Riello RS 190 Quick start guide

2916007 (14) - 01/2017
Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
Instruções de instalação, uso e manutenção
Forced draught gas burners
Quemadores de gas con aire soplado
Queimadores a gás com ar insuflado
Two-stage progressive operation
Funcionamiento a dos llamas progresivas
Funcionamento a duas chamas progressivas
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3785814 - 20011705 RS 190 835 T1
GB
E
P

Translation of the original instructions
Traducción de las instrucciones originales
Tradução das instruções originais

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

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m s.l.m.
(2) Pressure at test point 17)(A)p.3, with zero pressure in the combustion chambre, with open gas ring 2)(B)p.7 an maximum burner output
(3) Sound pressure measured in 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.
ELECTRICAL DATA
GAS CATEGORY
VARIANTS
MODEL RS 190
OUTPUT (1) 2nd stage kW
Mcal/h 1279 - 2290 1100 - 1970
min. 1st stage kW
Mcal/h 470 405
FUEL NATURAL GAS: G20 - G21 - G22 - G23 - G25
G20 G25
- pressure at max. delivery (2) mbar 15 22
OPERATION • On-Off (1 stop min each 24 hours).
• Two-stage (high and low flame) and single stage (all - nothing)
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATUR °C 0 - 40
COMBUSTION AIR TEMPERATURE °C max 60
IN CONFORMITY WITH DIRECTIVES 2009/142 - 2006/42 - 2014/35 - 2014/30
NOISE LEVELS (3) SOUND PRESSURE
SOUND POWER dB(A) 83,1 94,1
APPROVAL CE 0085AT0042
MODEL RS 190
ELECTRICAL SUPPLY V
Hz 400 with neutral ~ +/-10% 50 - three-phaes 230 with neutral ~ +/-10% 50 - three-phaes
ELECTRIC MOTOR IE2 rpm
W
V
2900
4500
400
2900
4500
230
Running current A 9,1 15,8
Start-up current A 81 141
IGNITION TRANSFORMER V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
ELECTRICAL POWER CONSUMPTION W max 5500
ELECTRICAL PROTECTION IP 44
COUNTRY CATEGORY
IT - AT - GR - DK - FI - SE
ES - GB - IE - PT
NL
FR
DE
BE
LU - PL
II2H3B / P
II2H3P
I2L - I2E - I2(43,46 ÷ 45,3 MJ/m3(0°C))
II2Er3P
II2ELL3B /P
I2E(R)B, I3P
II2E 3B/P
Model Code Power supply
electrical
RS 190 3785814 400 V
RS 190 20011705 230 V

3
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4Sleeve
5 Servomotor controlling the gas butterfly
valve and of air gate valve (by means of a
variable profile cam mechanism).
When the burner is stopped the air gate
valve will be completely closed to reduce
heat loss due to the flue draught, which
tends to draw air from the fan air inlet.
6 Plug-socket on ionisation probe cable
7 Extension for slide bars 16)
8 Motor contactor and thermal cut-out reset
button
9 Flame stability disk
10 Terminal strip
11 Fairleads for electrical connections by installer
12 Two switches:
- one “burner off-on”
- one for “1st - 2nd stage operation”
13 Control box with lock-out pilot light and lock-
out reset button
14 Flame inspection window
15 Minimum air pressure switch
(differential operating type)
16 Slide bars for opening the burner and
inspecting the combustion head
17 Gas pressure test point and head fixing screw
18 Air pressure test point
19 Flame sensor probe
20 Air gate valve
21 Air inlet to fan
22 Screws securing fan to sleeve
23 Gas input pipework
24 Gas butterfly valve
25 Boiler mounting flange
26 Socket for electrical connections
Two types of burner failure may occur:
•Control box lock-out: if the control box
13)(A) pushbutton (red led) lights up, it indi-
cates that the burner is in lock-out.
To reset, hold the pushbutton down for
between 1 and 3 seconds.
•Motor trip: release by pressing the pushbut-
ton on thermal cutout 8)(A).
PACKAGING - WEIGHT (B)
Approximate measurements
• The burner stands on a wooden base which
can be lifted by fork-lifts.
Outer dimensions of packaging are indicated
in (B).
• The weight of the burner complete with pack-
aging is indicated in Table (B).
MAX. DIMENSIONS (C)
Approximate measurements
The maximum dimensions of the burner are
given in (C).
Bear in mind that inspection of the combustion
head requires the burner to be opened by with-
drawing the rear part on the slide bars.
The maximum dimension of the burner when
open is give by measurement I.
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
6 - Flange fixing screws M 10 x 30
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the
boiler: M 12 x 35
3 - Plugs for electrical connections
1 - Instruction booklet
1 - Spare parts list
(A)
(B)
(C)
D36
D731
mm A B C kg
RS 190 1250 725 785 82
mm ABCDEFGH I LMN O
RS 190 681 366 315 555 872 372 222 430 1328 246 150 186 2”
D7860

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

5
GAS PRESSURE
The adjacent table shows minimum pressure
losses along the gas supply line depending on
the burner output in 2nd stage operation.
Column 1
Pressure loss at combustion head.
Gas pressure measured at test point 1)(B), with:
• Combustion chamber at 0 mbar
• Burner operating in 2nd stage
• Combustion head adjusted as indicated in
diagram (C)p. 7.
Column 2
Pressure loss at gas butterfly valve 2)(B) with
maximum opening: 90°.
The values shown in the various tables refer to:
– natural gas G 20 PCI 9,45 kWh/Sm3(8,2
Mcal/Sm3)
– natural gas G 25 PCI 8,13 kWh/Sm3(7,0
Mcal/Sm3)
Calculate the approximate 2nd stage output of
the burner thus:
- Subtract the combustion chamber pressure
from the gas pressure measured at test point
1)(B).
- Find the nearest pressure value to your result
in column 1 of the table (A).
- Read off the corresponding output on the left.
Example:
• 2nd stage operation
• Gas pressure at test point 1)(B) =12.9 mbar
• Pressure in combustion chamber = 3 mbar
12,9 - 3=9,9 mbar
A 2nd stage output of 1800 kW shown in Table
(A) corresponds to 9.9 mbar pressure, column
1.
This value serves as a rough guide, the effective
delivery must be measured at the gas meter.
To calculate the required gas pressure at test
point 1)(B), set the output required from the
burner in 2nd stage operation:
- Find the nearest output value in the table (A).
- Read off the pressure at test point 1)(B) on
the right in column 1.
- Add this value to the estimated pressure in
the combustion chamber.
Example:
• Required burner output in 2nd stage opera-
tion: 1800 kW
• Gas pressure at burner output of 1800 kW,
taken from table (A), column 1 =9.9 mbar
• Pressure in combustion chamber = 3 mbar
9.9 + 3 =12.9 mbar
pressure required at test point 1)(B).
(A)
(B)
kW 1 p (mbar) 2 p (mbar)
G 20 G 25 G 20 G 25
1280 9.6 14.3 1.3 2.0
1500 9.7 14.5 1.8 2.7
1800 9.9 14.8 2.7 4.0
2100 12.6 18.8 3.6 5.4
2290 14.9 22.2 4.3 6.4
S8883
1
2

6
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling. The length avail-
able, L (mm), is 372 mm.
For boilers with front flue passes 15) or flame
inversion chambers, protective fettling in refrac-
tory material 13) must be inserted between the
boiler fettling 14) and the blast tube 12).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the
refractory fettling 13)-14)(B) is not required
unless it is expressly requested by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER
(B)
Before securing the burner to the boiler, check
through the blast tube opening to make sure
that the flame sensor probe and the ignition
electrode are correctly set in position, as shown
in (C).
Now detach the combustion head from the
burner, fig.(B):
- Loosen the 4 screws 3) and remove the cover 1)
- Disengage the articulated coupling 7) from
the graduated sector 8).
- Remove the screws 2) from the slide bars 5).
- Remove the two screws 4) and pull the burner
back on slide bars 5) by about 100 mm.
Disconnect the wires from the probe and the
electrode and then pull the burner completely
off the slide bars.
Secure the flange 11)(B) to the boiler plate, inter-
posing the thermal insulating screen 9)(B) sup-
plied with the burner. Use the 4 screws, also
supplied with the unit, after first protecting the
thread with an anti-locking product.
The seal between burner and boiler must be air-
tight.
If you noticed any irregularities in positions of
the probe or ignition electrode during the check
mentioned above, remove screw 1)(D), extract
the internal part 2)(D) of the head and proceed
to set up the two components correctly.
Do not attempt to turn the probe. Leave it in the
position shown in (C) since if it is located too
close to the ignition electrode the control box
amplifier may be damaged.
(A)
(B)
(C)
(D)
D455
D3036
D1265
D1266
mm A B C
RS 190 230 325-368 M 16
PROBE ELECTRODE

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

8
GAS LINE
• The gas train must be connected to the gas
attachment 1)(A), using flange 2), gasket 3)
and screws 4) supplied with the burner.
• The gas train can enter the burner from the
right or left side, depending on which is the
most convenient, see fig.(A).
• Gas solenoids 8)-9)(B) must be as close as
possible to the burner to ensure gas reaches
the combustion head within the safety time
range of 3 s.
• Make sure that the pressure governor calibra-
tion range (colour of the spring) comprises the
pressure required by the burner.
GAS TRAIN (B)
Type-approved in accordance with EN 676 and
supplied separately from the burner.
To select the correct model of the gas train, refer
to the “burner-gas train combination” manual
supplied.
KEY (B)
1 Gas input pipe
2 Manual valve
3 Vibration damping joint
4 Pressure gauge with pushbutton cock
5Filter
6A Includes:
–Filter
– working valve
– safety valve
– pressure adjuster
6C Includes
– safety valve
– working valve
6D Includes:
– safety valve
– working valve
7 Minimum gas pressure switch
8 Leak detection device, supplied as an ac-
cessory or incorporated, based on the gas
train code. In compliance with the EN 676
standard, the leak detection control is com-
pulsory for burners with maximum outputs
over 1200 kW.
9 Gasket, for “flanged” versions only
10 Pressure adjuster
11 Train-burner adaptor, supplied separately
P2 Upstream pressure of valves/adjuster
P3 Upstream pressure of the filter
L Gas train supplied separately
L1 The responsibility of the installer
Note
See the accompanying instructions for the
adjustment of the gas train.
(A) D722
20057264
MB
20062223
MBC
20062227
DMV
20062228
CB
(B)