Riello 835 T80 Quick start guide

Installation, use and maintenance instructions
Instrucciones de Instalación, Funcionamiento y Mantenimiento
Instruções de Instalação, Funcionamento e Manutenção
Forced draught gas burners
Quemadores de gas
Queimadores a gás
2916014 (9) - 09/2013
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3785820 RS 190 835 T80
20011699 RS 190 835 T80
GB
E
P
Progressive two-stage operation
Funcionamiento a dos llamas progresivas
Funcionamento a duas chamas progressivas

1
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustments before firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner calibration: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 - Firing output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 - 2nd stage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 - 1st stage output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 - Intermediates outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 - Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 - Minimum gas pressure switch. . . . . . . . . . . . . . . . . . . . . . . . 15
Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 18
Resetting the control box and using diagnostics. . . . . . . . . . . 18
Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 19
Normal operation / flame detection time. . . . . . . . . . . . . . . . . . . 20
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
N.B.
Figures mentioned in the text are identified as follows:
1)(A) =part 1 of figure A, same page as text;
1)(A)p.3 =part 1 of figure A, page number 3.
GB

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m s.l.m.
(2) Pressure at test point 17)(A)p.3, with zero pressure in the combustion chambre, with open gas ring 2)(B)p.7 an maximum burner output
(3) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.
ELECTRICAL DATA
Motor IE1
Motor IE2
GAS CATEGORY VARIANTS
MODEL RS 190
CODE 3785820 20011699
OUTPUT (1) 2nd stage kW
Mcal/h
1279 - 2290
1100 - 1970
min. 1st stage kW
Mcal/h
470
405
FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25
G20 G25
- net calorific value kWh/Sm3
Mcal/Sm3
9.45
8.2
8.13
7.0
- absolute density kg/Sm30.71 0.78
- max. delivery Sm3/h 230 267
- pressure at max. delivery mbar 15 22
OPERATION • On-Off (1 stop min each 24 hours).
• Two-stage (high and low flame) and single stage (all - nothing)
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATUR °C 0 - 40
COMBUSTION AIR TEMPERATURE °C max 60
IN CONFORMITY WITH EEC DIRECTIVES 2004/108 - 2006/95 - 2006/42
NOISE LEVELS (2) dBA 83.1
MODEL RS 190
ELECTRICAL SUPPLY V
Hz
380 ~ +/-10%
60 - three-phase
220 ~ +/-10%
60 - three-phase
AUXILIARY CIRCUITS SUPPLY V 220
ELECTRIC MOTOR rpm
W
V
3430
4000
380
3430
4000
220
Running current A 9.1 15.8
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
ELECTRICAL POWER CONSUMPTION W max 5500
ELECTRICAL PROTECTION IP 44
MODEL RS 190
ELECTRICAL SUPPLY V
Hz
380 ~ +/-10%
60 - three-phase
220 ~ +/-10%
60 - three-phase
AUXILIARY CIRCUITS SUPPLY V 220
ELECTRIC MOTOR rpm
W
V
3540
4000
220-380
3540
4000
220
Running current A 13.8 / 8 13.8 / 8
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
ELECTRICAL POWER CONSUMPTION W max 5000
ELECTRICAL PROTECTION IP 44
COUNTRY CATEGORY
IT - AT - GR - DK - FI - SE
ES - GB - IE - PT
NL
FR
DE
BE
LU - PL
II2H3B / P
II2H3P
II2L3B / P
II2Er3P
II2ELL3B /P
I2E(R)B, I3P
II2E 3B/P
Model Code Power supply
electrical
RS 190 3785820 380 V
RS 190 20011699 220 V

3
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4Sleeve
5 Servomotor controlling the gas butterfly
valve and of air gate valve (by means of a
variable profile cam mechanism).
When the burner is stopped the air gate
valve will be completely closed to reduce
heat loss due to the flue draught, which
tends to draw air from the fan air inlet.
6 Plug-socket on ionisation probe cable
7 Extension for slide bars 16)
8 Motor contactor and thermal cut-out reset
button
9 Flame stability disk
10 Terminal strip
11 Fairleads for electrical connections by installer
12 Two switches:
- one “burner off-on”
- one for “1st - 2nd stage operation”
13 Control box with lock-out pilot light and lock-
out reset button
14 Flame inspection window
15 Minimum air pressure switch
(differential operating type)
16 Slide bars for opening the burner and
inspecting the combustion head
17 Gas pressure test point and head fixing screw
18 Air pressure test point
19 Flame sensor probe
20 Air gate valve
21 Air inlet to fan
22 Screws securing fan to sleeve
23 Gas input pipework
24 Gas butterfly valve
25 Boiler mounting flange
Two types of burner failure may occur:
•Control box lock-out: if the control box
13)(A) pushbutton (red led) lights up, it indi-
cates that the burner is in lock-out.
To reset, hold the pushbutton down for
between 1 and 3 seconds.
•Motor trip: release by pressing the pushbut-
ton on thermal cutout 8)(A).
PACKAGING - WEIGHT (B)
Approximate measurements
• The burner stands on a wooden base which
can be lifted by fork-lifts.
Outer dimensions of packaging are indicated
in (B).
• The weight of the burner complete with pack-
aging is indicated in Table (B).
MAX. DIMENSIONS (C)
Approximate measurements
The maximum dimensions of the burner are
given in (C).
Bear in mind that inspection of the combustion
head requires the burner to be opened by with-
drawing the rear part on the slide bars.
The maximum dimension of the burner when
open is give by measurement I.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
6 - Flange fixing screws M 10 x 30
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the
boiler: M 12 x 35
1 - Instruction booklet
1 - Spare parts list
(A)
(B)
(C)
D7861
D36
D731
mm A B C kg
RS 190 1250 725 785 82
mm ABCDEFGH I LMN O
RS 190 681 366 315 555 872 372 222 430 1328 246 150 186 2”

4
FIRING RATES (A)
The RS 190 model burner can work in two way:
one-stage and two-stage.
MAXIMUM OUTPUT must be selected in area
A.
MINIMUM OUTPUT must not be lower than the
minimum limit shown in the diagram.
RS 190 = 470 kW
Important
The FIRING RATE area values have been ob-
tained considering a surrounding temperature of
20 °C, and an atmospheric pressure of 1013
mbar (approx. 0 m above sea level) and with the
combustion head adjusted as shown on page 7.
TEST BOILER (B)
The firing rates were set in relation to special
test boilers, according to EN 676 regulations.
Figure (B) indicates the diameter and length of
the test combustion chamber.
Example:
Output 756 kW:
diameter = 60 cm; length = 2 m.
COMMERCIAL BOILERS
The burner/boiler combination does not pose
any problems if the boiler is CE type-approved
and its combustion chamber dimensions are
similar to those indicated in diagram (B).
If the burner must be combined with a commer-
cial boiler that has not been CE type-approved
and/or its combustion chamber dimensions are
clearly smaller than those indicated in diagram
(B), consult the manufacturer.
(A)
(B) D715
D1262
RS 190
pressure mbar
Combustion chamber
length m
Combustion chamber

5
GAS PRESSURE
The adjacent table shows minimum pressure
losses along the gas supply line depending on
the burner output in 2nd stage operation.
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0 mbar
• Burner operating in 2nd stage
• Combustion head adjusted as indicated in
diagram (C)p. 7.
Column 2
Pressure loss at gas butterfly valve 2)(B) with
maximum opening: 90°.
Column 3
Pressure loss of gas train 3)(B) includes: adjust-
ment valve VR, safety valve VS (both fully
open), pressure governor R, filter F.
The values shown in the table refer to:
natural gas G 20 NCV 9.45 kWh/Sm3
(8,2 Mcal/Sm3)
With:
natural gas G 25 NCV 8,13 kWh/Sm3
(7,0 Mcal/Sm3) multiply tabulated values:
- column 1 - 2: by 1.5
- column 3: by 1.35.
Calculate the approximate 2nd stage output of
the burner thus:
- Subtract the combustion chamber pressure
from the gas pressure measured at test point
1)(B).
- Find the nearest pressure value to your result
in column 1 of the table (A).
- Read off the corresponding output on the left.
Example:
• 2nd stage operation
• Natural gas G 20 NCV 9.45 kWh/Sm3
• Gas pressure at test point 1)(B) = 11 mbar
• Pressure in combustion chamber = 3 mbar
11 - 3= 8 mbar
A 2nd stage output of 1600 kW shown in Table
(A) corresponds to 8 mbar pressure, column 1.
This value serves as a rough guide, the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B), set the output required from the
burner in 2nd stage operation:
- Find the nearest output value in the table (A).
- Read off the pressure at test point 1)(B) on
the right in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
Example:
• Required burner output in 2nd stage opera-
tion: 1600 kW
• Natural gas G 20 NCV 9.45 kWh/Sm3
• Gas pressure at burner output of 1600 kW,
taken from table (A), column 1 = 8 mbar
• Pressure in combustion chamber = 3 mbar
8 + 3 = 11 mbar
pressure required at test point 1)(B).
(A)
RS 190 p (mbar)
kW 1 2
3
3970181
3970182
3970221
3970225
3970222
3970226
3970223
3970227
1280 7.0 1.3 28.6 10.3 7.2 4.8
1400 7.3 1.6 33.5 12.1 8.2 5.2
1500 7.6 1.8 37.7 13.6 9.0 5.5
1600 8.0 2.1 41.8 15.2 9.9 5.8
1700 8.7 2.4 46.0 16.7 10.7 6.1
1800 9.3 2.7 50.2 18.2 11.6 6.5
1900 10.2 3.0 54.3 19.8 12.5 6.8
2000 11.3 3.3 59.3 21.6 13.6 7.3
2100 12.5 3.6 64.4 23.5 14.8 7.7
2290 15.0 4.3 74.1 27.1 17.0 8.6
(B)
D3734
MB 420
MBC 1200
MBC 1900
MBC 3100

6
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling. The length avail-
able, L (mm), is 372 mm.
For boilers with front flue passes 15) or flame
inversion chambers, protective fettling in refrac-
tory 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 having a water-cooled front the
refractory fettling 13)-14)(B) is not required
unless it is expressly requested by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER
(B)
Before securing the burner to the boiler, check
through the blast tube opening to make sure
that the flame sensor probe and the ignition
electrode are correctly set in position, as shown
in (C).
Now detach the combustion head from the
burner, fig.(B):
- Loosen the 4 screws 3) and remove the cover 1)
- Disengage the articulated coupling 7) from
the graduated sector 8).
- Remove the screws 2) from the slide bars 5).
- Remove the two screws 4) and pull the burner
back on slide bars 5) by about 100 mm.
Disconnect the wires from the probe and the
electrode and then pull the burner completely
off the slide bars.
Secure the flange 11)(B) to the boiler plate, inter-
posing the thermal insulating screen 9)(B) sup-
plied with the burner. Use the 4 screws, also
supplied with the unit, after first protecting the
thread with an anti-locking product.
The seal between burner and boiler must be air-
tight.
If you noticed any irregularities in positions of
the probe or ignition electrode during the check
mentioned above, remove screw 1)(D), extract
the internal part 2)(D) of the head and proceed
to set up the two components correctly.
Do not attempt to turn the probe. Leave it in the
position shown in (C) since if it is located too
close to the ignition electrode the control box
amplifier may be damaged.
(A)
(B)
(C)
(D)
PROBE ELECTRODE
D455
D3036
D1265
D1266
mm A B C
RS 190 230 325-368 M 16

7
SETTING THE COMBUSTION HEAD
Installation operations are now at the stage
where the blast tube and sleeve are secured to
the boiler as shown in fig. (B). It is now a very
simple matter to set up the combustion head, as
this depends solely on the output developed by
the burner in 2nd stage operation.
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 adjustment (B) See diagram (C).
Turn screw 4)(B) until the notch identified is
aligned with the front surface 5)(B) of the flange.
Gas adjustment (A)
When the burner is installed for an output in 2nd
stage 1300 Mcal/h (about 1500 kW) assemble
the supplied disks 1)-2)(A) removing the inner
pipe 3)(A). If there is little gas in the network, the
head may be left in standard configuration, limit-
ing the minimum modulation to 450 Mcal/h
(circa 520 kW).
Example
Burner output = 1593 kW (1370 Mcal/h).
If we consult diagram (C) we find that for this
output, air must be adjusted using notch 3, as
shown in fig. (B).
Continuing with the previous example, page 5
indicates that for burner with output of 1593 kW
(1370 Mcal/h) a pressure of approximately 8
mbar is necessary at test point 6)(B).
Once you have finished setting up the head, refit
the burner to the slide bars 3)(D) at approxi-
mately 100 mm from the sleeve 4)(D) - burner
positioned as shown in fig. (B)p. 6 - insert the
flame detection probe cable and the ignition
electrode cable and then slide the burner up to
the sleeve so that it is positioned as shown in
fig. (D).
Refit screws 2) on slide bars 3).
Secure the burner to the sleeve by tightening
screw 1).
Reconnect the articulation 7) to the graduated
sector 6).
Important
When fitting the burner on the two slide bars, it
is advisable to gently draw out the high tension
cable and flame detection probe cable until they
are slightly stretched.
(A)
(C)
(B)
(D)
Burner output in 2nd stage operation
Nr. Notches
D1267
D1268
D3037

8
GAS LINE
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient.
• Gas valves must be as close as possible to the
burner to ensure gas reaches the combustion
head within the safety time range of 3 s.
• Make sure that the pressure governor calibra-
tion range (colour of the spring) comprises the
pressure required by the burner.
GAS TRAIN (A)
It is type-approved according to EN 676 Stand-
ards and is supplied separately from the burner
with the code indicated in Table (B).
KEY (A)
1 - Gas input pipe
2 - Manual valve
3 - Vibration damping joint
4 - Pressure gauge with pushbutton cock
5 - Filter
6A - Threaded” Multibloc including:
- filter (replaceable)
- functioning valve
- pressure governor
6B - Flanged” Multibloc including:
- safety valve
- functioning valve
- pressure governor
7 - Minimum gas pressure switch
8 - Gas valve leak detection control device.
In accordance with EN 676 Standards,
gas valve leak detection control devices
are compulsory for burners with maximum
outputs of more than 1200 kW.
9 - Gasket
10 - Standard issue burner gasket
11 - Gas adjustment butterfly valve
12 - Maximum gas pressure switch
13 - Gas train/burner adaptor
- supplied with burner
- supplied on requested separately with the
gas ramp for flanged versions
P1 - Pressure at combustion head
P2 - Up-line pressure valve/adjuster
P3 - Pressure up-line from the filter
L - Gas train supplied separately with the code
indicated in Table (B)
L1 - The responsibility of the installer
KEY TO TABLE (B)
C.T.= Gas valves leak detection control devic-
es:
- = Gas train without gas valve leak de-
tection control device; device that can
be ordered separately and assem-
bled subsequently (see column 8).
= Gas train with assembled VPS valve
leak detection control device.
8 = VPS valve leak detection control de-
vice.
Supplied separately from gas train on
request.
13 = Gas train/burner adaptor.
Supplied separately from gas train on
request.
Note
See the accompanying instructions for the ad-
justment of the gas train.
(B)
P2
56B
8
8
6A
P2
P1
P1
13
12
10
12
10
123
4
7
9
123
4
7
13
11
11
L1 L
L1 L
P3
BURNERS AND RELEVANT GAS TRAINS APPROVED ACCORDING TO EN 676
GAS TRAINS - L 8 13
Code Model Ø C.T. Code Code
3970181 MBD 420 2” - 3010123 -
3970182 MBD 420 CT 2” --
3970221 MBC-1200-SE-50 2” - 3010123 -
3970225 MBC-1200-SE-50 CT 2” --
3970222 MBC-1900-SE-65 FC DN 65 - 3010123 3000825
3970226 MBC-1900-SE-65 FC CT DN 65 - 3000825
3970223 MBC-3100-SE-80 FC DN 80 - 3010123 3000826
3970227 MBC-3100-SE-80 FC CT DN 80 - 3000826
(A) D3735