GB Forced draught gas burners

One-stage operation
 Contents

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 Maximum dimensions.................................................................................................................................................. 8
4.6 Firing rate .................................................................................................................................................................... 9
4.6.1 Test boiler.................................................................................................................................................................... 9
4.6.2 Commercial boilers...................................................................................................................................................... 9
4.7 Correlation between gas pressure and burner output ................................................................................................. 9
4.8 Burner description ..................................................................................................................................................... 10
4.9 Burner equipment...................................................................................................................................................... 10
4.10 Electrical control box ................................................................................................................................................. 11

5 Installation ................................................................................................................................................................................ 12
5.1 Notes on safety for the installation ............................................................................................................................ 12
5.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 12
5.3 Handling .................................................................................................................................................................... 12
5.4 Preliminary checks .................................................................................................................................................... 13
5.4.1 Control of the supply ................................................................................................................................................. 13
5.4.2 Control of burner characteristics ............................................................................................................................... 13
5.5 Operating position ..................................................................................................................................................... 13
5.6 Securing the burner to the boiler ............................................................................................................................... 14
5.7 Combustion head adjustment.................................................................................................................................... 14
5.8 Positioning the probe - electrode............................................................................................................................... 15
5.9 Gas feeding ............................................................................................................................................................... 15
5.9.1 Gas feeding line ........................................................................................................................................................ 15
5.9.2 Gas train.................................................................................................................................................................... 16
5.9.3 Gas train installation.................................................................................................................................................. 16
5.10 Electrical wiring ......................................................................................................................................................... 17
5.10.1 Notes on safety for the electrical wiring..................................................................................................................... 17
5.10.2 Control box ................................................................................................................................................................ 17
5.10.3 Electrical diagram...................................................................................................................................................... 18
5.10.4 Ionisation current....................................................................................................................................................... 18

6 Start-up, calibration and operation of the burner ................................................................................................................. 19

6.1 Notes on safety for the first start-up .......................................................................................................................... 19
6.2 Adjustments prior to ignition ...................................................................................................................................... 19
6.3 Combustion adjustment............................................................................................................................................. 19
6.4 Air pressure switch .................................................................................................................................................... 19
6.5 Operation sequence of the burner............................................................................................................................. 20
6.5.1 Regular operation...................................................................................................................................................... 20
6.5.2 Lockout due to ignition failure.................................................................................................................................... 21
6.5.3 Lockout due to a flame or flame simulation detected during pre-purging.................................................................. 21
6.5.4 Lockout types and triggering times in case of burner malfunction ............................................................................ 22
6.6 Control box reset ....................................................................................................................................................... 22
6.6.1 Reset using built-in button......................................................................................................................................... 22
6.6.2 Reset using remote connection................................................................................................................................. 22
6.6.3 Colour code of the control box reset button LED ...................................................................................................... 22
6.7 Recycle function (in the event of flame disappearance during operation)................................................................. 22
6.8 Logging of burner operating parameters ................................................................................................................... 22

1 GB 20063642
 Contents

6.9 Additional, programmable control box functions ........................................................................................................23

6.9.1 Post-purging function (t6)...........................................................................................................................................23
6.9.2 Continuous purging function (only for applications in which this is provided for) .......................................................23
6.9.3 Function setting procedure using the reset button .....................................................................................................23
6.10 Visual diagnostics of the control box..........................................................................................................................23

7 Maintenance ..............................................................................................................................................................................25
7.1 Notes on safety for the maintenance .........................................................................................................................25
7.2 Maintenance programme ...........................................................................................................................................25
7.2.1 Maintenance frequency..............................................................................................................................................25
7.2.2 Checking and cleaning...............................................................................................................................................25
7.3 Opening the burner ....................................................................................................................................................26

8 Faults - Possible causes - Solutions.......................................................................................................................................27

8.1 Start-up problems ......................................................................................................................................................27
8.2 Operating faults..........................................................................................................................................................28

A Appendix - Accessories ...........................................................................................................................................................29

20063642
2 GB
 Information and general warnings

2 Information and general warnings

2.1 Information about the instruction manual

2.1.1 Introduction WARNING: MOVING PARTS

The instruction manual supplied with the burner: This symbol indicates that you must keep limbs
 is an integral and essential part of the product and must not away from moving mechanical parts; danger of
be separated from it; it must therefore be kept carefully for crushing.
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to DANGER: EXPLOSION
another system. If the manual is lost or damaged, another This symbol signals places where an explosive at-
copy must be requested from the Technical Assistance mosphere may be present. An explosive atmos-
Service of the area; phere is defined as a mixture - under atmospheric
 is designed for use by qualified personnel; conditions - of air and flammable substances in
 offers important indications and instructions relating to the the form of gases, vapours, mist or dust in which,
installation safety, start-up, use and maintenance of the after ignition has occurred, combustion spreads to
burner. the entire unburned mixture.

Symbols used in the manual PERSONAL PROTECTION EQUIPMENT

In some parts of the manual you will see triangular DANGER These symbols indicate the equipment that must
signs. Pay great attention to these, as they indicate a situation of be worn and kept by the operator for protection
potential danger. against threats against safety and/or health while
at work.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
Maximum danger level!
This symbol indicates operations which, if not car- OBLIGATION TO ASSEMBLE THE COVER
ried out correctly, cause serious injury, death or AND ALL THE SAFETY AND PROTECTION DE-
DANGER long-term health risks. VICES
This symbol signals the obligation to reassemble
This symbol indicates operations which, if not car- the cover and all the safety and protection devices
ried out correctly, may cause serious injury, death of the burner after any maintenance, cleaning or
or long-term health risks. checking operations.
WARNING
ENVIRONMENTAL PROTECTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma- This symbol gives indications for the use of the
chine and/or injury to people. machine with respect for the environment.
CAUTION
IMPORTANT INFORMATION
2.1.3 Other symbols This symbol indicates important information that
you must bear in mind.
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-  This symbol indicates a list.
ried out correctly, lead to electric shocks with le-
DANGER
thal consequences.
DANGER: FLAMMABLE MATERIAL Abbreviations used
This symbol indicates the presence of flammable Ch. Chapter
materials. Fig. Figure
Pag. Page
Sec. Section
DANGER: BURNING
Tab. Table
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.

20063642
4 GB
 Information and general warnings

2.1.4 Delivery of the system and the instruction  The system supplier must carefully inform the user about:
manual – the use of the system;
– any further tests that may be required before activating the
When the system is delivered, it is important that:
system;
 the instruction manual is delivered to the user by the system
– maintenance, and the need to have the system checked at
manufacturer, with the recommendation to keep it in the
least once a year by a representative of the manufacturer
room where the heat generator is to be installed.
or another specialised technician.
 The instruction manual shows:
To ensure a periodic check, the manufacturer recom-
– the serial number of the burner;
mends the drawing up of a Maintenance Contract.
.........................................................................................

– the address and telephone number of the nearest Assist-

ance Centre

.........................................................................................
.........................................................................................
.........................................................................................

2.2 Guarantee and responsibility

The manufacturer guarantees its new products from the date of

installation, 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.
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
WARNING tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.
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;
 continuation of use of the burner when a fault has occurred;
 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;
 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.

5 GB 20063642
 Safety and prevention

3 Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the
current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for
rules of safety and envisaging all the potential danger situations. which the burner has been regulated, the pressurisation of the
It is necessary, however, to bear in mind that the imprudent and combustion chamber, the dimensions of the combustion cham-
clumsy use of the equipment may lead to situations of death risk ber and the room temperature must all be within the values indi-
for the user or third parties, as well as the damaging of the burner cated in the instruction manual.
or other items. Inattention, thoughtlessness and excessive confi-  Modification of the burner to alter its performance and desti-
dence often cause accidents; the same applies to tiredness and nations is not allowed.
sleepiness.  The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
It is a good idea to remember the following:
be quickly eliminated.
 The burner must only be used as expressly described. Any
 Opening or tampering with the burner components is not
other use should be considered improper and therefore dan-
allowed, apart from the parts requiring maintenance.
gerous.
 Only those parts envisaged by the manufacturer can be
replaced.
In particular: The manufacturer guarantees safety and proper
it can be applied to boilers operating with water, steam, diather- functioning only if all burner components are intact
mic oil, and to other uses expressly foreseen by the manufactur- and positioned correctly.
er; WARNING

3.2 Personnel training

The user is the person, body or company that has acquired the In addition:
machine and intends to use it for the specific purpose. He is re-
 must take all the measures necessary to pre-
sponsible for the machine and for the training of the people work-
vent unauthorised people gaining access to
ing around it.
the machine;
The user:  the user must inform the manufacturer if
 undertakes to entrust the machine exclusively to suitably faults or malfunctioning of the accident pre-
trained and qualified personnel; vention systems are noticed, along with any
 undertakes to inform his personnel in a suitable way about presumed danger situation;
the application and observance of the safety instructions.  personnel must always use the personal pro-
With that aim, he undertakes to ensure that everyone knows tective equipment envisaged by legislation
the use and safety instructions for his own duties; and follow the indications given in this man-
 Personnel must observe all the danger and caution indica- ual.
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.

20063642
6 GB
 Technical description of the burner

4 Technical description of the burner

4.1 Burner designation

Range: RIELLO 40 F

Fuel: S Natural gas

- Gas oil
SP LPG
D Light oil - Natural gas

Size

Variations: R Light oil with pre-heater

K Conical head
S Reduced ignition output
D Two-stage

Head : TC Standard head

TL Long head

Electrical supply of the system: 1/230/50 1/230V/50Hz

1/230/60 1/230V/60Hz

F S 3 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION

4.2 Models available

Designation Voltage Code

RIELLO 40 FS3 1/230/50 3756505
RIELLO 40 FS3 1/230/50 3756506

4.3 Burner categories - Countries of destination

Country of destination Gas category

SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L
FR I2Er
BE I2E(R)B
LU - PL I2E
Tab. A

7 GB 20063642
 Technical description of the burner

4.4 Technical data

Model RIELLO 40 FS3

Type 565 M
kW 11  35
Heat output (Hi) (1) min - max
kcal/h 9,500  30,000
Fuel NCV 8  12 kWh/m3 – 7,000 10,340 kcal/m 3
Family 2
Pressure: min. 10 mbar – max. 200 mbar
Operation Intermittent (FS1)
Use Boilers: water and diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Electrical supply 1/230V/50Hz
rpm - rad/s 2800 - 294
V - Hz 230 - 50
Fan motor
W 90
A 0.75
Ignition transformer Primary 230V / 0.2A – Secondary 8 kV
Capacitor F 2
Absorbed electrical power kW 0.15
Protection level IP40
Weight kg 11
Noise levels (2) Sound pressure 53.8
dB(A)
Sound power 65.0
Tab. B
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) 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.

For gas family 3 (LPG) ask for separate kit.

WARNING

4.5 Maximum dimensions

The maximum dimensions of the flange and burner are given in

Fig. 1.

Flange Burner
Ø 170 252 100 230

° 45
45 °
Ø 91
Rp 1/2
215

132
140

165
10

130 25 Rp 3/8
D5061 A
55 37
Fig. 1
Key (Fig. 1)
A Reduction pipe coupling Rp 1/2 - R 3/8

20063642
8 GB
 Technical description of the burner

4.6 Firing rate

The burner output is chosen from within the diagram area

The firing rate value (Fig. 2) has been obtained
(Fig. 2).
considering an ambient temperature of 20°C, an
atmospheric pressure of 1013 mbar (approx. 0 m
WARNING above sea level), and with the combustion head
adjusted as shown on pag. 14.
D5038
0.8
Combustion chamber

0.6
pressure - mbar

0.4

0.2

0
10 15 20 25 30 35 kW

10,000 15,000 20,000 25,000 30,000 kcal/h

Thermal power
Fig. 2

4.6.1 Test boiler 4.6.2 Commercial boilers

The firing rate has been defined according to EN 676 standard. The burner-boiler matching is assured if the boiler conforms to
EN 303 and the combustion chamber dimensions are similar to
those shown in the diagram EN 676.
For applications where the boiler does not conform to EN 303, or
where the combustion chamber is much smaller than the dimen-
sions given in EN 676, please consult the manufacturers.

4.7 Correlation between gas pressure and burner output

To obtain the maximum output (Fig. 3), it is necessary to have 4.5 ber at 0 mbar and gas G20 - NCV = 10 kWh/Nm3 (8,570 kcal/
mbar measured on the pipe coupling, with the combustion cham- Nm3).
D5037
6
combustion head - mbar

5
Gas pressure at

0
10 15 20 25 30 35 kW

10,000 15,000 20,000 25,000 30,000 kcal/h

Thermal power Fig. 3

Gas pressure at combustion head – mbar

9 GB 20063642
 Technical description of the burner

4.8 Burner description

20065543

Fig. 4
1 Air damper 11 Gas train elbow
2 Damper fixing screws 12 Flange
3 Pressure test point (-) 13 Pressure test point (+)
4 Cover fixing screw 14 Combustion head
5 Air pressure switch 15 Electrode-probe
6 Motor
The cable grommet, supplied as standard, should
7 Lock-out signal with reset button be assembled on the same side as the gas train.
8 Control box
Check that it is possible to access the cover fixing
9 6-pole socket for gas train WARNING
screws once the burner has been installed. If nec-
10 Capacitor essary, replace them with the ones supplied

4.9 Burner equipment

Screws with nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4

Insulating gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Cover fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 3
Cable grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Reducing pipe coupling Rp 1/2 - R 3/8 . . . . . . . . . . . . . . . No. 1
7-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 6
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

20063642
10 GB
 Technical description of the burner

4.10 Electrical control box

Warnings Electrical characteristics

To avoid accidents, material or environmental Unit of
damage, observe the following instructions! meas-
Description Parameters
The control box is a safety device! Avoid opening ure-
WARNING
or modifying it, or forcing its operation. Riello ment
S.p.A. cannot assume any responsibility for dam- Rated power supply voltage
V A.C. 210...230, +10 -15%
age resulting from unauthorised interventions! (range), tolerance
Rated power supply frequency
 All interventions (assembly and installation operations, Hz 50...60, +5%, -5%
(range), tolerance
assistance, etc.) must be carried out by qualified personnel.
Operation temperature °C -20...+60
 Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply Protec-
IP 00
(omnipolar separation). tion
 Protection against electrocution from the control box and all Auxiliary circuit voltage V 230AC, 48DC, 5DC
connected electric components is obtained with the correct Electrical input power VA 40
assembly.
 Before any intervention (assembly and installation opera- Extreme operating current:
tions, assistance, etc.), ensure the wiring is in order and that - terminals V1, V2, S3 0, 5  cos  = 0, 6 
the parameters are correctly set, then make the safety - terminals MV, SM A 3  cos  = 0, 6 
checks. - terminals B4 0, 1  cos  = 0, 6 
 Falls and collisions can negatively affect the safety func-
Extreme length of the input signals:
tions. In this case, the control box must not be operated,
even if it displays no evident damage. - inputs T1, T2, RS 20
- inputs PA, PG m 1
For safety and reliability, comply with the following instruc-
- input SO 0.5
tions:
– avoid conditions that can favour the development of conden- Internal fuse F1, T4AL250V
sate and humidity. Otherwise, before switching on again, Classification EN298 FTCLBN
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.

Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit, make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.

E9256
Fig. 5

11 GB 20063642
 Installation

5 Installation

5.1 Notes on safety for the installation

After carefully cleaning all around the area where the burner will
The installation of the burner must be carried out
be installed, and arranging the correct lighting of the environ-
by qualified personnel, as indicated in this manual
ment, proceed with the installation operations.
and in compliance with the standards and regula-
All the installation, maintenance and disassembly WARNING tions of the laws in force.
operations must be carried out with the electricity
Combustion air inside the boiler must be free from
supply disconnected.
DANGER
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
DANGER out cleaning and maintenance more frequently.

5.2 Instructions to avoid burnout or bad combustion of the burner

1 The burner can not be installed outside as it is suitable for case, check that when the burner stops the extractors do
operation in closed rooms only. not draw hot fumes from pipes through the burner.
2 The premises the burner operates in must have openings 4 When the burner is stopped, the smoke pipe must be kept
for the air need for the combustion. open and a natural draft created in the combustion cham-
To be sure about this, you have to control CO2 and CO in ber.
the exhaust gases with all the windows and doors closed. If the smoke pipe is closed, the burner must be drawn back
3 If there are air extractors in the premises the burner works, till the extraction of blast tube from the furnace. Before oper-
make sure that there are openings for air to be taken in that ating in this way take the voltage off.
are big enough to ensure the required air change; In any

5.3 Handling

The transport weight is given in chapter "Technical data" on page

8.
Observe the permissible ambient temperatures for storage and
transport: -20 ..... + 70 °C, with max. relative humidity 80%.

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

The operator must use the required equipment

during installation.

20063642
12 GB
 Installation

5.4 Preliminary checks

5.4.1 Control of the supply A burner label that has been tampered with, re-
After removing all the packaging, check the integ- moved or is missing, along with anything else that
rity of the contents. prevents the definite identification of the burner
In the event of doubt, do not use the burner; con-
WARNING makes any installation or maintenance work diffi-
CAUTION
tact the supplier. cult.

The packaging elements (cardboard box, clips, The figure of the label (Fig. 6) is indicative. Some
plastic bags, etc.) must not be abandoned as they of the data may be arranged in a different position.
are potential sources of danger and pollution; they
WARNING
should be collected and disposed of in the appro-
priate places.

5.4.2 Control of burner characteristics

Check the identification label of the burner(Fig. 6), showing:
A the burner model
B the burner type
C the cryptographic year of manufacture 20065195
D the serial number Fig. 6
E the data for electrical supply and the protection level
F the electrical power consumption
G the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate.

5.5 Operating position

 The burner is designed to operate only in  Any other position could compromise the cor-
positions 1, 2, 3 and 4 (Fig. 7). rect operation of the appliance.
 Installation 1 is preferable, as it is the only  Installation 5 is prohibited for safety reasons.
WARNING one that allows the maintenance operations DANGER
as described in this manual.
 Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.

1 2 3 4 5

20065196
Fig. 7

13 GB 20063642
 Installation

5.6 Securing the burner to the boiler

Provide an adequate lifting system of the burner. 1 3 2

 Separate the combustion head assembly from the burner

body by removing nut 1) and removing the group A)(Fig. 8).
 Fix the group B)(Fig. 8) to the boiler plate 2), inserting the
supplied insulating gasket 3).

The seal between burner and boiler must be

airtight. D5062
WARNING

A B
Fig. 8

5.7 Combustion head adjustment

To adjust, proceed as follows:

 loosen the two screws A)(Fig. 9), move the elbow B) so that
the rear plate of the coupling C) coincides with the desired
notch;
 screw in the two screws A).
S7020

To disassemble the diffuser disc holding head, proceed as fol-

lows:
 loosen the two screws A)(Fig. 9) without removing them; C
 pull back the head, rotating it by about 180°,
 extract the head, tilting it downwards,

Example:
The burner is installed in a 21 kW boiler. A B A
Considering an efficiency of 90%, the burner must supply around Fig. 9
23kW.
The diagram (Fig. 10) shows that for this output the adjustment
must be made on notch 1. kcal/h kW D5051
40
The diagram is to be used only for initial settings,. To ensure
good air pressure switch operation it may be necessary to reduce 30,000 35
this combustion head opening (notch toward pos. 0).
25,000 30

25
20,000 23
20
15,000
15
10,000 10
0 0.5 1 1.5 2
Notch No.
Fig. 10

20063642
14 GB
 Installation

5.8 Positioning the probe - electrode

Do not turn the ignition electrode but leave it as Place the ceramic part of the electrode A) against
shown in Fig. 11. the diffuser disc B)(Fig. 11).
if the ignition electrode is put near the ionisation
WARNING WARNING
probe, the control box amplifier might be dam-
aged.

B A Probe Diffuser Electrode

Probe
Electrode
1,7

D5033

2.5 - 3.5 mm

Fig. 11

5.9 Gas feeding

Explosion danger due to fuel leaks in the pres- The fuel supply line must be installed by qualified
ence of a flammable source. personnel, in compliance with current standards
Precautions: avoid knocking, attrition, sparks and and laws.
WARNING
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.

5.9.1 Gas feeding line

MBC 65/1 1 2 3 M1 4 5 6 8 7

D7733

M2 Fig. 12
Key (Fig. 12)
1 Gas input pipe
2 Manual gate (the responsibility of the installer)
3 Gas pressure gauge (the responsibility of the installer)
4 Filter
5 Gas pressure switch
6 Safety valve
7 Pressure stabiliser
8 Adjustment valve
M1 Gas-supply pressure test point on the gas pressure switch
M2 Pressure coupling test point

15 GB 20063642
 Installation

5.9.2 Gas train

Approved according to standard EN 676 and provided separately
from the burner. Supplied separately for its adjustment, see the
enclosed instructions.
The train-burner combination is indicated in Tab. C.
Connections
Code Model Use
Gas train Burner
3970569 MBC 65/1 - RSD 20 Rp 1/2 Rp 1/2 Natural gas and LPG
Tab. C

5.9.3 Gas train installation

Disconnect the electrical power using the main

switch.
DANGER

Check that there are no gas leaks.

Pay attention when handling the train: danger of

crushing of limbs. 20065208

Make sure that the gas train is properly installed

Fig. 13
by checking for any fuel leaks.

The gas train 1)(Fig. 13) leaves the factory ready for installation
to the burner's left.
If it is to be installed on the right, fit the valve turned by 90° with
respect to the gas-out flange and with the gas pressure switch
pointed upwards.
Connection between the gas supply line and the train must be
made using the gas-in flange 3) supplied, and fastening screws.
It is best to tighten screws in a criss-cross pattern.
Do not, under any circumstances, install the valve
with the coil facing down.
WARNING

Connect the 6 pin plug 2)(Fig. 13 of the gas train to the 6-pole
socket 9)(Fig. 4 on page 10) of the burner.
Once installation is complete, you must check for
fuel leaks and make sure the gas train is working
properly.
WARNING

20063642
16 GB
 Installation

5.10 Electrical wiring

5.10.1 Notes on safety for the electrical wiring

 The electrical wiring must be carried out with the electrical supply disconnected.
 Electrical wiring must be made in accordance with the regulations currently in force in the country of destination
and by qualified personnel. Refer to the wiring diagrams.
DANGER  The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-
ing diagrams.
 Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual.
 The burner has been type-approved for intermittent use.
In the event of continuous operation, a cycle arrest must be ensured within 24 hours with the use of a time switch
positioned in series with the thermostatic line. Refer to the wiring diagrams.
 The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event of
doubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing system
for electrical devices.
 The electrical system must be suitable for the maximum power absorption of the device, as indicated on the label
and in the manual, checking in particular that the section of the cables is suitable for that level of power absorp-
tion.
 For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use a multiple pole switch with at least a 3 mm gap between the contacts (overvoltage category III), as envis-
aged by the present safety standards.
 Do not touch the device with wet or damp body parts and/or in bare feet.
 Do not pull the electric cables.
Before carrying out any maintenance, cleaning or checking oper-
ations:

Disconnect the electrical supply from the burner

by means of the main system switch.
DANGER

Turn off the fuel interception tap.

DANGER
1
Avoid condensate, ice and water leaks from form-
ing.

DANGER

If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams. E9322
Fig. 14

5.10.2 Control box

Disconnect the electrical supply from the burner

by means of the main system switch.
DANGER

To remove the control box from the burner it is necessary to:

 disconnect all the connectors connected to it, the 6-pin plug,
the high voltage cables, and the earth wire (TB);
 loosen the screw 1)(Fig. 14) and pull the control box in the
direction of the arrow.
For the installation:
 tighten screw 1)(Fig. 14) with a tightening torque of
1 ÷ 1.2 Nm;
 reconnect all previously disconnected connectors, making
sure to connect the 7 pin power plug as the final step.
After carrying out maintenance, cleaning or
checking operations, reassemble the hood and all
the safety and protection devices of the burner.

17 GB 20063642
 Installation

5.10.3 Electrical diagram

Key (Fig. 15)
C Motor capacitor
CN1 Ionisation probe connector Main switch
E Ignition electrode
h1 Hour counter (230V - 0.1A max.)
MV Fan motor
PA Air pressure switch
PG Min. gas pressure switch
RS Remote reset connection
SB Lockout light (230V - 0.5A max.)
SM One-stage damper conn.
SO Ionisation probe
TB Burner earth
TL Limit thermostat
TS Safety thermostat
T6A Fuse
V1 Adjustment valve
VS Safety valve
XP6 6 pin plug/socket
XP7 7 pin/plug socket

Testing Black

CONTROL BOX
 Check the shut down of the burner by opening the thermo- White

MG557-5
Blue
stats.
 Check that the burner is blocked while working by opening
the connector (CN1) inserted in the probe red wire and
located outside the control box.

5.10.4 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)(Fig. 15) on the red wire and insert a
microammeter as shown in Fig. 16.

D7057

Fig. 15

Connector

Control box
+ -

Probe

D4625
Fig. 16

20063642
18 GB
 Start-up, calibration and operation of the burner

6 Start-up, calibration and operation of the burner

6.1 Notes on safety for the first start-up

The first start-up of the burner must be carried out Check the correct working of the adjustment, com-
by qualified personnel, as indicated in this manual mand and safety devices.
and in compliance with the standards and regula-
WARNING tions of the laws in force. WARNING

6.2 Adjustments prior to ignition

 Check the adjustment of the head as shown in pag. 14. We recommend using a plastic tube routed outside the build-
 Check that the air damper has been correctly adjusted. ing and to purge air until gas is smelt.
 Slowly open the manual valves situated upstream from the
Before starting up the burner, it is good practice to
gas train.
adjust the gas train so that ignition takes place in
 Adjust the air pressure switch (Fig. 17) to the start of the
conditions of maximum safety, i.e. with gas deliv-
scale. CAUTION ery at the minimum.
 Purge the air from the gas line.

6.3 Combustion adjustment

In conformity with Efficiency Directive 92/42/EC the application of temperatures and the average temperature of the water in the
the burner on the boiler, adjustment and testing must be carried boiler.
out observing the instruction manual of the boiler, including veri- It is advisable to set the burner according to the type of gas used
fication of the CO and CO2 concentration in the flue gases, their and following the indications inTab. D.
EN 676 Air excess: max. output.   1.2 – min. output  1.3
Theoretical max Setting CO2 %
CO NOx
GAS CO2
 = 1.2  = 1.3 mg/kWh mg/kWh
0 % O2
G 20 11.7 9.7 9.0  100  170
G 25 11.5 9.5 8.8  100  170
G 30 14.0 11.6 10.7  100  230
G 31 13.7 11.4 10.5  100  230
Tab. D

6.4 Air pressure switch

Adjust the air pressure switch (Fig. 17) after performing all other
burner adjustments with the air pressure switch set to the start of
the scale.
With the burner function at the required output, turn the knob
slowly in a clockwise direction until burner lockout.
Then turn the knob anticlockwise to an extent that is around 20%
of the adjusted value and then check that the burner starts up
properly.
If the burner locks out again turn the knob slightly in an anticlock-
wise direction.
In conformity with the standard, the air pressure
switch must prevent the air pressure falling below
80% of the adjusted value and the CO in the flue D7404
WARNING gases exceeding 1% (10,000 ppm). Fig. 17
To check this, insert a combustion analyser in the
flue, slowly reduce the burner air setting (for ex-
ample with a piece of cardboard) and verify that
the burner locks out before the CO value in the
flue gases exceeds 1%.

19 GB 20063642
 Start-up, calibration and operation of the burner

6.5 Operation sequence of the burner

6.5.1 Regular operation

P Key (Fig. 18)

TL I Ignition transformer
t2 LED Reset button LED indicating operating status
t1
t3 M Fan motor
M M
SO Ionisation probe
t 4i
TL Limit thermostat
I V Gas valve
ts
V

SO

Green

LED Red (LED signalling)

Flame loss during operation (Recycle max. 3 attempts)
MV = idle Green (LED signalling)
t 4L
No signal needs to be received
.
Lockout

SO
Red

Green

LED D7393
Fig. 18

Operating times (in seconds)

t1, t3l, t4l, t4a t2l t2 t2a t3 t3a t3r ts, t4i t6
max max - - - max max - max
1 30 3 120 40 15 70 5 360
Tab. E

t1 Standby time pending an input signal to control box: re- t3r A recycle attempt is made if there is a pressure drop dur-
action time, the control box remains idle for the time t1. ing the pre-purging stage:
there is then a lockout in the event of a second loss of
t1I Flame or flame simulation detected before demand for
air pressure between the 16th second and the 29th; is a
heat: the control box remains idle.
loss of pressure between the 30th second and the 40th,
t2 Standby time after a heat request: the control box re- the device goes immediately into lockout mode.
mains idle for the t2 time.
ts Safety time: if at the end of the ts time there is no flame,
t2a Check whether the air pressure switch has already been a lockout follows.
moved to the work position before the required heat: the
t4a Air pressure drop checking time during the ts time and
control box remains in standby status, a lockout follows
the normal operation:
if the air pressure switch remains switched for the T2a
the control box locks out immediately.
time.
t4i Transformer ignition time: total ignition time.
t2I Flame or flame simulation detected before during stand-
by time: lockout occurs if flame or flame simulation per- t4l Loss of flame during operation: maximum reaction time
sists for time t2l. for dropped valve - after 3 recycle attempts there is a
lockout.
t3 Pre-purge time: start of the fan motor.
t6 Post-purge time: additional purging time on the opening
t3a Time for checking the switching of the air pressure
of the heat limit thermostat (TL).
switch in the operating position during the pre-purging
time: if the pressure switch does not switch within t3a a Tab. F
lockout follows.
t3I Flame or flame simulation detected during pre-purging:
immediate lockout.

20063642
20 GB
 Start-up, calibration and operation of the burner

6.5.2 Lockout due to ignition failure

P Key (Fig. 19)

TL I Ignition transformer
t2 LED Reset button LED indicating operating status
t1 t3 M Fan motor
M M SO Ionisation probe
t 4i TL Limit thermostat
I V Gas valve
ts
V
Red (LED signalling)
Lockout
.

Green (LED signalling)

SO

Green Red

LED D7394
Fig. 19

6.5.3 Lockout due to a flame or flame simulation

detected during pre-purging

P
Key (Fig. 20)
TL I Ignition transformer
t2 LED Reset button LED indicating operating status
t1 t3 M Fan motor
M M SO Ionisation probe
TL Limit thermostat
I V Gas valve
ts
V
Red (LED signalling)
SO Green (LED signalling)
Lockout
Green Red
.

LED D7395
Fig. 20

Operating times (in seconds)

t1, t3l, t4l, t4a t2l t2 t2a t3 t3a t3r ts, t4i t6
max max - - - max max - max
1 30 3 120 40 15 70 5 360
Tab. G

21 GB 20063642
 Start-up, calibration and operation of the burner

6.5.4 Lockout types and triggering times in case of

burner malfunction
Description of types of faults Lockout
Presence of flame during standby time “t2” After max. 30 seconds (after TL)
Presence of flame in pre-purging, or loss of air pressure during Within 1 second
operation
Air pressure loss during pre-purging; After max. 1 repetition within 1 second
No ignition at the end of the safety time “ts” Within 5 seconds
Disappearance of flame during operation After max. 3 repetitions within 1 second
Fault in air pressure switch before or after the start-up of the burn- Within 120 seconds, within 15 seconds
er
Tab. H

6.6 Control box reset

6.6.1 Reset using built-in button 6.6.3 Colour code of the control box reset button
To carry out the control box reset, proceed as follows: LED
 Press and hold the reset button for 1-2 seconds. Operating status LED colour codes
 In case the burner does not restart it is necessary to check if
LED switched
the limit thermostat (TL) is closed. Waiting
off
 If the control box reset button continues to blink, signalling
the cause of the failure (red LED), it is necessary to press Pre-purging Green
the button again for no more than 2 seconds. Ignition transformer Green
If the reset button is pressed for more than 2 sec- Regular flame Green
onds, the control box goes into visual diagnostic Post-purging Green
mode and the signalling LED begins to blink (see
Recycle Green
WARNING "Visual diagnostics of the control box" on page
23). Continuous purging (*) Green
Presence of flame during waiting LED switched
6.6.2 Reset using remote connection time off
Lockout Red
An accessory connection is provided for the remote reset of the
control box. Lockout with continuous purging (*) Red + Green
(*) only for suitable applications.

6.7 Recycle function (in the event of flame disappearance during operation)

The control box allows recycling, i.e. the complete repetition of The further disappearance of the flame (4th time) determines the
the starting programme, for 3 attempts maximum, in the event the lockout of the burner.
flame goes out during operation. If there is a new heat request during the recycle, the 3 attempts
are restored to the switch-over of the limit thermostat (TL).

6.8 Logging of burner operating parameters

The control box allows the logging (even without the electrical
power supply) of the number of lockouts that have occurred, the
type of lockout that has occurred (only the last one) and the op-
erating time of the opening of the oil valve.
That way, you can determine how much fuel has been consumed
during operation.
For the display of these parameters it is necessary to connect the
diagnostic software kit.

20063642
22 GB
 Start-up, calibration and operation of the burner

6.9 Additional, programmable control box functions

6.9.1 Post-purging function (t6) 6.9.2 Continuous purging function (only for
Post-ventilation is a function that maintains air ventilation even applications in which this is provided for)
after the burner is switched off. The switching off of the burner Continuous purging is a function that maintains the air ventilation
comes about when the limit thermostat (TL) opens, with the con- independently of the request for burner ignition.
sequent interruption of the supply of fuel of the valves. To use this From the moment when it is set, the motor remains in operation
function the reset button must be pressed when the limit thermo- both when the limit thermostat (TL) is not switched over (burner
stat is not switched over (burner switched off). switched off), and when the burner is in lockout.
The post-purging time can be set for a maximum of 6 minutes, On the switch-over of the limit thermostat (TL) the motor stops for
proceeding as follows: a waiting time of 4 seconds (waiting position = t2 + t1), there is a
 press the reset button for at least 5 seconds, until the signal- subsequent check of the air pressure switch and the start of a
ling LED turns red. new operational cycle for the burner.
 Set the desired time by pressing the button repeatedly: once
= post-ventilation for 1 minute. The function can be set via the reset button when the limit ther-
 after 5 seconds the control box will automatically indicate the mostat (TL) is not switched over (burner switched off), following
minutes set, via the blinks of the red LED: 1 blink = post- the procedure of the "post-purging function" paragraph and
purging for 1 minute. pressing the button 7 times = continuous purging.

To reset this function, simply press and hold the button for 5 sec- To reset this function, simply press and hold the button for 5 sec-
onds until the LED indicator goes red and release it without per- onds until the LED indicator goes red and release it without per-
forming any operation, then wait for at least 20 seconds to allow forming any operation, then wait for at least 20 seconds to allow
the burner to restart. the burner to restart.

If during post-ventilation there is a new request for heat, post- The control box leaves the factory with the following setting: 0
ventilation time is halted and a new operating cycle starts when minutes = no continuous post-purging.
the limit thermostat (TL) switches over.
The control box leaves the factory with the following setting: 0
minutes = no post-purging.

6.9.3 Function setting procedure using the reset button

Control box function Actions on the reset button Status of possible use of the reset button
Reset 1 - 2 seconds After lockout of control box
Visual diagnostic of the lockout causes 3 seconds After lockout of control box
Post-purging 5 seconds, then press With limit thermostat (TL) not switched
1 time = 1 minute (burner off)
Continuous purging 5 seconds, then press With limit thermostat (TL) not switched
(only for suitable applications) 7 times = continuous purging (burner off)
Resetting set functions 5 seconds With limit thermostat (TL) not switched
(burner off)
Reset of operational parameters 5 seconds With limit thermostat (TL) switched over during
pre-purging
Tab. I

6.10 Visual diagnostics of the control box

The control box supplied features a diagnostics function through The control box sends a sequence of pulses that are repeated at
which any causes of malfunctioning can be identified (indicator: 2-second intervals.
red LED).
In order to be able to use this function, press and hold the reset
button for at least 3 seconds from when the appliance is made
safe (lockout).
RED LED ON - press the release button for 3s Blinks 2s interval Blinks
 

23 GB 20063642
 Start-up, calibration and operation of the burner

The sequence of led pulses issued by the control box identifies

the possible types of malfunction, which are listed in the table
Tab. J.
Signal Possible cause
The flame does not stabilise at the end of the safety time:
– faulty ionisation probe
2 blinks – faulty gas valve;
 – neutral/phase exchange;
– faulty ignition transformer
– poor burner regulation (insufficient gas)
Min. air pressure switch does not close or is already closed before the limit thermostat closing:
3 blinks
– air pressure switch faulty

– air pressure switch incorrectly regulated
Presence of flame:
4 blinks
– after the closure of the limit thermostat

– during pre-purging
Air pressure drop:
6 blinks
– during pre-purging

– during safety time or operation
Disappearance of the flame 4 times during operation:
– poor burner regulation (insufficient gas)
7 blinks
– faulty ionisation probe

– faulty gas valve
– short circuit between ionisation probe and earth
Tab. J
To reset the control box after the diagnostics dis-
play, press the lockout-reset button.

WARNING

20063642
24 GB
 Maintenance

7 Maintenance

7.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation,

safety, yield and duration of the burner. Disconnect the electrical supply from the burner
It allows you to reduce consumption and polluting emissions and by means of the main system switch.
to keep the product in a reliable state over time. DANGER

The maintenance interventions and the calibration

of the burner must only be carried out by qualified,
Turn off the fuel interception tap.
authorised personnel, in accordance with the con-
DANGER tents of this manual and in compliance with the DANGER
standards and regulations of current laws.
Wait for the components in contact with heat
Before carrying out any maintenance, cleaning or checking oper- sources to cool down completely.
ations:

7.2 Maintenance programme

7.2.1 Maintenance frequency Boiler

Clean the boiler as indicated in its accompanying instructions in
The gas combustion system should be checked at
order to maintain all the original combustion characteristics in-
least once a year by a representative of the man-
tact, especially the flue gas temperature and combustion cham-
ufacturer or another specialised technician.
ber pressure.

Gas train
7.2.2 Checking and cleaning Check that the gas train is suited to the burner capacity, the type
of gas used and the mains gas pressure.
The operator must use the required equipment
during maintenance.
Electrode-probe
Checking the proper positioning of the ionisation probe and elec-
trode as shown in Fig. 11 on page 15.

Pressure switches
Check that the air pressure switch and the gas pressure switch
are set correctly.

Gas leaks
Combustion
Make sure that there are no gas leaks on the pipe between the
Check there are no occlusions or obstructions in the fuel supply
gas meter and the burner.
or return lines, in the air suction areas, and in the combustion
product waste pipe.
Gas filter
Carry out an analysis of the combustion flue gases. Change the gas filter when it is dirty.
Significant differences with respect to the previous measure-
ments indicate the points where most care should be exercised Combustion
during maintenance. If the combustion values measured before starting maintenance
do not comply with applicable legislation or do not indicate effi-
Combustion head cient combustion, consult the Tab. D on page 19 or contact our
Check that the positioning of the combustion head is correct and Technical Support Service to implement the necessary adjust-
that it is properly fixed to the boiler. ments.
Open the burner and make sure that all components of the
combustion head are in good condition, not deformed by the
high temperatures, free of impurities from the surroundings
Leave the burner working without interruptions for 10 min. and set
and correctly positioned.
rightly all the components stated in this manual. Then carry out a
combustion check verifying:
Burner
– Percentage of CO2 (%);
Check that there are not excess wear or loosen screws.
– CO content (ppm)
Clean the outside of the burner.
– NOx content (ppm)
Fan – Ionisation current (µA)
Check that the air damper is positioned correctly. – Smoke temperature at the flue
Check to make sure that no dust has accumulated inside the fan
or on its blades, as this condition will cause a reduction in the air
flow rate and provoke polluting combustion.

25 GB 20063642
 Maintenance

7.3 Opening the burner

Disconnect the electrical supply from the burner

by means of the main system switch.
DANGER

Turn off the fuel interception tap.

DANGER

Wait for the components in contact with heat

sources to cool down completely.

If maintenance of the combustion head is required, refer to the in-

structions given in "Operating position" on page 13.
For accessing to the interior of the burner, loosen the screws that
secure the cover and proceed with the maintenance operation.
Operating safety hazards
Repairs to the following components may only be
carried out by the respective manufacturers or by
DANGER
personnel instructed by them:
– fan motor
– actuator
– air damper servomotor
– electromagnetic valves
– burner programmer

Check the operation

– Start-up of the burner with a sequence of functions
(see chapter "Operation sequence of the burner" on page
20).
– Ignition device
– Air pressure switch
– Flame monitoring
– Tightness test of components to the passage of fuel
After carrying out maintenance, cleaning or
checking operations, reassemble the hood and all
the safety and protection devices of the burner.

20063642
26 GB
 Faults - Possible causes - Solutions

8 Faults - Possible causes - Solutions

Here below you can find some causes and the possible solutions
In the event the burner stops, in order to prevent
for some problems that could cause a failure to start or a bad
any damage to the installation, do not unblock the
working of the burner
burner more than twice in a row. If the burner
In most cases, an operation irregularity leads to the lighting up of WARNING locks out for a third time, contact the customer
the signal inside the reset button of the control box (Fig. 4 on service.
page 10).
In the event there are further lockouts or faults
When lockout lamp lights the burner will attempt to light only after
with the burner, the maintenance interventions
pushing the reset button After this if the burner functions correct-
must only be carried out by qualified, authorised
ly, the lockout can be attributed to a temporary fault. DANGER personnel, in accordance with the contents of this
However, if lockout continues, you must determine the cause of manual and in compliance with the standards and
the problem and take the action illustrated in Tab. K and Tab. L. regulations of current laws.

8.1 Start-up problems

Faults Possible Causes Solution

The burner does not start when Lack of electrical supply. Check presence of voltage in the L1-N clamps of
the limit thermostat closes (TL). the 7 pin plug.
Check the conditions of the fuses.
Check that safety thermostat (TS) is not in lockout.
Lack of gas. Check the manual cock opening.
Check that the valves charge over to the opening
position and there are not short circuits.
The gas pressure switch does not close its Adjust them.
contact.
The connections in the control box are wrongly Check and connect completely all the plugs.
inserted.
The air pressure switch is changed over to the Replace the pressure switch.
operational position.
Burner runs normally in pre- The phase-neutral connection is inverted. Invert them.
purging and ignition cycle and The earth connection lacks or is inefficient. Make the earth connection efficient.
locks out after the safety time.
The ionisation probe is earthed or not in con- Check the right position and if necessary set it ac-
tact with the flame, or its wiring to the control cording to the instructions of this manual.
box is broken, or there is a fault on its insulation Reset the electrical connection.
to the earth.
Replace the faulty connection.
Burner starts with an ignition The ignition electrodes is wrongly positioned. Adjust it according to the instructions of this man-
delay. ual.
Air output is too high. Set the air output according to the instructions of
this manual.
Valve brake is too close with insufficient gas Adjust it.
output.
The burner locks out after the The solenoid valves is passing too little gas. Check the pressure in the network and/or adjust
pre-purge phase due to flame- the solenoid valve according to the instructions of
failure. this manual.
The solenoid valves are defective. Change them.
The ignition arc is irregular or has failed. Check the right insertion of the connectors.
Check the right position of the electrode according
to the instructions of this manual.
The pipe has not been purged from the air. Carry out a complete breathing of the line of gas-
supply.
The burner locks out during the The air pressure switch does not change over The pressure switch is faulty, change it.
pre-purge phase. to the operational position. The air pressure is too low, (the head is bad adjust-
ed).
The flame exists. Faulty valves: replace them.

27 GB 20063642
 Faults - Possible causes - Solutions

Faults Possible Causes Solution

The burner continues to re- The gas pressure in the gas-mains lies very Lower and set the pressure switch.
peat the starting cycle without close to the value to which the gas pressure
going on lockout. switch has been set.
The sudden drop in pressure when the valve is
opened provokes the opening of the pressure
switch itself, so the valve closes again immedi-
ately and the motor stops.
The pressure then starts to increase again, the
pressure switch closes, the start-up cycle be-
gins again and so on.
Tab. K

8.2 Operating faults

Fault Possible Causes Solution

The burner locks out during op- Earth probe. Check the right position and if necessary set it ac-
eration. cording to the instructions of this manual.
Clean or replace the ionisation probe.
The flame disappears 4 times. Check the gas pressure in the network and/or ad-
just the solenoid valve according to the instruc-
tions of this manual .
Air pressure switch opening. The air pressure is too low, (the head is bad adjust-
ed).
The air pressure switch is faulty: change it.
Burner shut down. Gas pressure switch opening. Check the pressure in the network and/or adjust
the solenoid valve according to the instructions of
this manual.
Tab. L

20063642
28 GB
 Appendix - Accessories

A Appendix - Accessories

Long head kit

Standard length Long head length

Burner Code
(mm) (mm)
RIELLO 40 FS3 100 125 3000820

LPG kit

Burner Code
RIELLO 40 FS3 3000881

Town gas kit

Burner Code
RIELLO 40 FS3 3000888

Remote reset kit for control box MG 557-5

Burner Code
RIELLO 40 FS3 3002750

Air suction kit

Burner Code
RIELLO 40 FS3 20027571

Faults kit

Burner Code
RIELLO 40 FS3 3001180

7 pin plug kit

Burner Code
RIELLO 40 FS3 3000945

Software diagnostics kit

Burner Code
RIELLO 40 FS3 3002731

Gas trains in compliance with EN 676

Please refer to manual.

29 GB 20063642
Subject to modifications