Riello RLS 810/E FGR Quick start guide

Installation, use and maintenance instructions
20171988 (1) - 12/2019
Dual fuel gas oil/ gas burner
Modulating operation
CODE MODEL
20170200 RLS 810/E FGR
GB

Original instructions

1 20171988
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 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 8
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 rates ................................................................................................................................................................ 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description ..................................................................................................................................................... 11
4.10 Burner equipment...................................................................................................................................................... 11
4.11 Electrical panel description........................................................................................................................................ 12
4.12 Control box for the air/fuel ratio (BT340) ................................................................................................................... 13
4.13 Burner operating sequence (GAS OPERATION)...................................................................................................... 14
4.14 Burner operating sequence (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 Securing the burner to the boiler............................................................................................................................... 18
5.7 Access to head internal part...................................................................................................................................... 19
5.8 Position of the electrodes and central gas nozzles ................................................................................................... 20
5.9 FGR duct system....................................................................................................................................................... 21
5.9.1 Flue gas recirculation line sizing ............................................................................................................................... 22
5.9.2 Calculating the percentage of recirculated flue gas .................................................................................................. 22
5.10 Combustion head adjustment.................................................................................................................................... 22
5.11 Nozzle installation ..................................................................................................................................................... 23
5.11.1 Recommended nozzle............................................................................................................................................... 23
5.12 Light oil supply........................................................................................................................................................... 24
5.12.1 Double-pipe circuit..................................................................................................................................................... 24
5.12.2 The loop circuit.......................................................................................................................................................... 24
5.12.3 Hydraulic connections ............................................................................................................................................... 24
5.12.4 Priming pump ............................................................................................................................................................ 25
5.12.5 Pressure variator ....................................................................................................................................................... 25
5.12.6 Hydraulic circuit diagram ........................................................................................................................................... 26

20171988 2
GB
Contents
5.13 Gas pressures............................................................................................................................................................27
5.13.1 Gas feeding line .........................................................................................................................................................27
5.13.2 Gas train ....................................................................................................................................................................28
5.13.3 Gas train installation ..................................................................................................................................................28
5.13.4 Gas pressure .............................................................................................................................................................29
5.14 Electrical wiring ..........................................................................................................................................................30
5.14.1 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
6.3 Burner ignition (light oil) .............................................................................................................................................31
6.3.1 Burner adjustment (light oil) .......................................................................................................................................31
6.4 Adjustments prior to ignition (gas) .............................................................................................................................32
6.5 Burner start-up (gas)..................................................................................................................................................32
6.6 Burner ignition............................................................................................................................................................32
6.7 Change of fuel............................................................................................................................................................32
6.8 Air / fuel adjustment ...................................................................................................................................................33
6.8.1 Air adjustment for maximum output ...........................................................................................................................33
6.8.2 Air/fuel adjustment and output modulation system ....................................................................................................33
6.8.3 Burner adjustment......................................................................................................................................................33
6.8.4 Output upon ignition...................................................................................................................................................33
6.8.5 Maximum output ........................................................................................................................................................33
6.9 Final adjustment of the pressure switches.................................................................................................................34
6.9.1 Air pressure switch.....................................................................................................................................................34
6.10 Pressure switch adjustment .......................................................................................................................................35
6.10.1 Maximum gas pressure switch...................................................................................................................................35
6.10.2 Minimum gas pressure switch....................................................................................................................................35
6.10.3 PVP pressure switch kit .............................................................................................................................................35
6.10.4 Minimum oil pressure switch......................................................................................................................................35
6.10.5 Maximum oil pressure switch .....................................................................................................................................35
6.11 Operation ...................................................................................................................................................................36
6.12 Ignition failure.............................................................................................................................................................36
6.13 Burner flame goes out during operation.....................................................................................................................36
6.14 Stopping of the burner ...............................................................................................................................................36
6.15 Final checks ...............................................................................................................................................................36
6.16 Fan motor and pump motor lockout ...........................................................................................................................37
7 Maintenance ..............................................................................................................................................................................38
7.1 Notes on safety for the maintenance .........................................................................................................................38
7.2 Maintenance programme ...........................................................................................................................................38
7.2.1 Maintenance frequency..............................................................................................................................................38
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................38
7.2.3 Checking and cleaning...............................................................................................................................................38
7.2.4 Safety components ....................................................................................................................................................39
7.3 Opening the burner ....................................................................................................................................................40
7.4 Closing the burner......................................................................................................................................................40
7.4.1 Checking the air and gas pressure on the combustion head.....................................................................................40
8 Faults - Possible causes - Solutions.......................................................................................................................................41
8.1 List of fault code.........................................................................................................................................................41
A Appendix - Accessories ...........................................................................................................................................................45
B Appendix - Electrical panel layout...........................................................................................................................................46

3 20171988
GB
Declarations
Declaration of Conformity in accordance with ISO / IEC 17050-1
These products are in compliance with the following Technical Standards:
• EN 12100
•EN676
•EN267
According to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
1 Declarations

20171988 4
GB
Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere 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 20171988
GB
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 equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
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.

20171988 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, 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:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20171988
GB
Technical description of the burner
4.1 Burner designation
4 Technical description of the burner
Range: R
Size
Fuel: Natural gas
Gas oil
Gas oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous working (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 810 ETC FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Long head
Emission: C01 - ...
C02 - MZ
C03 - BLU
C03 - MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
FGR: Induced Flue Gas Recirculation
FGR

20171988 8
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Technical description of the burner
4.2 Models available
Tab. A
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 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point of the pressure switch 6)(Fig. 4 on page 11) with zero pressure in the combustion chamber and at maximum burner
output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3”, as described by EN ISO
3746”.
(4) Not intended for operation with induced smoke recirculation (FGR).
Designation Voltage Start-up Code
RLS 810/E FGR 3/400/50 Star/Triangle 20170200
Gas category Destination country
I2H SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO
I2ELL DE
I2E - I2(43,46 ÷ 45,3 MJ/m3(0°C)) NL
I2Er FR
I2E(R)B BE
I2E LU - PL
Model RLS 810/E FGR
Power(1)
Delivery (1)
min - max kW
Kg/h
1080 ÷ 5400
140 ÷ 424
Fuels Natural gas: G20 (methane gas)
Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5°E - 6 cSt) (4)
Gas pressure at max. output (2)
Gas: G20 mbar 43.0
Operation FS1: Intermittent (min. 1 stop in 24 hours)
Pump
Minimum output at 16.5 bar
Pressure range
kg/h
bar
TA 5
1270
7/30
Fuel temperature °c max 140
Nozzles number 1
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise level (3)
Sound pressure
Sound power
dB(A) 90
104.6
WARNING
In order to reduce the nitrogen oxides NOx in case
of FGR system, the maximum burner capacity ob-
tained, changes within the limits agreed with the
Riello Technical Dept. for the specific application.

9 20171988
GB
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 turned on the hinge.
The maximum dimensions of the open burner are indicated by
the L and R positions.
The l position is reference for the refractory thickness of the boiler
door.
Tab. E
STAR - TRIANGLE START UP
Model RLS 810/E FGR
Main electrical supply 3N~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2960
400/690
22
37.6 - 21.7
Pump motor IE3
rpm
V
kW
A
2890
220 - 380
1.5
5.9 - 3.4
Absorbed electrical power
Gas
Light oil
kW max 22.8
24.4
A
R
I
TP
E
S
C
N
D
F
R1
L
G M
A
R
R2
Fig. 1
20172264
mm A C D E F* G I L M N P R R1 R2 S T
RLS 810/E FGR 1200 173 363 585 DN80 629 405 1442 813 260 1360 1055 DN150 1240 453 580
WARNING
*The gas adaptor is set also for DN 80 bore.

20171988 10
GB
Technical description of the burner
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the diagram area
(Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
Tab. F
NOTE:
OIL OPERATION: max 5 kW for smoke index <1.
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the manufac-
turer.
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 5000 kW - diameter 100 cm - length 5 m
RLS 810/E FGR GAS 1080 kW
OIL 1650 kW
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 22.
Pressure in
combustion head - mbar
Thermal power – kW
Fig. 2
20176363
20057548 Fig. 3
Combustion chamber
m

11 20171988
GB
Technical description of the burner
4.9 Burner description
1 Cover for electrical panel
2 Maximum oil pressure switch
3 Delivery pressure gauge
4 Minimum oil pressure switch
5 Lifting rings
6 Pressure test point for air pressure switch "+"
7 Lever for combustion head movement
8 Air pressure test point for combustion head
9 Combustion head
10 Ignition electrode
11 Shutter
12 Flame stability disc
13 Ignition pilot (gas operation)
14 Return pressure gauge
15 Oil modulator
16 Gas inlet flange
17 Flame inspector window
18 Maximum gas pressure switch
19 Protection
20 Fan air inlet
21 Pump motor
22 Flue gas servomotor
23 Valve group
24 Protection for viewing port
25 Reset button
26 Ignition pilot valve
27 Flame stability disk
28 Ignition electrodes (oil operation)
29 Gas butterfly valve
30 Pump
31 Flue gas entrance flange
32 Flue gas temperature probe
33 Gasket for boiler fixing
34 Gas pressure test point for combustion head
35 Air pressure test point for combustion head
36 Hinge for opening the burner
37 Flame sensor
38 Air pressure switch
39 Fan Motor
40 Fan
41 Air damper servomotor
42 Gas butterfly valve and oil modulator servomotor
4.10 Burner equipment
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
M 12 x 16 replacement screws to secure the combustion head. . No. 2
M18 x 70 screws to secure the burner to the boiler . . . . . . No. 4
18 washer to secure the burner to the boiler . . . . . . . . . No. 4
M16 x 67 stud bolts to fix the gas elbow to the
pipe coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 8
M16 nuts to fix the gas elbow to the pipe coupling. . . . . . . No. 8
16 washer to secure the gas flange . . . . . . . . . . . . . . . . No. 8
Pressure kit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flexibles pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Unioon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
26 27
28
29
30
31
32
34 35 36 37
39
40
42 41
38
33
55
167
9
8
10 11
12
13
15
16
1718
19
20
21
22
4
23
14
23
24
25
Fig. 4
ASSEMBLY VIEW
20172297
The burner can be opened to the right or to the left
without links to the fuel supply side.
WARNING
To open the burner see section “Access to head
internal part” on page 19.

20171988 12
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Technical description of the burner
4.11 Electrical panel description
1 Electrical control box
2 ON/OFF selector
3 Output power regulator module (LCM100)
4 Earth terminal
5 Supply cables and external connections passage. See sec-
tion “Electrical wiring” on page 30
6 Fuel management module (DFM300)
7 Main terminal supply board
8 Relay with clean contacts for signalling the burner is in lock-
out and that the burner is operating
9 Available
10 Auxiliary circuits fuse (includes a spare fuse)
11 Air pressure switch
12 Ignition transformer (oil operation)
13 Valve group terminal board
14 Operator panel with LCD display
15 Ignition transformer (gas operation)
16 Auxiliary contracts
17 Thermal relay (with RESET button)
18 Pump motor thermal relay (with RESET button)
19 Pump motor contact maker
20 Change of fuel selector
21 Fan motor cables sheath
22 Flame sensor sheath
23 Fuel servomotor cable
24 Maximum gas pressure switch sheath
25 Air servomotor sheath
26 Safety valve sheath (VS1)
27 Return line valve sheath (VR)
28 Working valve sheath (VF)
29 Safety valve sheath (VS)
30 Minimum oil pressure switch sheath
31 Maximum oil pressure switch sheath
32 Pump motor cables sheath
33 Fuel gases servomotor cable
34 Star-powered/delta -powered starter timer
35 Star/triangle starter line contactor
36 Starter/delta contactor (Star-powered/delta-powered)
37 Triangle contactor (Star-powered/delta-powered)
Fig. 5
20158207
VIEW FROM A
A
45
4
11
1
14
7
2
4
12
5
4
4
20
15
34
36
37
35
16
17
20175027

13 20171988
GB
Technical description of the burner
4.12 Control box for the air/fuel ratio (BT340)
Warnings
For the safety and reliability of the equipment, also follow these
guidelines.
After commissioning and after each maintenance action
check the exhaust gas values across the entire power
range!
Qualified specialist staff are required to carry out all activities
(assembly, installation, servicing, etc.).
Before working in the connection area, switch off the power
supply to the plant from all poles. Ensure that it cannot be
switched back on and that the plant is voltage-free. There is
a risk of electric shock when the plant is not switched off.
Place and secure the protection against contact on the
BT340 and on all connected electrical parts. The cover must
fulfil the design, stability and protection requirements of EN
60730.
After each activity (e.g. assembly, installation, servicing,
etc.) check wiring and parameters to make sure it is in good
working condition.
If the equipment is dropped or suffers impact, you should no
longer commission it. The safety functions may also be
impaired but fail to show any obvious external damage.
When the ratio curves are being programmed, the adjuster
will continually monitor the quality of the plant's combustion
(e.g. using an exhaust gas analysis station). In the event that
the combustion values are inadequate or the conditions are
potentially harmful, the adjuster will take suitable action, e.g.
switch off the system manually.
These operating instructions describe many possible appli-
cations and functions and should be used as guidelines.
Carry out functional tests on the test bench and/or in the
plant application to ensure correct functioning and document
the results.
Condensation and humidity are to be avoided. If necessary,
make sure that the installation is sufficiently dry before you
switch it on.
Avoid static charge having a destructive effect in case of
touching the device's electronic components.
Technical data
Tab. G
WARNING
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
Mains voltage 230 V +10/-15 % 50-60 Hz
Power absorption max. 30 VA
Cables 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 conditions:
- Climatic conditions
- Mechanical conditions
- Temperature range
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electric safety IP40 (casing)
IP20 (terminals)
Fig. 6
20127488

20171988 14
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Technical description of the burner
4.13 Burner operating sequence (GAS OPERATION)
Key to layout (Fig. 7)
Tab. H
Key to layout (Fig. 7)
FGR FGR release
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 Fault
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 condition
t1 Waiting time for safety circuits consent
(boiler fuel)
t2 Opening time of the gas valve (with
sealing control active) 2.4 s
t3 Servomotor opening time 30/60 s
t4 Activation time FGR servomotor 0 - t5
t5 Pre-purge time adjustable
t6 Pre-ignition time adjustable
t7 Ignition flame safety time 3 s
t8 Flame stabilization time adjustable
t9’ Safety time 2nd stage 3 s
t10 Modulation phase
t11 Adjustment time
t12 Opening time of the gas valve (with
sealing control active)
3 s
t13 Post-purge time adjustable
t15 Post-combustion time adjustable
t16 Checking time for flame extinction 5 s
t17 Checking time for gas valve (with seal-
ing control active) 30 s

15 20171988
GB
Technical description of the burner
4.14 Burner operating sequence (LIGHT OIL OPERATION)
Key to layout (Fig. 8)
Tab. I
Key to layout (Fig. 8)
X01 1st meter oil valve
X02 2nd meter oil valve
X03 3th meter oil valve
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 (disable)
Fig. 8
X07
X06
X10
X08
X20+X21
X32+X34
X33
X4
X03
X01
X02
X25
S9782
CPI/POC
X26
X05
CPI= Close Position Indicator
POC= Prove 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 condition
t1 Waiting time for safety circuits consent
(boiler fuel)
t2 Opening time of the gas valve (with
sealing control active) 2.4 s
t3 Servomotor opening time 30/60 s
t4 Activation time FGR servomotor 0 - t5
t5 Pre-purge time adjustable
t6 Pre-ignition time adjustable
t7 Ignition flame safety time 3 s
t8 Flame stabilization time adjustable
t9’ Safety time 2nd stage 3 s
t10 Modulation phase
t11 Adjustment time
t12 Opening time of the gas valve (with
sealing control active)
3 s
t13 Post-purge time adjustable
t15 Post-combustion time adjustable
t16 Checking time for flame extinction 5 s
t17 Checking time for gas valve (with seal-
ing control active) 30 s

20171988 16
GB
Technical description of the burner
4.15 Servomotor (662R5...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the servomotor connection
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.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit 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. J
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)(Fig. 10). The red “TEST” button 3) opens the
NC (95-96) contact and stops the motor.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
WARNING
Assembly notes
The connection between the actuator command
shaft and the control element must be rigid, with-
out any mechanical play.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
WARNING
Avoid condensate, ice and water leaks from form-
ing!
Model 662R5...
Adjustment time 5 sec / 90°
Rotation direction from
0° to 90° left - by the motor shaft side
Nominal torque (max) 3 Nm
Holding torque (max) 3 Nm
Weight 1,4 kg circa
Degree of protection IP54 according to DIN EN 60529-1
Environmental conditions:
- climatic condition
- mechanical condition
- temperature range
Classe 3K5 (DIN EN 60721-3)
Classe 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electric 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 20171988
GB
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 burner packaging includes a wooden platform, it is therefore
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model (A)(Fig. 11) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the data for electrical supply and the protection level (E);
the absorbed electrical power (F);
the types of gas used and the relative supply pressures (G);
the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate).
Warning. The burner output must be within the boiler's firing
rate;
the category of the appliance/countries of destination (I).
5 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; but should be collected and
disposed of in the appropriate places.
WARNING
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS- KAASU
GAZ- AEPI O
X
RIELLOS.p .A.
I-37045 Legnago ( VR)
A
DE
BC
F
I
G H
G H
Fig. 11
D10411

20171988 18
GB
Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in Fig. 13.
The position of the threaded holes can be marked using the ther-
mal 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.
For boilers with front flue passes 1)(Fig. 14) or flame inversion
chamber, a protection in refractory material 5) must be inserted
between the boiler fettling 2) and the blast tube 4).
The refractory can have a conical shape (minimum 60°).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 2)-
5)(Fig. 14) is not necessary, unless expressly requested by the
boiler manufacturer.
Tab. K
5.6 Securing the burner to the boiler
Fit the heat insulation supplied onto the blast tube
4)(Fig. 14).
Fit the entire burner onto the boiler hole prepared previously
(Fig. 13), and fasten with the screws supplied.
WARNING
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
mm D1 DF Ø
RLS 810/E FGR 400 495 M18
Fig. 13
Ø
45
45
DF
D1
20149117
Prepare a suitable lifting system using rings
3)(Fig. 14).
WARNING
The seal between burner and boiler must be
airtight.
4
1
1
5
2
33
Fig. 14
20172388