Riello 20194153 Quick start guide

Installation, use and maintenance instructions
20194185 (1) - 11/2021
Forced draught gas burners
Progressive two-stage operation
CODE MODEL
20194153 RS 68 BLU
20194154 RS 120 BLU
GB

Translation of the original instructions

1 20194185
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Contents
1 Information and general warnings............................................................................................................................................ 3
1.1 Information about the instruction manual .................................................................................................................... 3
1.1.1 Introduction.................................................................................................................................................................. 3
1.1.2 General dangers.......................................................................................................................................................... 3
1.1.3 Other symbols ............................................................................................................................................................. 3
1.1.4 Delivery of the system and the instruction manual...................................................................................................... 4
1.2 Guarantee and responsibility....................................................................................................................................... 4
2 Safety and prevention................................................................................................................................................................ 5
2.1 Background ................................................................................................................................................................. 5
2.2 Personnel training ....................................................................................................................................................... 5
3 Technical description of the burner ......................................................................................................................................... 6
3.1 Burner designation ...................................................................................................................................................... 6
3.2 Models available.......................................................................................................................................................... 6
3.3 Technical data ............................................................................................................................................................. 7
3.4 Electrical data.............................................................................................................................................................. 7
3.5 Maximum dimensions.................................................................................................................................................. 8
3.6 Burner equipment........................................................................................................................................................ 8
3.7 Firing rates .................................................................................................................................................................. 9
3.8 Test boiler.................................................................................................................................................................... 9
3.8.1 Commercial boilers.................................................................................................................................................... 10
3.9 Burner description ..................................................................................................................................................... 11
3.10 Electrical panel description........................................................................................................................................ 12
3.11 Control box RMG88................................................................................................................................................... 13
3.12 Servomotor (SQN73.4B4A20)................................................................................................................................... 14
4 Installation ................................................................................................................................................................................ 15
4.1 Notes on safety for the installation ............................................................................................................................ 15
4.2 Handling .................................................................................................................................................................... 15
4.3 Preliminary checks .................................................................................................................................................... 15
4.4 Operating position ..................................................................................................................................................... 16
4.5 Preparing the boiler ................................................................................................................................................... 16
4.5.1 Boring the boiler plate ............................................................................................................................................... 16
4.5.2 Blast tube length........................................................................................................................................................ 16
4.5.3 Securing the burner to the boiler ............................................................................................................................... 16
4.6 Access to head internal part...................................................................................................................................... 17
4.6.1 Combustion head calibration..................................................................................................................................... 17
4.7 Positioning the probe - electrode............................................................................................................................... 17
4.8 Combustion head adjustment.................................................................................................................................... 18
4.9 Gas feeding ............................................................................................................................................................... 19
4.9.1 Gas feeding line ........................................................................................................................................................ 19
4.9.2 Gas train.................................................................................................................................................................... 20
4.9.3 Gas train installation.................................................................................................................................................. 20
4.9.4 Gas pressure............................................................................................................................................................. 20
4.10 Electrical wiring ......................................................................................................................................................... 22
4.10.1 Supply cables and external connections passage .................................................................................................... 22
4.11 Calibration of the thermal relay ................................................................................................................................. 23
4.12 Measuring the ionisation current ............................................................................................................................... 23
5 Start-up, calibration and operation of the burner ................................................................................................................. 24
5.1 Notes on safety for the first start-up .......................................................................................................................... 24
5.2 Adjustments prior to ignition ...................................................................................................................................... 24
5.3 Burner start-up .......................................................................................................................................................... 24
5.4 Servomotor adjustment ............................................................................................................................................. 25
5.5 Burner ignition ........................................................................................................................................................... 26

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Contents
5.6 Adjusting the burner...................................................................................................................................................26
5.6.1 Ignition output ............................................................................................................................................................26
5.6.2 Output in 2nd stage....................................................................................................................................................26
5.6.3 Output in 1st stage.....................................................................................................................................................27
5.6.4 Air pressure switch.....................................................................................................................................................28
5.6.5 Minimum gas pressure switch....................................................................................................................................28
5.7 Operation sequence of the burner .............................................................................................................................29
5.7.1 Burner start-up ...........................................................................................................................................................29
5.7.2 Operation ...................................................................................................................................................................29
5.7.3 Ignition failure.............................................................................................................................................................29
5.7.4 Burner flame goes out during operation.....................................................................................................................30
5.8 Stopping of the burner ...............................................................................................................................................30
5.9 Final checks (with burner operating)..........................................................................................................................30
5.9.1 Checking the air and gas pressure on the combustion head .....................................................................................30
6 Maintenance ..............................................................................................................................................................................31
6.1 Notes on safety for the maintenance .........................................................................................................................31
6.2 Maintenance programme ...........................................................................................................................................31
6.2.1 Maintenance frequency..............................................................................................................................................31
6.2.2 Safety test - with gas feeding closed .........................................................................................................................31
6.2.3 Checking and cleaning...............................................................................................................................................31
6.2.4 Combustion control (gas)...........................................................................................................................................32
6.2.5 Safety components ....................................................................................................................................................32
6.3 Opening the burner ....................................................................................................................................................33
6.4 Closing the burner......................................................................................................................................................33
7 Faults - Possible causes - Solutions.......................................................................................................................................34
A Appendix - Accessories ...........................................................................................................................................................36
B Appendix - Electrical panel layout...........................................................................................................................................37

3 20194185
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Information and general warnings
1.1 Information about the instruction manual
1.1.1 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 Cen-
tre 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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 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 may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition 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.
OBLIGATION TO ASSEMBLE THE COVER AND
ALL THE SAFETY AND PROTECTION DEVICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
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.

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Information and general warnings
1.1.4 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.
1.2 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.
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 appliance;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optionals;
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 installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

5 20194185
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Safety and prevention
2.1 Background
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.
Namely:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses 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 ambient temperature must all be within the values in-
dicated 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.
2.2 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, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties.
Personnel must follow all the danger and caution indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel are obliged to 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 manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from the use of non-original parts.
In addition:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures neces-
sary to prevent 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 man-
ual.

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Technical description of the burner
3.1 Burner designation
3.2 Models available
3 Technical description of the burner
Designation Voltage Start-up Code
RS 68 BLU FS1 TC 3/230-400/50 Direct 20194153
RS 120 BLU FS1 TC 3/230-400/50 Direct 20194154
Series: RS
Size
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous working (1 stop every 72 h)
Electrical supply of the system:
1/230/50
3/230-400/50 3/230V/50Hz
Auxiliary voltage:
230/50/60
RS 68 TC
Emission: C01 or... Class 1 EN676
BLU or BLU Class 3 EN676
FS1 3/230-400/50 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
1 / 230V / 50Hz
3N/ 400V / 50Hz
230V / 50-60Hz
... Two-stage
/M Modulating
/1 one stage
Head: TC Standard head
TL Extended head
C02 or MZ Class 2 EN676
BLU

7 20194185
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Technical description of the burner
3.3 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 16)(Fig. 5) with zero pressure in 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 accurate “Accuracy: Category 3” measurement, as de-
scribed in EN ISO 3746.
3.4 Electrical data
Tab. B
Model RS 68 BLU RS 120 BLU
Power (1) 2nd stage kW 350 - 860 600 - 1300
Mcal/h 301 - 740 516 - 1118
min. 1st stage kW 150 300
Mcal/h 130 258
Fuel Natural gas: G20 - G25
G20 G25 G20 G25
- net calorific value kWh/Nm3
Mcal/Nm3
10 8.6 10 8.6
8.6 7.4 8.6 7.4
- absolute density kg/Nm3 0.71 0.78 0.71 0.78
- max delivery Nm3/h 116 135 151 175
- pressure at maximum delivery (2) mbar 11.7 17.3 22.5 33.3
Operation • On-Off (1 stop min each 24 hours).
• Two-stage (high and low flame) and one-stage (all - nothing)
Standard applications Boilers: water, steam, diathermic oil
Ambient Temperature °C 0 - 40
Temperatura aria comburente °C max 60
Noise levels (3) Sound Pressure
Sound Output dB(A) 77 88
78.5
89.5
Model RS 68 BLU RS 120 BLU
Main electrical supply 3 ~ 230 - 400V ~ +/-10% 50Hz
Auxiliary circuit electrical supply 1N ~ 230 V 50 Hz
Fan motor IE3 rpm
V
W
A
2890
220-240/380-415
1500
5.9 - 3.4
2890
220-240/380-415
2200
8.0 - 4.6
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electric power W max 2200 2800
Protection level IP 44

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Technical description of the burner
3.5 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Note that to inspect the combustion head the burner must be
moved backward and turned upward. The maximum dimension
of the open burner, without cover, is given by measurement I.
Tab. C
(1) Blast tube: short-long
3.6 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 fix the burner flange to the boiler: M 12 x 35 . . . No. 4
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
BT-T(1)
D
E
N
F
P
C
L
MG
H
U-U(1)
Fig. 1
20152197
mm BCDEFGHLMNP T-T
(1) U-U(1)
RS 68 BLU 217 131 189 425 2” 302 546 518 216 220 837 255 - 390 1222 - 1357
RS 120 BLU 217 131 189 425 2” 334 546 550 216 220 837 255 - 390 1222 - 1357

9 20194185
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Technical description of the burner
3.7 Firing rates
The burners can operate in two modes:
one-stage or two-stage.
The MAXIMUM OUTPUT is selected from within area A (Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RS 68 BLU = 150 kW
RS 120 BLU = 300 kW
3.8 Test boiler
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 3 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 756 kW: diameter = 60 cm; length = 2 m.
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1,013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 18.
Pressure in
combustion chamber - mbar
Fig. 2
D2373
Thermal power - kW
RS 120 BLU
Thermal power - kW
RS 68 BLU
Pressure in
combustion chamber - mbar

20194185 10
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Technical description of the burner
3.8.1 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 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 burners are suitable for operation on either flame-inversion
boilers*or boilers with combustion chambers featuring flow from
the base (three flue passes) on which the best results are ob-
tained in terms of low NOx emissions.
The burner-boiler match is assured where the boiler is EC type-
approved; for boilers and furnaces with combustion chambers
featuring dimensions differing considerably from those given in
the diagram (Fig. 4), it is advisable to perform preliminary tests.
* The maximum depth of the boiler door is referred to
dimension “I”. (Fig. 1 on page 8).
NOTE:
For flame inversion boilers, a kit is available to reduce CO
emissions if required. The kit includes 5 gas pipes, identical
to the other 5 already fitted to the burner head. In standard
conditions, the burner head is fitted with a second group of
pipes, with gas outlet in a different direction with respect to
the others. With this Kit, the second group of pipes is re-
placed, so that all the pipes are the same. After fitting the kit,
ensure they work correctly by measuring the CO and flue
gases emissions.
Fig. 3
Combustion chamber
m
D715
Fig. 4
*
D1079

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Technical description of the burner
3.9 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Pipe coupling
5Fanmotor
6Fanairinlet
7 Air damper
8 Flame stability disc
9 Boiler fixing flange
10 Gas butterfly valve
11 Gas input pipe
12 Control box with lockout pilot light and lockout reset button
13 Flame inspection window
14 Screw securing fan to pipe coupling
15 Slide bars for opening the burner and inspecting the com-
bustion head
16 Gas pressure test point and head fixing screw
17 Air pressure test point
18 Flame sensor probe
19 Lifting rings
Two types of burner failure may occur:
CONTROL BOX LOCKOUT:
if the control box button 12)(red led)(Fig. 5) lights up, it indicates
that the burner is in lockout.
To reset, hold the button down for between 1 and 3 seconds.
MOTOR LOCKOUT:
to release press the button on the thermal relay.
14
11 10 9 8
7 6
5 4 3 21
18171513 1612
Fig. 5
20194403

20194185 12
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Technical description of the burner
3.10 Electrical panel description
1 Plug-socket on ionisation probe cable
2 Motor contactor and thermal relay with reset button
3 Two switches:
- one for “on - off burner”
- one for “1st - 2nd stage”
4 Terminal board for electric connection
5 Cable grommets for electrical wiring (to be carried out by the
installer)
6 Minimum air pressure switch (differential type)
7 Ignition transformer
8 Control box base
9 Filter to protect against radio disturbance
10 Relay
11 Servomotor
12
3
4
5
6
7
8
9
10 11
Fig. 6
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13 20194185
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Technical description of the burner
3.11 Control box RMG88...
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation). Check the system is not powered
and cannot be accidentally reconnected. Failure to do this
will lead to the risk of electrocution.
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
Press the reset button of the burner lockout command or the
reset button (by applying a force of not more than 10 N),
without the aid of tools or sharp objects.
For the safety and reliability of the control box, comply with the
following instructions:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
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.
Technical data
Mechanical structure
The control box is made of plastic to resist knocks, heat and
flame propagation.
The control box contains the following components:
• a microprocessor that controls the program sequence, and a
relay for controlling the load;
• an electronic flame signal amplifier;
• a built-in reset button with 3 signalling colours (LED) for status
and error messages.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box RMG88... is a safety device!
Avoid opening or modifying it, or forcing its opera-
tion. Riello S.p.A. cannot assume any responsibil-
ity for damage resulting from unauthorised
interventions!
Mains voltage AC 220...240 V +10 % / -15 %
Mains frequency 50 / 60 Hz ±6%
Power absorption 20 VA
Protection level IP20
Safety class I
Weight approx. 260g
Cable length
Thermostat cable
Air pressure switch
Gas pressure switch
Remote reset
CPI
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95 % r.h.
Fig. 7
S8906

20194185 14
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Technical description of the burner
3.12 Servomotor (SQN73.4B4A20)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the connection area of the
servomotor, fully disconnect the burner control device from
the power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• When assembling the servomotor and connecting the damp-
er, the gears can be disengaged by means of a lever, allow-
ing the drive shaft to be easily adjusted in both directions of
rotation.
Technical data
Tab. D
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
The servomotor contains electric and electronic
components that must not be disposed of with
normal domestic waste.
Respect all current local legislation.
Operating voltage AC 230 V -15% / +10%
Mains frequency 50/60 Hz ±6%
Energy consumption 6 VA
Angular positioning Max. 160°, extension of the scale
0-130 °
Assembly position any
Protection level IP 54, in accordance with DIN 40050
Switching voltage 24...250V AC
Type of motor synchronous
Environmental
conditions
Storage
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60°C
< 95% RH
Connection of the cable Two grafting seats for the connec-
tion terminals
Type CUM / Stelvio manufacturer
for connector:
- type CUF 5-4 (grafting seat X1)
- type CUF 5-5 (grafting seat X2)
Recommended section for cable
braided min. 0.5 mm² and max.
1.5mm².
Fig. 8
20194236

15 20194185
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Installation
4.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
4.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 9), showing:
A the burner model;
B the burner type;
C the cryptographic year of manufacture;
D the serial number;
E the data for electrical supply and the protection level;
F the electrical power consumption;
G the types of gas used and the relative supply pressures;
H the data of the burner's possible minimum and maximum
output (see Firing rate).
Warning:. The burner output must be within the boiler's fir-
ing rate;
I the category of the appliance/countries of destination.
4 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
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
A B
CD
E F
G
I I I I I I I I
G
I
H
H
Fig. 9
20186063

20194185 16
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Installation
4.4 Operating position
4.5 Preparing the boiler
4.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
Tab. E
4.5.2 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 door com-
plete with its fettling.
The range of lengths available, L, is as follows:
Tab. F
For boilers with front flue passes 15) or flame inversion chamber,
a protection in refractory material 13) must be inserted between
the boiler fettling 14) and the blast tube 12).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 13)-
14)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
4.5.3 Securing the burner to the boiler
Separate the combustion head from the rest of the burner
(Fig. 12):
loosen the 4 screws 3) and remove the hood 1)
disengage the articulated coupling 7) from the graduated
sector 8)
remove the screws 2) from the two slide bars 5)
remove the two screws 4) and pull the burner back on the
slide bars 5) by about 100 mm.
disconnect the electrode cables, then completely unthread
the burner from the slide bars.
WARNING
The burner is designed to work only in posi-
tions 1, 2, 3 and 4 (Fig. 10).
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.
Fig. 10
2 3 4 51
D7739
mm D1 DF 
RS 68 BLU 195 275-325 M12
RS 120 BLU 195 275-325 M12
mm RS 68 BLU RS 120 BLU
Standard 255 255
Long 390 390
Ø
45
45
DF
D1
Fig. 11
20149117
Provide an adequate lifting system.
WARNING
The seal between burner and boiler must be
airtight.
Fig. 12
D3031

17 20194185
GB
Installation
4.6 Access to head internal part
In order to reach inside the combustion head (Fig. 13) proceed as
follows:
remove the screw 1) and take out the internal part 2).
4.6.1 Combustion head calibration
At this point check, for model RS 120 BLU, whether the maximum
delivery of the burner in 2nd stage operation is contained in area
Aor in area Bof the firing rate.
See “Firing rates” on page 9.
– If it is in area A then no operation is required.
– If, on the other hand, it is in area B, before starting the burner
remove the 4 circular sectors 1)(Fig. 14) fastened behind the
stabilizing disc by removing the 8 screws 2)(Fig. 14).
4.7 Positioning the probe - electrode
If the probe or electrode is not correctly positioned, you must:
remove the screw 1)(Fig. 13);
take out the inner part 2)(Fig. 13) of the head, and then cali-
brate them.
Fig. 13
D1210
Fig. 14
1
2
D2382
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. 15.
WARNING
Do not rotate the probe: leave it as in Fig. 15 since
if it is located too close to the ignition electrode,
the control box amplifier may be damaged.
WARNING
Respect the dimensions shown in Fig. 15.
PROBE ELECTRODE
Fig. 15
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20194185 18
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Installation
4.8 Combustion head adjustment
Installation operations are now at the stage where the blast tube
and sleeve are secured to the boiler as shown in Fig. 16.
It is now a very simple matter to set up the combustion head, as
this depends solely on the MAX output developed by the burner.
It is therefore essential to establish this value before proceeding
to set up the combustion head.
There are two adjustments to make on the head:
• air delivery R1;
• gas delivery R2.
In diagram (Fig. 17) find the notch to use for adjusting the air and
the gas, and then proceed as follows:
Air adjustment
Turn screw 4)(Fig. 16) until the notch identified is aligned with the
front surface 5)(Fig. 16) of the flange.
NOTE:
in order to facilitate adjustment, loosen screw 6)(Fig. 16), ad-
just and then tighten.
Gas adjustment
Loosen the 3 screws 1)(Fig. 16) and turn ring 2)(Fig. 16) until the
notch identified is aligned with index 3)(Fig. 16).
Tighten the 3 screws 1)(Fig. 16) fully down.
Example:
RS 68 BLU, burner output = 500 kW.
If we consult diagram (Fig. 17) we find that for this output the ad-
justments are:
• air: R1 = notch 6;
• gas: R2 = notch 2.
NOTE:
Diagram (Fig. 17) indicates an optimal regulation for a type
of boiler seen in “Commercial boilers” on page 10.
If the pressure of gas allows it, by closing ring nut 2)(Fig. 16) a
reduction of the formation of NOx is obtained.
Continuing with the previous example, paragraph “Gas pressure”
on page 20 indicates that for burner RS 68 BLU with output of
500 kW a pressure of approximately 5.0 mbar is necessary at test
point 6)(Fig. 16). If this pressure cannot be reached, open the
ring 2)(Fig. 16) to notch 4 or 5.
Make sure that the combustion characteristics are satisfactory
and free of pulsations.
WARNING
The adjustments indicated can be modified during
the initial start-up.
Fig. 16
D1256
Fig. 17
No. notches
Burner output in 2nd stage
D2381