Riello RLS 120/E FGR Quick start guide

20168262 (3) - 01/2020
Installation, use and maintenance instructions
Dual fuel light oil/gas burner
Modulating operation
CODE MODEL
20166921 RLS 120/E FGR
GB

Translation of the original instructions

1 20168262
GB
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 Background ................................................................................................................................................................. 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 ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rate .................................................................................................................................................................. 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Commercial boilers.................................................................................................................................................... 11
4.10 Burner equipment...................................................................................................................................................... 11
4.11 Burner description ..................................................................................................................................................... 12
4.12 Control box for controlling the air/fuel ratio (BT340).................................................................................................. 13
4.13 Operation sequence of the burner (GAS operation).................................................................................................. 14
4.14 Operation sequence of the burner (LIGHT OIL operation)........................................................................................ 15
4.15 Servomotor (662R5...)............................................................................................................................................... 16
4.16 Calibration of the thermal relay ................................................................................................................................. 16
5 Installation ................................................................................................................................................................................ 17
5.1 Notes on safety for the installation ............................................................................................................................ 17
5.2 Handling .................................................................................................................................................................... 17
5.3 Preliminary checks .................................................................................................................................................... 17
5.4 Operating position ..................................................................................................................................................... 18
5.5 Preparing the boiler ................................................................................................................................................... 18
5.5.1 Boring the boiler plate ............................................................................................................................................... 18
5.5.2 Blast tube length........................................................................................................................................................ 18
5.6 Positioning electrode and pilot .................................................................................................................................. 19
5.6.1 Electrodes adjustment............................................................................................................................................... 19
5.6.2 Pilot operation parameters ........................................................................................................................................ 19
5.7 Securing the burner to the boiler............................................................................................................................... 20
5.8 Nozzle ....................................................................................................................................................................... 21
5.8.1 Recommended nozzles............................................................................................................................................. 21
5.8.2 Nozzle installation ..................................................................................................................................................... 21
5.8.3 Removing the nozzles ............................................................................................................................................... 22
5.9 Combustion head adjustment.................................................................................................................................... 22
5.10 Electrodes adjustment............................................................................................................................................... 22
5.11 Flue gases recirculation piping system ..................................................................................................................... 23
5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 24
5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 24
5.12 Closing the burner ..................................................................................................................................................... 24
5.13 Light oil supply........................................................................................................................................................... 25
5.13.1 Double-pipe circuit..................................................................................................................................................... 25
5.13.2 The loop circuit.......................................................................................................................................................... 25
5.13.3 Hydraulic connections ............................................................................................................................................... 25
5.13.4 Hydraulic circuit diagram ........................................................................................................................................... 26
5.13.5 Pump ......................................................................................................................................................................... 27
5.13.6 Priming pump ............................................................................................................................................................ 27
5.13.7 Pump motor rotation.................................................................................................................................................. 27
5.14 Gas supply ................................................................................................................................................................ 28
5.14.1 Gas feeding line ........................................................................................................................................................ 28

20168262 2
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Contents
5.14.2 Gas pressure .............................................................................................................................................................29
5.15 Electrical connections ................................................................................................................................................30
5.15.1 Supply cables and external connections passage .....................................................................................................30
6 Start-up, calibration and operation of the burner ..................................................................................................................31
6.1 Notes on safety for the first start-up...........................................................................................................................31
6.2 Adjustments prior to ignition (light oil) ........................................................................................................................31
6.2.1 Nozzle ........................................................................................................................................................................31
6.2.2 Combustion head.......................................................................................................................................................31
6.2.3 Pump pressure...........................................................................................................................................................31
6.2.4 Fan damper................................................................................................................................................................31
6.3 Operations before start-up (gas)................................................................................................................................31
6.4 Burner start-up ...........................................................................................................................................................32
6.5 Change of fuel............................................................................................................................................................32
6.6 Burner adjustment......................................................................................................................................................33
6.6.1 Gas/air delivery adjustment .......................................................................................................................................33
6.6.2 Light oil/air delivery adjustment..................................................................................................................................33
6.7 Final calibration of the pressure switches ..................................................................................................................33
6.7.1 Air pressure switch.....................................................................................................................................................33
6.7.2 Maximum gas pressure switch...................................................................................................................................34
6.7.3 Minimum gas pressure switch....................................................................................................................................34
6.7.4 PVP pressure switch kit .............................................................................................................................................34
6.7.5 Minimum oil pressure switch......................................................................................................................................34
6.7.6 Maximum oil pressure switch.....................................................................................................................................34
6.8 Start-up the flue gases recirculation system ..............................................................................................................35
6.9 Steady state operation ...............................................................................................................................................35
6.10 Ignition failure.............................................................................................................................................................35
6.11 Burner flame goes out during operation.....................................................................................................................36
6.12 Stopping of the burner ...............................................................................................................................................36
6.13 Final checks (with burner operating)..........................................................................................................................36
7 Maintenance ..............................................................................................................................................................................37
7.1 Notes on safety for the maintenance .........................................................................................................................37
7.2 Maintenance programme ...........................................................................................................................................37
7.2.1 Maintenance frequency..............................................................................................................................................37
7.2.2 Safety test - with gas feeding closed .........................................................................................................................37
7.2.3 Checking and cleaning...............................................................................................................................................37
7.2.4 Safety components ....................................................................................................................................................38
7.2.5 Checking the air and gas pressure on the combustion head.....................................................................................39
7.3 Opening the burner ....................................................................................................................................................40
7.4 Closing the burner......................................................................................................................................................40
8 Faults - Possible causes - Solutions.......................................................................................................................................41
8.1 List of error codes ......................................................................................................................................................41
A Appendix - Accessories ...........................................................................................................................................................46
B Appendix - Electrical panel layout...........................................................................................................................................47

3 20168262
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Dual fuel light oil / gas burner
Model: RLS 120/E FGR
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Quality is ensured by means of an ISO 9001:2015 certified quality and management system.
Legnago, 21.04.2018 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini

20168262 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
 is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance 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.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNINGWARNING
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.
DANGERDANGER
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.

5 20168262
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Information and general warnings
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
 The instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
 The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
 The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the 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.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNINGWARNING
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.

20168262 6
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Safety and prevention
3.1 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.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
 undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
 undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties.
 Personnel must observe all the danger and caution indica-
tions shown on the machine.
 Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
 Personnel must inform their superiors of every problem or
dangerous situation that may arise.
 The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNINGWARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
 must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
 the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
 personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20168262
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Designation Voltage Start-up Code
RLS 120/E FGR FS1 TC 3/400/50 Direct 20166921
Class 2 EN267 - Class 3 EN676
Range: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
RLS 120 ETC
Emission: C11 or... Class 1 EN267 - EN676
C22 or MZ Class 2 EN267 - EN676
C33 or BLU Class 3 EN267 - EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
FGR
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
SV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Long head
C23 or MX
C13 Class 1 EN267 - Class 3 EN676
EVi Electronic cam with integrated Inverter
FGR: Flue gases recirculation

20168262 8
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Technical description of the burner
4.3 Burner categories - Countries of destination
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1,013 mbar - Altitude 0 m a.s.l.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum 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 described in
EN ISO 3746.
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L - I2E - I2 (43.46 - 45.3 MJ/m3(0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E
Model RLS 120/E FGR FS1
Power (1)
Delivery (1)
min - max kW
kg/h
300/600 - 1200
25/50 - 101
Fuels Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5°E - 6 cSt)
Natural gas: G20 (methane gas)
Operation – Intermittent (min. 1 stop in 24 hours)
– Oil / Gas: modulating with kit
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Room temperature °C 0 - 40
Combustion air temperature °C max 60
Pump output (at 12 bar)
pressure range
fuel temperature
kg/h
bar
°C max
230
10 - 21
90
Noise levels (2) Sound pressure
Sound power dB (A) 85 96
Weight kg 100
WARNINGWARNING
To reduce the NOx of the nitric oxides in the event
of an FGR system, the maximum burner output
obtained chases based on the specific application
and within the limits agreed upon with the Riello
Technical Office.

9 20168262
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Technical description of the burner
4.5 Electrical data
Tab. D
4.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the slide
bars.
The dimensions of the open burner are indicated by position I.
Tab. E
Model RLS 120/E FGR FS1
Main electrical supply 3~ 400V - 50Hz +/-10%
Auxiliary circuit electrical supply 1N ~ 230V - 50Hz
Fan motor rpm
V
Hz
W
A
2890
380/415
50
2200
4.5
Pump motor rpm
V
Hz
W
A
2700
230
50
550
3.6
Ignition transformer V1 - V2
I1 - I2
230 V - 2 x 5 kV
1.9 A - 35 mA
Max. Absorbed electric power
main electrical supply
– light oil
–gas W2550
2550
Max. Absorbed electric power
auxiliary circuit electrical supply
– light oil
–gas W500
1300
Protection level IP 44
H
L
M
F
O
E
I
C
A
B
D
F1
S
NG
G1
Fig. 1
20169315
mm ABCDE F F1 GG1H I L M N O S
RLS 120/E FGR 886 330 556 640 950 245 192 189 218 425 1482 239 143 284 2” DN65

20168262 10
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Technical description of the burner
4.7 Firing rate
The maximum output should be chosen within area A)(Fig. 2) of
the diagram.
The minimum output must not be lower than the minimum limit
of the diagram.
4.8 Test boiler
The firing rates were established in special test boilers, according
to EN 676 regulations.
In Fig. 3 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 756 kW (650 Mcal/h): diameter 60 cm, length 2 m.
WARNINGWARNING
The firing rate was obtained at an ambient tem-
perature of 20°C and an atmospheric pressure of
1000 mbar (approx. 100 m above sea level), and
with the combustion head adjusted as shown on
page 22.
WARNINGWARNING
For the operation inside the area B)(Fig. 2)
remove the gas nozzle as shown (“Removing
the nozzles” on page 22).
A
9
-1
1
3
5
7
11
mbar
12
10
8
6
4
2
0
10496877971
62
54
4637
29
2112
kg/h
kW
100
1000 1100 1200 1300500 600 700 900
200
300 400 800
BA
Heat output
Fig. 2
Pressure in combustion chamber mbar
20094439
Fig. 3
D715
Length of combustion chamber
m

11 20168262
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Technical description of the burner
4.9 Commercial boilers
The burner is suitable for operating on both flame inversion boil-
ers (*), as well as on boilers with a combustion chamber with run-
off from the bottom (three flue passes) on which the best results
for low NOxemissions are obtained.
The boiler front door maximum thickness must not exceed 250
mm (Fig. 4).
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of (Fig. 3)
preliminary checks are recommended.
(*) For flame inversion boilers, a kit is available to reduce the CO,
if necessary.
4.10 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Slide bar extensions (TL version). . . . . . . . . . . . . . . . . . . . No. 4
Gasket for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M10x40 screws to fix the gas flange . . . . . . . . . . . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M12x35 to fix the burner flange
to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Fittings for hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 4
250 mm MAX
D1079

20168262 12
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Technical description of the burner
4.11 Burner description
1 Combustion head
2 Ignition electrode for pilot
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling
6 Gas servomotor
7 Flame sensor
8 Motor contact maker and thermal relay with reset button
9 “OFF/ON” (0-1) selector
10 Terminal board for electrical wiring
11 Operator panel with LCD display
12 Control box for checking flame and air/fuel ratio
13 K5 relay
14 Suppressor
15 Flame inspection window
16 GAS ignition transformer
17 Cable grommets for electrical wiring (to be carried out by the
installer)
18 Air servomotor
19 Air pressure switch (differential type)
20 Guides for opening the burner and inspecting the combus-
tion head
21 Gas pressure test point and head fixing screw
22 Air pressure socket
23 Pilot
24 Air damper
25 Fan air inlet
26 Screws to secure fan to pipe coupling
27 Gas input pipe
28 Gas butterfly valve
29 Boiler fixing flange
30 Flame stability disc
31 Connector G1/4
32 Lifting rings
33 Flue gas recirculation butterfly valve
34 Flue gas recirculation servomotor
35 Pilot gas train
36 Flue gas temperature probe
37 K1 relay
38 K2 relay
39 K3 relay
40 Minimum oil pressure switch
41 OIL ignition transformer
42 OIL ignition electrodes
43 “OIL-EXT-GAS” selector
44 Nozzle return pressure gauge
45 Nozzle delivery pressure gauge
46 Maximum oil pressure switch
47 Oil modulator
48 Pump motor
49 Pump
50 Safety valve
51 Operation valve
52 Return valve (VR)
53 Guides extensions
54 Fan motor
55 Auxiliary terminal board
56 Auxiliary circuit fuse
57 LCM100 module
58 DFM300 module
59 Pump motor relay (KMP)
13
9
43
17 24 48 34 25 31 33 50
51
49
45
36
18
46
52
41
47
44
15
26
22
29
30135
21
20
12
11
42
23
2
4
7
28
6
27
35
54 16 19 810
32
41
37
38
39
40
55
56
53
57
58
14
59
Fig. 5
Seen from “A”
A
20169319

13 20168262
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Technical description of the burner
4.12 Control box for controlling the air/fuel ratio (BT340)
Warning
For the safety and reliability of the control box, comply also with
the following instructions.
After commissioning and after each maintenance interven-
tion, check the combustion gases values in the overall per-
formance control!
All activities (assembly, installation, assistance) should only
be carried out by qualified specialist personnel
Before carrying out work in the connection area, disconnect
the power supply voltage of the system at all the poles.
Secure it, then, from depression and make sure there is no
voltage. if the system has not been deactivated there is a
risk of an electrical shock.
Ensure the BT340 is protected from electrical contact and all
the electric components through the assembly. The cover
should meet EN 60730 standards concerning the implemen-
tation, stability and protection.
After carrying out all the activities (assembly, installation,
assistance etc.) check the wiring and the parametrisation
making sure they are in a good state.
If the appliances fall or are jolted, do not restart them. The
safety functions might be compromised even without any
noticeable damage on the outside.
When programming the configuration curves, the regulator
constantly checks the quality of the system's combustion (for
example using a station for analysing the combustion
gases). If the combustion values are unsatisfactory or in the
event of dangerous conditions, the regulator adopts suitable
measures, like for example manually disarming the system.
These instructions describe numerous possible applications
and should be used as guidelines. Please always check and
corroborate the fact the system is operating correctly by
means of functional tests on the test bench when the system
is operating! Comply with the additional instructions to
ensure the BT340 is safe and reliable.
Avoid the penetration of dew and humidity. If necessary,
before starting the system, make sure it is dry!
Avoid static charges. On contact they destroy the appli-
ance's electrical components.
Technical data
Tab. F
WARNINGWARNING
To avoid accidents, material and/or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
The operators must be aware that the incorrect
setting of the visualisation and operation control
box, and of the positions of the fuel and/or air ac-
tuators, can cause dangerous conditions during
burner operation.
Model BT340
Electrical power 230 V +10/-15 % 50-60 Hz
Input power max. 30 VA
Cable length
- control load
-external
reset button
- fuel valve
- other lines
Max. 20 m
Max. 20 m
Max. 10 m
Max. 20 m
Weight 1 kg
Environmental operating conditions:
- climatic condition
- mechanical condition
- temperature interval
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electrical safety IP40 (housing)
IP20 (terminals)
Fig. 6
20127488

20168262 14
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Technical description of the burner
4.13 Operation sequence of the burner (GAS operation)
Key to layout (Fig. 7)
Tab. G
Key to layout (Fig. 7)
FGR FGR enabling
X01 Gas valve 1
X02 Gas valve 2
X03 Pilot valve
X04 Ignition transformer
X05 Gas pressure > min.
X06 Gas safety circuit
X07 Boiler safety circuit
X08 Air pressure switch
X10 Burner on
X20+X21 Flame signal
X24 Lockout
X25 Fan on
X32 Air servomotor
X33 Fuel servomotor
X34 FGR servomotor
Fig. 7
X07
X06
X10
X05
X08
X20+X21
FGR
X32
X33
X34
X04
X03
X01
X02
X25
X24
S9612
Any position
t1 Safety circuits enabling standby time
(boiler and fuel)
t2 Gas valve opening time (with valve leak
detection control device active)
2.4 s
t3 Servomotor opening time 30/60 s
t4 FGR servomotor activation time 0 - t5
t5 Pre-purging time adjustable
t6 Pre-ignition time adjustable
t7 Flame ignition safety time 3s
t8 Flame stabilisation time adjustable
t9’ 2nd stage safety time 3s
t10 Modulation phase
t11 Adjustment time
t12 Gas valve opening time (with valve leak
detection control device active)
3s
t13 Post-purging time adjustable
t15 post-combustion time adjustable
t16 Flame switching off control time 5 s
t17 Gas valve control time (with valve leak
detection control device active)
30s

15 20168262
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Technical description of the burner
4.14 Operation sequence of the burner (LIGHT OIL operation)
Key to layout (Fig. 8)
Tab. H
Key to layout (Fig. 8)
X01 Oil valve 1st level
X02 Oil valve 2nd level
X03 Oil valve 3rd level
X04 Ignition transformer
X05 Oil pressure > min.
X06 Oil safety circuit
X07 Boiler safety circuit
X08 Air pressure switch
X10 Burner on
X20+X21 Flame signal
X25 Fan on
X26 Oil pump
X32 Air servomotor
X33 Fuel servomotor
X34 FGR servomotor (disabled)
Fig. 8
X07
X06
X10
X08
X20+X21
X32+X33
X34
X4
X03
X01
X02
X25
S9782
CPI/POC
X26
X05
CPI= Closed Position Indicator
POC= Proof Of Closure
(3)
Oil irrelevance time P323, has an effect on the oil safety chain and on the minimum oil pressure when the air valve is opened.
Any position
t1 Safety circuits enabling standby time
(boiler and fuel)
t2 Gas valve opening time (with valve leak
detection control device active)
2.4 s
t3 Servomotor opening time 30/60 s
t4 FGR servomotor activation time 0 - t5
t5 Pre-purging time adjustable
t6 Pre-ignition time adjustable
t7 Flame ignition safety time 3s
t8 Flame stabilisation time adjustable
t9’ 2nd stage safety time 3s
t10 Modulation phase
t11 Adjustment time
t12 Gas valve opening time (with valve leak
detection control device active)
3s
t13 Post-purging time adjustable
t15 post-combustion time adjustable
t16 Flame switching off control time 5 s
t17 Gas valve control time (with valve leak
detection control device active)
30s

20168262 16
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Technical description of the burner
4.15 Servomotor (662R5...)
Warning
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring of the servomotor in the connec-
tion area, 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.
After every intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order, then
make the safety checks.
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.
Installation notes
The static torque is reduced when the electrical supply of the
actuator is switched off.
Technical data
Tab. I
4.16 Calibration of the thermal relay
The thermal relay serves to avoid damage to the motor due to an
excessive absorption increase or if a phase is missing.
For calibration 2), see the table in the wiring diagram.
To reset, in case of an intervention of the thermal relay, press the
"RESET" button 1) of Fig. 10. The red “TEST” button 3) opens the
NC (95-96) contact and stops the motor.
WARNINGWARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Do not open, modify or force the actuators.
WARNINGWARNING
Assembly notes
The connection between the actuator command
shaft and the control element must be rigid, with-
out any mechanical play.
WARNINGWARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
WARNINGWARNING
Condensation, the formation of ice and the entry
of water are prohibited!
Model 662R5...
Adjustment time 5 sec / 90°
Rotation direction from
0° towards 90° left - view from motor shaft
Rated torque (max.) 3 Nm
Static torque (max.) 3 Nm
Weight approx. 1.4 kg
Type of protection IP54 according to DIN EN 60529-1
Environmental operating conditions:
- climatic condition
- mechanical condition
- temperature interval
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electrical safety Protection class 2
according to DIN EN 60730
D8271 Fig. 9
CAUTION
The automatic reset (Position “A” button 1) can be
dangerous. This operation is not anticipated in the
burner's operation, leave it always on “H”. There-
fore do not position the “RESET” button 1) on
“A”.
Fig. 10
3
1
2
RESET
HA
TEST
95 96 97 98
20073932

17 20168262
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Installation
5.1 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.
5.2 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.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
 the model (A) and type of burner (B);
 the year of manufacture, in cryptographic form (C);
 the serial number (D);
 the data for electrical supply and the protection level (E);
 the absorbed electrical power (F);
 the types of gas used and the relative supply pressures (G);
 the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate)
Warning. The output of the burner must be within the
boiler's firing rate;
 the category of the appliance/countries of destination (I).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the mains
electricity supply disconnected.
WARNINGWARNING
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.
WARNINGWARNING
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.
WARNINGWARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
Fig. 11
D7738
R. B. L.
GAS- KAASU
GAZ- AEPI O
0085
RI ELLO S. p. A.
I- 37045 Legnago (VR)
CE
ABC
EDF
HG
GH
I

20168262 18
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 13.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
5.5.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling.
The available lengths L are those indicated in the table below.
Tab. J
For boilers with a front flue gas passes 13)(Fig. 15 on page 19)
or flame inversion chamber, a protection device in refractory ma-
terial 11) must be inserted between the boiler fettling 12) and the
blast tube 10).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled frontal, a refractory lining is not
necessary 11)-12) unless expressly requested by the boiler man-
ufacturer.
Tab. K
WARNINGWARNING
 The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 12).
 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. 12
2 3 4 51
D7739
Blast tube (mm) Short
RLS 120/E FGR 245
mm ABC
RLS 120/E FGR 230 325-368 M 16
Fig. 13
D455