Riello RS 1000/EV BLU Quick start guide

Installation, use and maintenance instructions
20123781 (1) - 02/2017
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20116496 RS 1000/EV BLU 1133 T2
20116498 RS 1200/EV BLU 1134 T2
GB

Translation of the original instructions

1 20123781
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual.................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Technical data............................................................................................................................................................. 8
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Burner categories - Countries of destination............................................................................................................... 9
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rates ................................................................................................................................................................ 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description..................................................................................................................................................... 11
4.10 Electrical panel description........................................................................................................................................ 12
4.11 Burner equipment...................................................................................................................................................... 12
4.12 Air/fuel ratio control box (ETAMATIC OEM).............................................................................................................. 13
4.13 Display....................................................................................................................................................................... 15
4.14 Flame sensor FFS 06................................................................................................................................................ 15
4.15 Servomotors.............................................................................................................................................................. 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 Removing the shutter lockout screws........................................................................................................................ 18
5.6 Preparing the boiler................................................................................................................................................... 18
5.6.1 Boring the boiler plate ............................................................................................................................................... 18
5.6.2 Blast tube length........................................................................................................................................................ 18
5.7 Securing the burner to the boiler............................................................................................................................... 19
5.8 Access to head internal part...................................................................................................................................... 19
5.9 Electrodes adjustment............................................................................................................................................... 20
5.10 Combustion head adjustment.................................................................................................................................... 20
5.11 Gas feeding............................................................................................................................................................... 21
5.11.1 Gas feeding line ........................................................................................................................................................ 21
5.11.2 Gas train.................................................................................................................................................................... 22
5.11.3 Gas train installation.................................................................................................................................................. 22
5.11.4 Gas pressure............................................................................................................................................................. 22
5.12 Electrical wiring ......................................................................................................................................................... 24
5.12.1 Supply cables and external connections passage .................................................................................................... 24
5.12.2 Shielding the connections ......................................................................................................................................... 25
5.12.3 Motor rotation............................................................................................................................................................ 25
6 Start-up, calibration and operation of the burner ................................................................................................................. 26
6.1 Notes on safety for the first start-up.......................................................................................................................... 26
6.2 Adjustments prior to ignition...................................................................................................................................... 26
6.2.1 Rpm sensor............................................................................................................................................................... 26
6.3 Burner start-up .......................................................................................................................................................... 27
6.4 Burner ignition........................................................................................................................................................... 28
6.5 Combustion air adjustment........................................................................................................................................ 28

20123781 2
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Contents
6.5.1 Air / gas adjustment and output modulation...............................................................................................................28
6.6 Pressure switch adjustment.......................................................................................................................................29
6.6.1 Air pressure switch - check CO..................................................................................................................................29
6.6.2 Maximum gas pressure switch...................................................................................................................................29
6.6.3 Minimum gas pressure switch....................................................................................................................................29
6.6.4 PVP pressure switch kit .............................................................................................................................................29
6.7 Final checks (with burner operating)..........................................................................................................................30
7 Maintenance ..............................................................................................................................................................................31
7.1 Notes on safety for the maintenance.........................................................................................................................31
7.2 Maintenance programme...........................................................................................................................................31
7.2.1 Maintenance frequency..............................................................................................................................................31
7.2.2 Checking and cleaning...............................................................................................................................................31
7.2.3 Positioning the rpm sensor ........................................................................................................................................32
7.3 Opening the burner....................................................................................................................................................32
7.4 Closing the burner......................................................................................................................................................32
8 Faults - Probable causes - Solutions......................................................................................................................................33
A Appendix - Accessories ...........................................................................................................................................................34
B Appendix - Electrical panel layout...........................................................................................................................................36

3 20123781
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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: Forced draught gas burners
Model: RS 1000/EV BLU
RS 1200/EV BLU
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm-
SchV revision 26.01.2010”.
Product Type Model Output
Forced draught gas burners 1133 T2 RS 1000/EV BLU 1100 - 10100 kW
1134 T2 RS 1200/EV BLU 1500 - 11100 kW
Legnago, 01.12.2015 General Manager
RIELLO S.p.A. - Burners Department Research and Development Director RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini
RS 1000/E BLU CE-0085CN0119 Class 3 (EN 676)
RS 1200/E BLU CE-0085CN0120 Class 3 (EN 676)

20123781 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.
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 is present. An explosive atmosphere is
defined as a mixture of dangerous substances
with air, under atmospheric conditions, in the form
of gases, vapours, mist or dust in which, after ig-
nition 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.
MOUNT CASING
This symbol indicates that it is mandatory to
mount casing again after maintenance, cleaning
or checks.
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 20123781
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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 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.

20123781 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 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, 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 20123781
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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
RS 1000/EV BLU TC 3/400/50 Direct/Inverter 20116496
RS 1200/EV BLU TC 3/400/50 Direct/Inverter 20116498
Range: R
Grandezza
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
R S 1000 SV TC
Emission: C01 or... Class 1 EN676
BLU or BLU Class 3 EN676
FS2 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
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
C02 or MZ Class 2 EN676
WARNING
The burners are certified according to the EMC
European Directive (2014/30 / EU) for operation in
industrial environments. Operation in residential
applications is not permitted.

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Technical description of the burner
4.3 Technical data
Tab. B
(1) Reference conditions: ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure on the socket 5) (Fig. 4) 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 “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
4.4 Electrical data
Tab. C
Model RS 1000/EV BLU RS 1200/EV BLU
Type 1133 T2 1134 T2
Power(1)
Output (1) min - max kW 1100/4000 - 10100 1500/5500 - 11100
Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2) -
Gas: G20/G25 mbar 64.5/92.7 80.5/114
Operation - Intermittent (min. 1 stop in 24 hours) - Continuous (min. 1 stop in 72 hours)
- Modulating
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 85 99 89.3 99.7
Weight Kg 460 500
Model RS 1000/EV BLU RS 1200/EV BLU
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
Hz
V
kW
A
2880
50
400/690
22
38,2/22,3
2880
50
400/690
25
43,4/25,1
Ignition transformer V1 - V2
I1 - I2 230 V - 2 x 5 kV 1.9 A - 35 mA
Absorbed electrical power kW max 24 27.2
Protection level IP 55

9 20123781
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Technical description of the burner
4.5 Burner categories - Countries of destination
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
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
Fig. 1
20061119
mm ABCDEFGH I LR
RS 1000/EV BLU 1637 669 200 413 885 DN80 1206 1338 485 1493 1350
RS 1200/EV BLU 1637 670 200 456 885 DN80 1250 1338 485 1493 1350

20123781 10
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Technical description of the burner
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the continuous
diagram area (Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RS 1000/EV BLU = 4000 kW
RS 1200/EV BLU = 5500 kW
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 7000 kW - diameter 120 cm - length 6 m
MODULATING RATIO
The modulating ratio, obtained in test boilers in accordance with
standard EN 676, is 7:1.
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1,013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 20.
1000 1800 2600 3400 4200 5000 5800 6600 7400 8200 9000 10600
0
2
4
6
8
10
12
14
16
18
20
22
24
26
9800 11400 12200
Pressure in
combustion chamber - mbar
Thermal power – kW Fig. 2
RS 1200/EV BLURS 1000/EV BLU
D11991
Fig. 3
Combustion chamber
m
D2448

11 20123781
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Technical description of the burner
4.9 Burner description
1 Lifting rings
2 Impeller
3Fanmotor
4 Air damper servomotor
5 Electrode
6 Combustion head
7 Combustion head gas pressure test point
8 Flame stability disc
9 Electrical panel casing
10 Hinge for opening the burner
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas regulator
15 Shutter
16 Combustion head movement lever
17 Air damper movement lever
18 Minimum air pressure switch (differential operating type)
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 Flame sensor
22 Pressure test point for air pressure switch “+”
23 Gas butterfly valve servomotor
24 Screws to lock the shutter during transportation (replace
them with the M12x25 screws supplied as standard)
11
12
4
913 515 8
23 14
1
17
10
24
19 24 16 20 721
6
2
3
25
18
19
11
5
Fig. 4
20122016
CAUTION
The burner can be opened to the right or to the left
without links to the fuel supply side.
When the burner is closed, the hinge can be refit-
ted on the opposite side.

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Technical description of the burner
4.10 Electrical panel description
1 Clean contact relay
2 Electronic control box
3 Ignition transformer
4 Stop push-button
5 Off-automatic selector
6 Display
7 Light signalling of mains live state
8 Fan motor lockout warning lamp
9 Light signalling burner lockout
10 Rpm sensor terminal board
11 Selectors for Service
12 Flame sensor plug/sensor socket
13 Main terminal supply board
14 Air pressure switch
15 Supply cables, external connections and kits
16 Auxiliary circuits fuse
17 Air servomotor plug/socket
18 Air servomotor plug/socket
19 Filter
NOTE
Two types of burner failure may occur:
Control box lockout: switching on of button 13)(Fig. 5) (red
led) signals that the burner is in lockout. Release by press-
ing the push-button on the display 6)(Fig. 5).
Motor lockout: see inverter manual
4.11 Burner equipment
Gasket for gas train flange. . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M12x25 screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
M16x70 screws to fix the gas flange . . . . . . . . . . . . . . . . . No. 8
M20x70 screws to fix the burner flange
to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Pressure switch (for leak detection control). . . . . . . . . . . . . . . .1
Cable grommets kit for optional electrical wiring input. . . . No. 1
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
14
13 10 4569781
2
3
16
19 11
15
12
17
18
Fig. 5
20122512

13 20123781
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Technical description of the burner
4.12 Air/fuel ratio control box (ETAMATIC OEM)
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation). Check the system is not powered
and cannot be accidentally reconnected. Failure to do this
will lead to the risk of electrocution.
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
After every intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then perform the safety
checks.
Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
For the safety and reliability of the control box, comply with the
following instructions:
- avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
- Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Electrical wiring of the flame detectors
It is important for signal transmission to be almost totally free of
any disturbances or loss:
Always separate the detector cables from the other cables:
- Line capacitance reduces the magnitude of the flame sig-
nal.
- Use a separate cable.
Observe the allowed cable lengths.
Key (Fig. 7)
F1 Control box
F2 Adjustment components
F3 Main valve GAS1
F4 Main valve GAS2
F5 Ignitiontransformer, fan, ignition valve, fault message
F6 24VDC
S1 9-pole Sub-D connector for LAMTEC -SYSTEM-BUS
S2 Communications interface
WARNING
To avoid accidents, material 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.
Fig. 6
S8836
F2
F1
F4
F6
F5
24
1
59
35
60
25
68
4AF
2AT
315 mAmT
1,2 AT
2AT
F3
2AT
34
S1 S2
S8842 Fig. 7

20123781 14
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Technical description of the burner
Mechanical structure
- The control box manages up to 4 adjustment components
based on a command value, according to the freely program-
mable curves.
- The control box has 4 three-point command outputs.
- The control box has 3 three-point command outputs and one
4-20 mA output.
- The control box has a 25-pole Sub-D connector with serial in-
terface for the control and remote display via PC (Windows
software provided separately).
- Connections for Interbus-S, Profibus-DP CANopen, TCP/IP
(Modbus TCP) and Modbus available as an option.
- Other BUS systems available on request.
- The connection of other system components, e.g. Fault warn-
ing system, O adjustment, is performed via the LAMTEC bus
interface system with a D-sub 9-pole connector.
- The control box constantly monitors their functions and those
of the adjustment components connected.
Installation notes
- Check that the electrical wiring inside the boiler complies with
the national and local safety regulations.
- The live and neutral must not be switched.
- Make certain that strain relief of the connected cables is in
compliance with the relevant standards (e.g. DIN EN 60730
and DIN EN 60335).
- Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
- Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
- The burner manufacturer must protect unused AC 230V ter-
minals with dummy plugs (refer to sections Suppliers of other
accessory items).
- When wiring the unit, make sure that AC 230V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
Technical data
Tab. F
Control box Mains voltage From 115V -15 % to 230V +10 %
Mains frequency 50/60 Hz ±6 %
Power absorption approx. 50 VA
Load on
‘input’ terminals Unit fuse (internal) F1 4A F2 315mA
F3 2AT
F4 2AT
F5 2AT
F6 1.2AT
Primary perm. mains fuse (external) Max. 6 AT
In- and Outputs Mains voltage
14 digital inputs 24V
16 digital outputs 230V
1 analogue output (ETAMATIC)
3 analogue inputs - all powered
AC 230V -15 % / +10 %
Load on a single contact:
Fan motor contact maker(nominal voltage)
• Nominal current
• Power factor 1A
cos> 0.8-1
Ignition transformer (nominal voltage)
• Nominal current
• Power factor 1A
cos> 0.2
Gas valve (nominal voltage)
• Nominal current
• Power factor 1A
cos> 0.4
Fault signal
• Signal contact of a fault condition max. 0,5 A, cos= 0.8...1
Oil valve (nominal voltage)
• Nominal current
• Power factor 1A
cos> 0.4
Cable lengths Main line Max. 100 m
Ambient tempera-
ture Operation Transport/Storage
Permissible ambient humidity
+0 C … +60 C
-25 C … +60 C
Class F, DIN 40040
Weight Approx. 2.3 kg
Protection level According to DIN 40 050 - IP40

15 20123781
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Technical description of the burner
4.13 Display
Technical data
Customer interface (Fig. 8)
Meaning of the buttons
4.14 Flame sensor FFS 06
Installation and operation of the flame sensor
Install the flame sensor (Fig. 9) with its assembly bracket to the
opening of the burner, so that the flame of the burner can be mon-
itored and visible during the burner ignition phase.
The min. threshold value for the IR flame sensor is 15 mV and 25
mV for the UV flame sensor. Additional information on installation
are included in the technical documentation of the flame monitor-
ing devices.
The flame sensor must be connected according to the colour cod-
ing of the monitoring device used, respectively from the allocation
of the ETAMATIC terminals (Fig. 10).
The connection cable has an additional measuring wire (pink) that
can be used to measure the signal voltage via a hand-held digital
multimeter (according to EN 61010, input impedance >5 M).
The voltage is measured between the earth potential (blue wire)
and the additional measurement wire (pink wire) of the connec-
tion cable to determine an optimum flame detection.
Power Supply 24V DC
Max. output consumption 24W
Fig. 8
S8843
Reset
Load / faults report up
Load / faults report down
Manual mode On / Off
Display switching
– Compound
– O2
– Flame intensity
– Operating time
WARNING
The UV flame sensors do not have the ability to
adjust the sensitivity of the sensor.
To obtain the optimum angle of incidence for
flame monitoring, the signal voltage must be
measured at its maximum.
Fig. 9
S8838
Fig. 10
B
L
YE
WH
GN
RD
PK
BU
S8839

20123781 16
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Technical description of the burner
4.15 Servomotors
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the connection area of the
servomotor, fully disconnect the burner control device from
the power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit must not be operated, even if it
displays no evident damage.
Assembly notes
Check the relevant national safety standards are respected.
The connection between the actuator command shaft and
the control element must be rigid, without any mechanical
play.
To avoid an excessive load on the bearings due to rigid
hubs, the use of compensation clutches without any
mechanical play is recommended (e.g. metal bellows-type
clutches).
Installation notes
Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
To prevent the risk of electrocution, check that the 230 VAC
section of the servomotor is completely separated from the
low voltage section.
The static torque is reduced when the electrical supply of the
actuator is switched off.
The housing cover may only be removed for short periods of
time for wiring or when making the addressing. In similar
cases, make sure that dust or dirt does not penetrate inside
the actuator.
The top side of the board carries a cover which affords pro-
tection against direct contact. This protective cover must not
be removed! The underside side of the board must not be
touched.
Technical data
Tab. G
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actuators.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
Model 662R2111 662R2127
Operating voltage 230V - 50Hz via the connection cable to
the base unit
Safety class Extra low-voltage with safe isolation
from mains voltage
Power absorption 6.45 VA 3 VA
Protection level EN 60 529, IP 54
with adequate cable grommets
Cable connection with terminals
Rotation direction - Anticlockwise (standard)
- Clockwise (inverted rotation)
Nominal torque (max) 20 Nm 6 Nm
Holding torque (max) 20 Nm 6 Nm
Operation time (min.)
for 90° 60 s.
Weight approx. 1.7 kg
Environmental conditions:
Operation
Temp. range
Humidity
DIN EN 60 721-3-3
-20...+60°C
< 95% RH
S8837 Fig. 11

17 20123781
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, 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 (Fig. 12), showing:
A the burner model
B the burner type
C the cryptographic year of manufacture
D the serial number
E the data for electrical supply and the protection level
F the electrical power consumption
G the types of gas used and the relative supply pressures
H the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
I the category of the appliance/countries of destination.
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; they should be collected and
disposed of in the appropriate places.
WARNING
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult
R.B.L.
GAS- KAASU
GAZ-AEPIO X
RIELLOS.p.A.
I-37045 Legnago(VR)
A
DEBC
F
I
G H
G H
Fig. 12
D10411

20123781 18
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Installation
5.4 Operating position
5.5 Removing the shutter lockout screws
5.6 Preparing the boiler
5.6.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber,as in Fig.15.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
5.6.2 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 doorcom-
plete with its fettling.
For boilers with a front flue gas passes 1)(Fig. 16) or flame inver-
sion chamber, a protection device in refractory material 5) must
be inserted between the boiler fettling 2) and the blast tube 4).
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. 16) is not necessary, unless expressly requested by the
boiler manufacturer.
Tab. H
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 13).
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.
2 3 4 51
20062309
Fig. 13
WARNING
Remove the screws 1)-2) and nuts before fitting
the burner onto the boiler (Fig. 14).
Replace them with screws 3) M12x25 supplied as
standard.
Fig. 14
20061924
mm ABC
RS 1000/EV BLU 460 608 M 20
RS 1200/EV BLU 500 608 M 20
Fig. 15
D455