Riello RS 55/M BLU Quick start guide

20040559 (4) - 07/2017
Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
Forced draught gas burners
Quemadores de gas con aire soplado
Progressive two stage or modulating operation
Funcionamiento a dos llamas progresivo o modulante
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
20038459 - 20038484 RS 55/M BLU 832T
20038482 - 20038486 RS 55/M BLU 832T
GB
E

Translation of the original instructions
Traducción de las instrucciones originales

1 20040559
GB
Index
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual.................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
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 Burner designation...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination............................................................................................................... 7
4.4 Technical data............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Burner weight.............................................................................................................................................................. 8
4.7 Maximum dimensions.................................................................................................................................................. 9
4.8 Firing rate.................................................................................................................................................................... 9
4.9 Test boiler.................................................................................................................................................................. 10
4.10 Commercial boilers.................................................................................................................................................... 10
4.11 Burner description..................................................................................................................................................... 11
4.12 Burner equipment...................................................................................................................................................... 11
5 Installation ................................................................................................................................................................................ 12
5.1 Notes on safety for the installation............................................................................................................................ 12
5.2 Handling.................................................................................................................................................................... 12
5.3 Preliminary checks.................................................................................................................................................... 12
5.4 Operating position..................................................................................................................................................... 13
5.5 Preparing the boiler................................................................................................................................................... 13
5.5.1 Boring the boiler plate ............................................................................................................................................... 13
5.5.2 Blast tube length........................................................................................................................................................ 14
5.6 Securing the burner to the boiler............................................................................................................................... 14
5.7 Positioning the probe - electrode............................................................................................................................... 15
5.8 Combustion head adjustment.................................................................................................................................... 15
5.8.1 Air adjustment ........................................................................................................................................................... 15
5.8.2 Gas/air adjustment.................................................................................................................................................... 15
5.9 Gas feeding............................................................................................................................................................... 17
5.9.1 Gas train.................................................................................................................................................................... 17
5.9.2 Gas feeding line ........................................................................................................................................................ 18
5.9.3 Gas pressure............................................................................................................................................................. 19
5.10 Electrical wiring ......................................................................................................................................................... 20
5.10.1 Supply cables passage ............................................................................................................................................. 20
5.11 Thermal relay adjustment.......................................................................................................................................... 21
6 Start-up, calibration and operation of the burner ................................................................................................................. 22
6.1 Notes on safety for the first start-up.......................................................................................................................... 22
6.2 Adjustments prior to ignition...................................................................................................................................... 22
6.3 Servomotor................................................................................................................................................................ 23
6.4 Burner start-up .......................................................................................................................................................... 23
6.5 Burner ignition........................................................................................................................................................... 23
6.6 Burner adjustment..................................................................................................................................................... 23
6.6.1 Determining ignition output (minimum)...................................................................................................................... 23
6.6.2 Ignition output (minimum).......................................................................................................................................... 24

20040559 2
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Index
6.6.3 MAX output ................................................................................................................................................................24
6.6.4 Intermediate outputs..................................................................................................................................................25
6.6.5 Air pressure switch.....................................................................................................................................................25
6.6.6 Maximum gas pressure switch...................................................................................................................................26
6.6.7 Minimum gas pressure switch....................................................................................................................................26
6.7 Operation sequence of the burner .............................................................................................................................27
6.7.1 Burner start-up...........................................................................................................................................................27
6.7.2 Operation ...................................................................................................................................................................27
6.7.3 Ignition failure.............................................................................................................................................................27
6.7.4 Burner flame goes out during operation.....................................................................................................................27
6.8 Final checks (with burner operating)..........................................................................................................................28
7 Maintenance ..............................................................................................................................................................................29
7.1 Notes on safety for the maintenance.........................................................................................................................29
7.2 Maintenance programme...........................................................................................................................................29
7.2.1 Maintenance frequency..............................................................................................................................................29
7.2.2 Checking and cleaning...............................................................................................................................................29
7.3 Opening the burner....................................................................................................................................................30
7.4 Closing the burner......................................................................................................................................................30
8 Faults - Probable causes - Solutions......................................................................................................................................31
8.1 Normal operation / flame detection time ....................................................................................................................33
A Appendix - Accessories ...........................................................................................................................................................34
B Appendix - Electrical panel layout...........................................................................................................................................36

3 20040559
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burners
Model: RS 55/E BLU
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE 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
It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE conformity decla-
ration 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.
Type of product: Forced draught gas burners
Model: RS 55/E BLU
Regulation applied: EN 267 and A.R. dated January 8, 2004 - July 17, 2009
Control body: TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
Measured value: CO max: 20 mg/kWh
NOx max: 67 mg/kWh
Legnago, 21.05.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
CE-0085CM0293

20040559 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 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 Ser-
vice 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.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
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
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere is present. An explosive atmosphere is
defined as a mixture of dangerous substances
with air, under atmospheric conditions, in the form
of gases, vapours, mist or dust in which, after ig-
nition has occurred, combustion spreads to the
entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
MOUNT CASING
This symbol indicates that it is mandatory to
mount casing again after maintenance, cleaning
or checks.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20040559
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Information and general warnings
2.1.4 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 Assis-
tance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. 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 eventof damageto things or injury to peo-
ple, 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 irregularity;
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.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installation
and carrying out of non authorised modifications
will result in the annulment by the manufacturer of
the guarantee that it supplies with the burner.

20040559 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 technical
rules of safety and envisaging all the potential danger situations.
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, diather-
mic oil, and to other users expressly named by the manufacturer;
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 pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated 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;
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;
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.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation.
Personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this manual.

7 20040559
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Technical description of the burner
4.1 Burner designation
4.2 Models available
4.3 Burner categories - Countries of destination
Tab. A
4 Technical description of the burner
Designation Combustion head Voltage Start-up Code
RS 55/M BLU TC 3/400/50 Direct 20038459 - 20038484
RS 55/M BLU TL 3/400/50 Direct 20038482 - 20038486
Range : R
Size
Fuel : Natural gas
Light oil
Light oil / Methane
Adjustment :
Flame control system :
FS1
FS2 Standard (1 stop every 24h) Continuous operation (1 stop every 72h)
Electrical supply of the system :
3/400/50
3/230/50
Voltage of auxiliaries :
230/50/60
110/50/60
R S 55 MTC
Emission : ... Class 1 EN267 - EN676
MY Class 1 EN267 - Class 3 EN676
BLU Class 3 EN267 - EN676
MX Class 2 EN267
Class 3 EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Long head
Gas category Destination country
I2E LU - PL
I2E(R) BE
I2ELL DE
I2Er FR
I2H AT - BG - CH - CZ - DK - EE - ES - FI - GB - GR - HU - IE - IS - IT - LT - LV
NO - PT - RO - SE - SI - SK - TR
I2E - I2(43,46 ÷ 45,3 MJ/m3(0°C)) NL

20040559 8
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Technical description of the burner
4.4 Technical data
Tab. B
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(2) Pressure on the socket 5) (Fig. 5) with zero pressure in the combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
4.5 Electrical data
Motor IE1
Motor IE2
Tab. C
4.6 Burner weight
The weight of the burner complete with its packaging is shown in
Tab. D.
Tab. D
Model RS 55/M BLU
Output (1)
Output (1)
min - max kW
Mcal/h 100/300 - 680 86/259 - 586
Fuel Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2)
Gas: G20/G25 mbar 15.2/20
Operation Intermittent
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 64 75
Model RS 55/M BLU
Electrical supply V
Hz 230 - 400 with neutral ~+/-10% 50 - three-phase
Fan motor rpm
V
kW
A
2810
230-400
1.1
4.7 - 2.7
Ignition transformer V1 - V2
I1 - I2 220-240 V - 1 x 15 kV 1 A - 25 mA
Absorbed electrical power kW max 1.5
Protection level IP40
Model RS 55/M BLU
Electrical supply V
Hz 230 - 400 with neutral ~+/-10% 50 - three-phase
Fan motor rpm
V
kW
A
2850
230-400
1.1
4 - 2.3
Ignition transformer V1 - V2
I1 - I2 220-240 V - 1 x 15 kV 1 A - 25 mA
Absorbed electrical power kW max 1.5
Protection level IP40
Model Combustion head kg
RS 55/M BLU TC 42
RS 55/M BLU TL 44

9 20040559
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Technical description of the burner
4.7 Maximum dimensions
The maximum dimensions of the burner are shown in Fig. 1.
Bear in mind that, in order to inspect the combustion head, the
burner must be pulled back and turned up.
The maximum dimension of the burner, without casing, when
open is given by position H.
Tab. E
(1) Blast tube: short-long
4.8 Firing rate
The maximum output is chosen from within the hatched area of
the diagram (Fig. 2).
The minimum output must not be lower than the minimum limit
of the diagram.
mm ABDE F
(1) HILONVM
RS 55/M BLU 533 300 490 640 255 - 390 189 352 222 870 134 221 2”
A
D
H
I
M
V
E
O
N
L F B
Fig. 1
D3906
WARNING
The firing rate value (Fig. 2) has 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 15.
Fig. 2
D11603
Thermal power
Combustion chamber
pressure - mbar

20040559 10
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Technical description of the burner
4.9 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram (Fig. 3), consult the
manufacturer.
The firing rates were obtained in special test boilers, according to
EN 676 regulations.
In Fig. 3 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 400 kW - diameter 50 cm - length 1.45 m.
4.10 Commercial boilers
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a commercial boiler that has
not been EC approved and/or its combustion chamber dimen-
sionsareclearlysmaller than thoseindicatedinthediagram,con-
sult the manufacturer.
In addition, for inversion boilers you are advised to check the
length of the combustion head, as indicated by the boiler manu-
facturer.
The boiler front door maximum thickness must not exceed
200 mm (Fig. 4).
Fig. 3
Combustion chamber
m
D497
Fig. 4
200 mm MAX
D1079

11 20040559
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Technical description of the burner
4.11 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Pipe coupling
5 Minimum air pressure switch (differential type)
6 Flame sensor probe
7 Air pressure socket
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 com-
bustion head
11 Servomotor controlling the gas butterfly valve and the air
damper valve (by means of an adjustable profile cam mech-
anism).
When the burner is not operating the air gate valve is fully
closed in order to reduce heat dispersion from the boiler due
to the flue draught which draws air from the fan suction inlet.
12 Plate with four hole knock-outs for electrical cable routing
13 Fan air inlet
14 Gas input pipe
15 Gas butterfly valve
16 Boiler fixing flange
17 Flame stability disc
18 Flame inspection window
19 Control box with lockout pilot light and lockout reset button
20 Power switch for:
automatic - manual - off
Button for: power increase - power reduction
21 Plugs for electrical wiring
22 Air damper
23 Plug-socket on ionisation probe cable
24 Maximum gas pressure switch
25 Motor contact maker and thermal relay with reset button
26 Motor protection
NOTE
Two types of burner lockout may occur:
Control box lockout:
if the control box 19)(Fig. 5) push-button lights up, it indi-
cates that the burner is in lockout.
To reset, press the button.
Motor lockout:
three-phase electrical supply; to unblock, press the thermal
relay switch 25)(Fig. 5).
4.12 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws, M 10 x 35 . . . . . . . . . . . . . . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to secure the burner flange to the boiler:. . . . . . . . No. 4
M 12 x 35
Cable grommets for the electrical wiring . . . . . . . . . . . . . . No. 5
Motor protection (with fixing screw) . . . . . . . . . . . . . . . . . . No. 1
Set of plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Technical instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 5
D11484
D11481
D3983

20040559 12
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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 burner is delivered in cardboard packaging, 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. 6) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the data for electrical supply and the protection level (E);
the absorbed electrical power (F);
the types of gas used and the relative supply pressures (G);
the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
the category of the appliance/countries of destination (I).
5Installation
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.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
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.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
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
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS−KAASU
GAZ−AEPIO
X
ABC
DEF
G
G
G
H
H
H
I
Fig. 6
S8375

13 20040559
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 9.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
Tab. F
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 7).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
2 3 4 51
Fig. 7
D3928
WARNING
The standard equipment motor protection
1)(Fig. 8), must be fixed on the bracket 2) using
the appropriate screws 3) with nut and washer
before fitting the casing.
Fix the bracket to the front shield of the burner
with screw 4).
4
3
1
2
D7648
Fig. 8
mm ABC
RS 55/M BLU 195 275 - 325 M12
Fig. 9
D455

20040559 14
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Installation
5.5.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler doorcom-
plete with its refractory.
The range of lengths available, L (mm), is as follows:
For boilers with front flue passes 1) (Fig. 10) or flame inversion
chamber, a protection in refractory material 5) must be inserted
between the boiler fettling 2) and the blast tube 4).
This protection must not compromise the extraction of the blast
tube.
For boilers with a water-cooled frontpiece, a refractory lining 2)-
5) (Fig. 10) is not necessary, unless expressly requested by the
boiler manufacturer.
5.6 Securing the burner to the boiler
Separatethe combustionhead fromthe rest of the burner, (Fig. 10).
Remove the screw 13) and extract the casing 14).
Disengage the articulated coupling 4) from the graduated
sector 5).
Remove the screws 2) from the two slide bars 3).
Remove the screw 1) and draw the burner back on the slide
bars 3) by about 100mm.
Disconnect the wires from the probe and the electrode and
then pull the burner completely off the slide bars, after
removing the split pin from the slide bar 3).
Fix the flange 9) (Fig. 10) to the boiler plate inserting the
supplied insulating gasket 6) (Fig. 10).
Use the 4 screws, also supplied with the unit, after protecting
the thread with anti-locking product.
Blast tube 10)
• short 255
• long 390
Prepare a suitable system to lift the burner.
WARNING
Before securing the burner to the boiler, check
(through the opening of the blast tube) that the
probe and electrode are correctly positioned, as in
Fig. 12.
WARNING
The seal between burner and boiler must be
airtight.
Carry out all installation work and mount the cas-
ing again.
13 14 2
13
789
46
10
11
12
15
100 5
L
Fig. 10
D11482

15 20040559
GB
Installation
5.7 Positioning the probe - electrode
If in the previous check the position of the probe or electrode was
not correct, remove the screw 1)(Fig. 11), extract the inner part
2)(Fig. 11) of the head and adjust them.
5.8 Combustion head adjustment
At this stage of installation the blast tube and the pipe coupling
are secured to the boiler as shown in A)(Fig. 13).
The adjustment of the combustion head is therefore particularly
easy, which depends solely on the maximum burner output.
Therefore, this value must be set before adjusting the combus-
tion head.
Two adjustments of the head are foreseen:
–airR1(A, Fig. 13)
– gas/air R2 (B, Fig. 13)
In the diagram (Fig. 14) find the notch at which to adjust both air
and gas.
5.8.1 Air adjustment
Rotate the screw 4)(Fig. 13) until the notch you have found cor-
responds with the front surface 5)(Fig. 13) of the flange.
5.8.2 Gas/air adjustment
Loosen all 3 screws 1)(Fig. 13) and rotate the ring nut 2) until the
notch you have found corresponds with the index 3). Block the 3
screws 1).
Example:
Burner output = 450 kW
In the diagram (Fig. 14) this burner output has the following ad-
justments:
NOTE:
The diagram (Fig. 14) indicates the optimum adjustment for a
type of boiler according to Fig. 3 on page 10. If the gas pressure
CAUTION
Do not rotate the probe: leave it as in (Fig. 12);
since if it is located too close to the ignition elec-
trode, the control box amplifier may be damaged.
D1210
Fig. 11
D1209
PROBE ELECTRODE
Fig. 12
CAUTION
To facilitate the adjustment, loosen the screw 6)
(Fig. 13), adjust, then block.
– air: R1 = notch 2
– gas/air: R2 = notch 6
D1256
Fig. 13
A B

20040559 16
GB
Installation
allows it, by closing the ring nut 2) (Fig. 13) you obtain reductions
in the formation of NOx.
Once the head is adjusted, reassemble the burner on the guides
3)(Fig. 15) at about 100 mm from the pipe coupling 4) - burner in
the position shown in Fig. 10 on page 14
Insert the probe and electrode cables, then slide the burner
as far as the pipe coupling - burner in the position shown in
(Fig. 15).
Refit screws 2) on slide bars 3).
Fix the burner to the pipe coupling with the screw 1).
Re-couple the articulated coupling 6) to the graduated sec-
tor 5).
WARNING
If the pressure in the combustion chamber is
equal to 0 mbar, the air and gas/air adjustments
must be adjusted with reference to the hatched
line in the diagrams.
WARNING
When fitting the burner on the two slide bars, it is
advisable to gently draw out the high voltage ca-
ble and the flame detection probe cable until they
are slightly stretched.
Fig. 14
N notches (air = gas)
Max. burner output
D11604
1
2
3
4
6
5
D11483
Fig. 15

17 20040559
GB
Installation
5.9 Gas feeding
The gas train must be connected to the gas connection
1)(Fig. 16), using the flange 2), gasket 3) and screws 4) supplied
with the burner.
The train can enter the burner from the right or left side, depend-
ing on which is the most convenient, see (Fig. 16).
The gas solenoids must be as close as possible to the burner to
ensure that the gas reaches the combustion head within the safe-
ty time of 3s.
Make sure that the pressure adjuster calibration range (colour of
the spring) comprises the pressure required by the burner.
5.9.1 Gas train
The train is type-approved in accordance with EN 676 and sup-
plied separately from the burner, with the code indicated in Tab. G.
Tab. G
Key (Tab. G)
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 Column 7).
= Train with seal checking device already assembled.
7 = Valve seal checking device VPS. Supplied separately
from gas train on request.
11 = Gas train/burner adaptor. Supplied separately from gas
train on request.
NOTE:
See the accompanying instructions for the adjustment of the
gas train.
Explosion danger due to fuel leaks in the pres-
ence of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure that the fuel interception tap is closed
before performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
WARNING
Make sure that the gas train is properly installed
by checking for any fuel leaks.
Make sure that there are no gas leaks on the
pipes between the gas meter and the burner.
Fig. 16
D505
Gas trains L 711
Code Model ØC.T. Code Code
3970144 MB-DLE 412 1”1/4” -3010123 3000843
3970197 MB-DLE 412 CT 1”1/4” 3010123 3000843
3970180 MB-DLE 415 1”1/2 -3010123 3000843
3970198 MB-DLE 415 CT 1”1/2 3010123 3000843
3970181 MB-DLE 420 2” -3010123 -
3970182 MB-DLE 420 CT 2” - -
3970221 MBC-1200-SE -50 2” -3010123 -
3970225 MBC-1200-SE-50 CT 2” - -

20040559 18
GB
Installation
5.9.2 Gas feeding line
Key (Fig. 17)
1 Gas input pipe
2 Manual valve
3 Vibration damping joint
4 Pressure gauge with pushbutton cock
5 Multibloc, including:
- filter (replaceable)
- working valve
- pressure adjuster
6 Minimum gas pressure switch
7 Valve leak detection control device. In compliance with the
EN 676 standard, leak detection control devices are com-
pulsory for burners with maximum outputs over 1200 kW.
8 Gasket
9 Gas adjustment butterfly valve
10 Maximum gas pressure switch (accessory)
11 Gas train/burner adaptor
P1 Pressure at combustion head
P2 Upstream pressure of valves/adjuster
P3 Upstream pressure of the filter
L Gastrainsuppliedseparatelywiththecode indicatedinTab.G
L1 Installer's responsibility
D3791
L1 L
P2
P1
123
4
5
67
8
9
10
11
Fig. 17
WARNING
Make sure that the gas train is properly installed
by checking for any fuel leaks along the fuel sup-
ply line.