MZ
• short 216 216
• long 351 351
For boilers with front flue passes 6) or flame
inversion chambers, protective fettling in refrac-
tory material 8), must be inserted between the
boiler fettling 7) and the blast tube 9).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers with a water-cooled frontpiece, a
heat-resistant cover is not necessary 7)-8)(C),
unless expressly requested from the boiler man-
ufacturer.
FIXING THE BURNER TO THE BOILER (C)
Before fixing the burner to the boiler, check
(from the opening of the blast tube) that the
probe and the electrode are correctly posi-
tioned, as in (D).
Separate the combustion head from the rest of
the burner, fig. (C):
- remove the screws 2) from the two slide
bars 3);
- remove screw 1) and pull the burner back on
slide bars 3) by about 100 mm;
- disconnect the probe and electrode leads,
then unthread the burner completely from the
guides.
Fix the unit 4)(C) to the boiler plate, inserting the
supplied insulating gasket 5)(C).
Use the 4 screws, also supplied with the unit,
after first protecting the thread with an anti-lock-
ing product. The seal between burner and boiler
must be airtight.
If, in the previous check, the position of the
probe or electrode was not correct, remove the
screw 1)(E), extract the inner part 2)(E) of the
head, and adjust them.
Do not rotate the probe: leave it as in (D).
If it is located too close to the ignition electrode,
the control box amplifier may be damaged.
ATTENTION
Proceed with the assembly of the
inner part 2)(E) of the combustion
head, tightening the screw 1)(E) with
a tightening torque of 4 ÷ 6 Nm.
mm A B C
RS 34/1 MZ
RS 44/1 MZ 160 160 224 224 M8 M8
(B)
(C)
D455
(D)
(E)
D3844
D3835
PROBE ELECTRODE
2 3 4 51
D3928
(A)
D7564
!
!
!

9
COMBUSTION HEAD SETTING
Installation operations are now at the stage
where the blast tube and sleeve are secured to
the boiler as shown in fig. (A). It is therefore par-
ticularly easy to adjust the combustion head.
Air adjustment (A - B)
Rotate the screw 1)(A) until the notch on the
lamina 2)(A) corresponds with the surface of the
plate 3)(A).
Example:
RS 44/1 MZ burner, output = 300kW.
From diagram (B) you can see that, for the MAX
output of 300 kW, the air should be adjusted at
notch 4, subtracted from the value of the pres-
sure in the chamber. In this case, the loss of
pressure in the combustion head is shown in col-
umn 1 on page 6 - 7.
Note
If the pressure in the chamber is equal to 0 mbar,
the air is adjusted with reference to the broken
line of the diagram (B).
Central air adjustment (A - C)
n case the application needs a particular setup,
it is possible to modify the central air delivery
using the ring nut 4)(A) up to the notch indicated
in diagram (C).
In order to carry out this operation, unscrew the
screws 5)(A) and lift up the ring nut 4)(A). At the
end, tighten the screws 5)(A) again.
Once you have finished adjusting the head,
reassemble the burner 4)(D) on the guides 3)(D)
at about 100mm from the pipe coupling 5)(D) -
burner in the position shown in fig. (C)p.8 -
insert the cable of the probe and the cable of the
electrode, then slide the burner as far as the
pipe coupling, burner in the position shown in
fig. (D).
Refit the screws 2) on the guides 3).
Fix the burner to the pipe coupling with the
screw 1).
Attention
When fitting the burner on the two slide bars, it
is advisable to gently draw out the high tension
cable and flame detection probe cable until they
are slightly stretched.
(A)
(B) Max burner output
N° Notches (air = gas)
D7565
D8458
(D)
D7566
Max burner output
(C) D8577
N° Notches (air = gas)

10
GAS FEEDING LINE
• The gas train must be connected to the gas
attachment 1)(A), using the flange 2), gasket
3) and screws 4) supplied with the burner.
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient, see fig. (A).
• The gas solenoids must be as close as possi-
ble to the burner, to ensure that the gas
reaches the combustion head within the safety
time of 3s.
GAS TRAIN (B)
Approved, together with the burner, according to
the regulation EN 676, and supplied separately
from the burner, with the code indicated in the
tables (C). It is possible to use the one-stage
gas train of table (C) up to a power of 550 kW,
limiting the ignition output according to the
standard, with the aid of only the brake, as spec-
ified on page 12.
KEY TO LAY-OUT (B)
1 - Gas input pipe
2 - Manual valve
3 - Vibration damping joint
4 - Pressure gauge with pushbutton cock
5 - Multibloc, including:
- filter (replaceable)
- one-stage or two-stage working valve
- pressure adjuster
6 - Minimum gas pressure switch
7 - Valve seal checking device.
In accordance with the standard EN 676,
gas valve leak detection control devices
are compulsory for burners with maximum
outputs of more than 1200 kW.
8-Gasket
9 - Gas train/burner adaptor
P1- Pressure at combustion head
P2- Up-line pressure of valves/adjuster
L - Gas train supplied separately with the code
indicated in tables (C)
L1 - The responsibility of the installer
KEY TO LAY-OUT FOR TABELS (C)
C.T.= Checking device for gas valves seal:
- = Gas train without gas valve leak
detection control device; device that
can be ordered separately and
assembled subsequently (see Col-
umn 7).
= Train with seal checking device
already assembled.
= With this train the integrated leak
detection cannot be activated.
7 = VPS valve leak detection control device.
Supplied separately from gas train on
request.
9 = Gas train/burner adaptor.
Supplied separately from gas train on
request.
Note
See the accompanying instructions for the
adjustment of the gas train.
(A)
(B)
D3839
D8066
5
P2
P1
10
8
123
4
11
9
67
L1 L
BURNERS AND RELATIVE GAS TRAINS APPROVED ACCORDING TO EN 676
*Trains complete with 6-pin plug for connection to burner.
GAS TRAINS L (One-stage) BURNER 7 9
Code Model Ø C.T. RS
34/1 RS 44/1 Code Code
3970602 MBC 120 3/4” • - - 3000824
3970553
3970229*MB-DLE 407 S20 3/4” - • - 3010123 3000824
3970599 MB-DLE 407 S52 3/4” - - • 3010123 3000824
3970554
3970230*MB-DLE 410 S20 1” - • • 3010123 3000824
3970258 MB-DLE 410 S52 1”1/4 • 3010123 3000824
3970144
3970231*MB-DLE 412 S20 1”1/4 - • • 3010123 -
3970180
3970232*MB-DLE 415 S20 1”1/2 - • • 3010123 -
3970181
3970233*
3970182
3970234*
MB-DLE 420 S20 2”
-
-


••
3010123
3010123
-
-3000822
GAS TRAINS L (Two-stage) BURNER 7 9
Code Model Ø C.T. RS
34/1 RS 44/1 Code Code
3970046 MB-ZRDLE 407 S20 3/4” - • - 3010123 3000824
3970079 MB-ZRDLE 410 S20 1” - • • 3010123 3000824
3970152 MB-ZRDLE 412 S20 1”1/4 - • • 3010123 -
3970183 MB-ZRDLE 415 S20 1”1/2 - • • 3010123 -
3970184
3970185 MB-ZRDLE 420 S20 2” - 
•
•• •3010123 -- 3000822
(C)

11
ADJUSTMENTS BEFORE FIRST FIRING
THE FIRST FIRING MUST BE CARRIED OUT
BY QUALIFIED PERSONNEL WITH THE
RIGHT INSTRUMENTS.
Adjustment of the combustion head, and air and
gas deliveries has been illustrated on page 9.
In addition, the following adjustments must also
be made:
- open manual valves up-line from the gas
train.
- Adjust the minimum gas pressure switch to
the start of the scale (A).
- Adjust the air pressure switch to the start of
the scale (B).
- Purge the air from the gas line.
Continue to purge the air (we recommend
using a plastic tube routed outside the build-
ing) until gas is smelt.
- Assemble a pressure gauge (C) on the gas
pressure socket of the pipe coupling.
The manometer readings are used to calcu-
late burner power using the tables on page 6
and 7.
- Connect two lamps or testers to the two gas
line solenoid valves VR and VS, to check the
exact moment at which voltage is supplied.
This operation is unnecessary if each of the
two solenoid valves is equipped with a pilot
light that signals voltage passing through.
- Fan air damper: leave at the factory setting.
Before starting up the burner, it is good practice
to adjust the gas train so that firing takes place
in conditions of maximum safety, i.e. with gas
delivery at the minimum.
BURNER START-UP
Close the control devices.
As soon as the burner starts check the direction
of rotation of the fan blade, looking through the
flame inspection window 18)(A)p.4.
Make sure that the lamps or testers connected
to the solenoids, or pilot lights on the solenoids
themselves, indicate that no voltage is present.
If voltage is present, then immediately stop the
burner and check electrical connections.
BURNER FIRING
Having completed the checks indicated in the
previous heading, ignition of the burner should
be achieved. If the motor starts but the flame
does not appear and the control box goes into
lockout, reset and wait for a new firing attempt.
If firing is still not achieved, it may be that gas is
not reaching the combustion head within the
safety time period of 3 seconds. In this case
increase gas firing delivery.
The arrival of gas to the pipe coupling is shown
by the pressure gauge (C).
Once firing has taken place, proceed with global
burner calibration operation.
(A)
(C)
MIN GAS PRESSURE SWITCH AIR PRESSURE SWITCH
(B)
D3855 D3854
D3841
!
ATTENTION

12
BURNER CALIBRATION
The optimum calibration of the burner requires
an analysis of the exhaust gases at the boiler
outlet.
Adjust successively:
1 - Maximum output;
2 - Air pressure switch;
3 - Minimum gas pressure switch.
DETERMINATION OF OUTPUT UPON FIR-
ING (MINIMUM)
According to the regulation EN 676.
Burners with MAX output up to 120 kW
Firing can be performed at the maximum opera-
tion output level. Example:
• max. operation output : 120 kW
• max. firing output : 120 kW
Burners with MAX output above 120 kW
Firing must be performed at a lower output than
the max. operation output.
If firing output does not exceed 120 kW, no cal-
culations are required. If firing output exceeds
120 kW, the regulations prescribe that the value
be defined according to the control box "ts"
safety time:
for "ts" = 3s, firing output must be equal to, or
lower than, 1/3 of max. operation output.
Example
MAX operation output of 450 kW.
The firing output must be equal to, or less than,
150 kW with ts = 3s
In order to measure the firing output:
- disconnect the plug-socket 23)(A)p.4 on the
ionisation probe cable (the burner will fire and
then go into lockout after the safety time has
elapsed).
- Perform 10 firings with consecutive lockouts.
- Read, on the meter, the quantity of gas
burned.
This quantity must be equal to, or lower than,
the quantity given by the formula, for ts = 3s:
Vg: volume supplied upon firings carried out
(Sm3)
Qa: firing output (Sm3/h)
n: number of firings (10)
ts: safety time (sec)
Example for gas G 20 (9.45 kWh/Sm3):
firing output 150 kW
corresponding to 15.87 Sm3/h.
After 10 firings with lockout, the output indicated
on the meter must be equal to, or less than:
1 - MAXIMUM OUTPUT
The maximum output of the burner must be set
within the firing rate range shown on page 5.
Adjusting gas delivery
Measure the delivery of gas from the gas meter.
A guideline indication can be calculated from the
tables on page 6, simply read off the gas pres-
sure on the manometer, see fig.(C) on page 11,
and follow the instructions on pages 6 - 7.
- If delivery needs to be reduced, diminish out-
let gas pressure and, if it is already very low,
slightly close adjustment valve VR2.
- If delivery needs to be increased, increase
outlet gas pressure.
Adjusting air delivery
Adjust the fan air damper by using the indexed
selector 1)(A) after having loosened the screw
2)(A).
(A) D593
Vg = 3600
Qa (max. burner output) x n x ts
Vg = 3600
15,87 x 10 x 3 = 0,132 Sm3

13
Note
Once you have finished adjusting maximum out-
put, check firing once again: noise emission at
this stage must be identical to the following
stage of operation. If you notice any sign of pul-
sations, reduce the firing stage delivery.
2 - AIR PRESSURE SWITCH (A)
Adjust the air pressure switch after having per-
formed all other burner adjustments with the air
pressure switch set to the start of the scale (A).
With the burner working insert a combustion
analyser in the stack, slowly close the suction
inlet of the fan (for example, with cardboard)
until the CO value does not exceed 100 ppm.
Then slowly turn the appropriate knob clockwise
until the burner reaches the lockout position.
Check the indication of the arrow pointing
upwards on the graduated scale (A). Turn the
knob clockwise again, until the value shown on
the graduated scale corresponds with the arrow
pointing downwards (A), and so recovering the
hysteresis of the pressure switch (shown by the
white mark on a blue background, between the
two arrows).
Now check the correct start-up of the burner.
If the burner locks out again, turn the knob anti-
clockwise a little bit more.
3 - MINIMUM GAS PRESSURE SWITCH (B)
With the burner operating, increase adjustment
pressure by slowly turning the relative knob
clockwise until the burner locks out.
Then turn the knob anti-clockwise by 5mbar and
repeat burner starting to ensure it is uniform.
If the burner locks out again, turn the knob anti-
clockwise again by 1mbar.
FLAME PRESENCE CHECK (C)
The burner is fitted with an ionisation system
which ensures that a flame is present. The mini-
mum current necessary for the control box oper-
ation is 5 A. The burner supplies a
significantly higher current value, so that no
check is usually needed. However, if it is neces-
sary to measure the ionisation current, discon-
nect the plug-socket 23)(A)p.4 on the ionisation
probe cable and insert a direct current microam-
perometer with a base scale of 100 μA. Care-
fully check polarities.
(A)
(C)
AIR PRESSURE SWITCH 4)(A)p. 4
MINIMUM GAS PRESSURE SWITCH
(B)
RMG
10
D3843
µA
D3855
D3951

14
BURNER OPERATION
BURNER START-UP (A)
• Control device TL closes.
After about 3s:
• 0 s : The control box starting cycle begins.
• 2 s : Fan motor starts.
The air gate valve is set on maximum
adjustment output.
The pre-purge stage follows.
• 43 s : Ignition electrode strikes a spark.
• Safety valve VS and the 1st stage
VR1 of the adjustment valve VR
open. The shutter of valve VR1 has a
first rapid run that determines a low
output firing, point A, which is fol-
lowed by a slow run. The output
increases progressively up to a 1st
stage value, section A-B.
• 45 s : The spark goes out.
• 53 s : The 2nd stage VR2 of valve VR opens
and the output passes slowly from the
1st stage to the maximum adjustment
valve, section C-D.
• The control value box starting cycle
ends.
STEADY STATE OPERATION (A)
At the end of the starting cycle, the control box
continues to check that the flame is present and
that the air pressure switch is in the correct posi-
tion.
The burner continues to operate at constant out-
put.
If the temperature or pressure in the boiler con-
tinues to rise, and opens load control TL, the
burner will stop, section F-G.
FIRING FAILURE (B)
If the burner does not fire, it goes into lockout
within 3 s of the opening of the gas solenoid
valve and 49 s after the closing of control
device TL.
The red led of the control box comes on.
UNDESIRED SHUTDOWN DURING OPERA-
TION
If the flame should accidentally go out during
operation, the burner will lock out within 1s.
(A)
(B)
STANDARD FIRING
(n° = seconds from the moment 0)
NO FIRING
D3024
Off Yellow Green Red
For further details see page 16.
*
D3025
Off Yellow Red
For further details see page 16.
*

15
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 air adduction tube of the pres-
sure switch;
• 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
control, always switch off the electrical
supply to the burner, using the main switch of
the system.
Combustion
The optimum calibration of the burner requires
an analysis of the exhaust gases. Significant dif-
ferences with respect to the previous measure-
ments indicate the points where more care
should be exercised during maintenance.
Gas leaks
Make sure there are no gas leaks on the pipe-
work between the gas meter and the burner.
Gas filter
Substitute the gas filter when dirty (see train
instructions).
Combustion head
Open the burner and make sure that all compo-
nents of the combustion head are in good condi-
tion, not deformed by the high temperatures,
free of impurities from the surroundings and cor-
rectly positioned. If in doubt, disassemble the
elbow.
Burner
Check for excess wear or loose screws in the
mechanisms that control the air damper and the
gas butterfly valve. In addition, the screws that
fix the cables in the terminal board must be
blocked, along with the burner sockets.
Clean the outside of the burner.
Combustion
Adjust the burner if the combustion values found
at the beginning of the operation do not comply
with the regulations in force, or at any rate, do
not correspond to good combustion.
Use the appropriate card to record the new
combustion values; they will be useful for subse-
quent controls.
!
!
!

16
BURNER START-UP PROGRAMME DIAGNOSTICS
During start-up, the indications are explained in the following table:
RESET OF CONTROL BOX AND DIAGNOSTICS USE
The control box supplied features a diagnostics function, through which any causes of malfunctioning can be easily identified (indicator: RED LED
signal).
To use this function, wait at least 10 seconds from when the safety condition has been set (lockout), then press the reset button.
The control box generates a sequence of led pulses (1 second apart) that is repeated at constant intervals of 3 seconds.
Once the number of LED pulses has been visualised, and the possible cause identified, it is necessary to reset the system, keeping the button
pressed for 1-3 seconds.
Below, a list of the possible methodologies for carrying out the resetting of the control box and for using the diagnostics.
CONTROL BOX RESET
To reset the control box, proceed as follows:
- Press and hold the button for 1-3 seconds.
The burner starts up again, 2 seconds after the button is released.
If the burner does not restart, make sure the limit thermostat is closed.
VISUAL DIAGNOSTICS
Indicate the type of burner fault that leads to the lockout.
To display the diagnostic, proceed as follows:
- Keep the button pressed for more than 3 seconds from when the red led (burner lockout) switches on.
The end of the operation will be shown by a yellow led pulse.
Release the button when you see the flashing. The number of times it pulses tells you the cause of the malfunction, according to the coding
system indicated in the table on page 17.
SOFTWARE DIAGNOSTICS
Gives an analysis of the life of the burner, through optical connections with a PC showing the working hours, number and types of lockout, control
box serial number etc.
To display the diagnostic, proceed as follows:
- Keep the button pressed for more than 3 seconds from when the red led (burner lockout) switches on.
The end of the operation will be shown by a yellow LED pulse.
Release the button for 1 second, then press it again for more than 3 seconds, until you see another yellow flash.
When you release the button, the red led will flash intermittently with high frequency: only then is it possible to insert the optical connection.
When the operation is completed, it is necessary to reset the start-up condition of the control box, using the reset procedure described above.
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table on page 17.
COLOUR CODE TABLE
Sequences Colour code
Pre-purging
Firing phase
Operation, flame OK
Operation with weak flame signal
Electrical supply lower than ~ 170V
Lockout
Extraneous light
Key to layout: Off Yellow Green Red
PRESSURE ON THE BUTTON STATE OF CONTROL BOX
From 1 to 3 seconds Reset of the control box without visualisation of the visual diagnostics.
More than 3 seconds Visual diagnostics of the lockout condition:
(led flashes at 1 second intervals).
More than 3 seconds, starting from the condition
of visual diagnostics Software diagnostics, with the help of optical interface and PC (possibility to visualise the working hours, irregularities, etc.)
Press reset
for > 3 s 3 sLED pulses LED pulses
RED LED illuminated
wait at least 10s Interval Lockout

17
Signal Problem Possible cause Recommended remedy
2 blinks Once the pre-purging phase
and safety time have passed,
the burner goes into lockout
without the appearance of the
flame
1 - The operation solenoid lets little gas through . . . . . . . . Increase
2 - One of the two solenoid valves does not open.. . . . . . . Replace
3 - Gas pressure too low. . . . . . . . . . . . . . . . . . . . . . . . . . . Increase pressure at governor
4 - Ignition electrode incorrectly adjusted . . . . . . . . . . . . . . Adjust, see fig. (D) page 8
5 - Electrode grounded due to broken insulation . . . . . . . . Replace
6 - High voltage cable defective . . . . . . . . . . . . . . . . . . . . . Replace
7 - High voltage cable deformed by high temperature . . . . Replace and protect
8 - Ignition transformer defective. . . . . . . . . . . . . . . . . . . . . Replace
9 - Incorrect valve or transformer electrical wiring . . . . . . . Check
10 - Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
11 - A closed valve upline the gas train . . . . . . . . . . . . . . . . Open
12 - Air in pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleed air
13 - Gas valves unconnected or with interrupted coil. . . . . . Check connections or replace coil
3 blinks The burner does not switch
on, and the lockout appears 14 - Air pressure switch in operating position . . . . . . . . . . . . Adjust or replace
The burner switches on, but
then stops in lockout - Air pressure switch inoperative due to insufficient air pressure:
15 - Air pressure switch incorrectly adjusted. . . . . . . . . . . . . Adjust or replace
16 - Pressure switch pressure test point pipe blocked . . . . . Clean
17 - Poorly adjusted head. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust
18 - High pressure in the furnace . . . . . . . . . . . . . . . . . . . . . Connect air pressure switch to fan suction
line
Lockout during pre-purging
phase 19 - Defective motor control contactor . . . . . . . . . . . . . . . . . (only three-phase version) Replace
20 - Defective electrical motor. . . . . . . . . . . . . . . . . . . . . . . . Replace
21 - Motor lockout (defective electrical motor) . . . . . . . . . . . Replace
4 pulses The burner switches on, but
then stops in lockout 22 - Flame simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace the control box
Lockout when burner stops 23 - Permanent flame in the combustion head or . . . . . . . .
flame simulation Eliminate persistence of flame or replace control box
7 blinks The burner goes into lockout
immediately following the
appearance of the flame
24 - The operation solenoid lets little gas through . . . . . . . . Increase
25 - Ionisation probe incorrectly adjusted . . . . . . . . . . . . . . . Adjust, see fig. (D) page 8
26 - Insufficient ionisation (less than 5 A) . . . . . . . . . . . . . . . Check probe position
27 - Earth probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Withdraw or replace cable
28 - Burner poorly grounded. . . . . . . . . . . . . . . . . . . . . . . . . Check grounding
29 - Phase and neutral connections inverted . . . . . . . . . . . . Invert them
30 - Defective flame detection circuit . . . . . . . . . . . . . . . . . . Replace the control box
Burner goes into lockout dur-
ing operation 31 - Probe or ionisation cable grounded. . . . . . . . . . . . . . . . Replace worn parts
10 blinks The burner does not switch
on, and the lockout appears 32 - Incorrect electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . Check
The burner goes into lockout 33 - Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
34 - Presence of electromagnetic disturbances in . . . . . . . .
the thermostat lines
35 - Presence of electromagnetic disturbance . . . . . . . . . . .
Filter or eliminate
Use the radio disturbance protection kit
No blink The burner does not start 36 - No electrical power supply. . . . . . . . . . . . . . . . . . . . . . . Close all switches - Check connections
37 - A limiter or safety control device is open . . . . . . . . . . . . Adjust or replace
38 - Line fuse blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
39 - Defective control box . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace
40 - No gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open the manual valves between contactor
and train
41 - Mains gas pressure insufficient . . . . . . . . . . . . . . . . . . . Contact your GAS COMPANY
42 - Minimum gas pressure switch fails to close. . . . . . . . . . Adjust or replace
The burner continues to
repeat the start-up cycle,
without lockout
43 - The gas pressure in the gas mains lies very close to the
value to which the minimum gas pressure switch has
been set. The sudden drop in pressure after valve open-
ing causes temporary opening of the pressure switch
itself, the valve immediately closes and the burner
comes to a halt. Pressure increases again, the pressure
switch closes again and the ignition cycle is repeated.
And so on
Reduce the minimum gas pressure switch
intervention pressure. Replace the gas filter
cartridge.
Ignition with pulsations 44 - Poorly adjusted head. . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust. See page 9
45 - Ignition electrode incorrectly adjusted . . . . . . . . . . . . . . Adjust, see fig. (D) page 8
46 - Incorrectly adjusted fan air damper: too much air . . . . . Adjust
47 - Output during ignition phase is too high. . . . . . . . . . . . . Reduce

18
NORMAL OPERATION / FLAME DETECTION TIME
The control box has a further function to guarantee the correct burner operation (signal: GREEN LED permanently on).
To use this function, wait at least ten seconds from the burner ignition and then press the control box button for a minimum of 3 seconds.
After releasing the button, the GREEN LED starts flashing as shown in the figure below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will measure the probe DETECTION TIME since the opening of gas valves, according to the following table:
KIT INTERFACE ADAPTER RMG TO PC Code 3002719
SIGNAL FLAME DETECTION TIME This is updated in every burner start-up.
Once read, the burner repeats the start-up cycle by briefly
pressing the control box button.
WARNING
If the result is > 2s, ignition will be retarded.
Check the adjustment of the hydraulic brake of the gas valve,
the air damper and the combustion head adjustment.
1 blink 0.4s
2 blinks 0.8s
6 blinks 2.8s
GREEN LED on
wait at least 10s Press button for > 3s signal signal
Interval
3s