Riello RS 200/M BLU Quick start guide

Installation, use and maintenance instructions
20152093 (2) - 10/2020
Forced draught gas burner
Progressive two-stage or modulating operation
CODE MODEL TYPE
20145799 RS 200/M BLU 1106T
GB

Translation of the original instructions

1 20152093
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 5
2.1 Information about the instruction manual .................................................................................................................... 5
2.1.1 Introduction.................................................................................................................................................................. 5
2.1.2 General dangers.......................................................................................................................................................... 5
2.1.3 Other symbols ............................................................................................................................................................. 5
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 6
2.2 Guarantee and responsibility....................................................................................................................................... 6
3 Safety and prevention................................................................................................................................................................ 7
3.1 Introduction.................................................................................................................................................................. 7
3.2 Personnel training ....................................................................................................................................................... 7
4 Technical description of the burner ......................................................................................................................................... 8
4.1 Burner designation ...................................................................................................................................................... 8
4.2 Burner categories........................................................................................................................................................ 8
4.3 Models available.......................................................................................................................................................... 9
4.4 Technical data............................................................................................................................................................. 9
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions................................................................................................................................................ 10
4.7 Firing rates ................................................................................................................................................................ 10
4.7.1 Firing rate according to air density ............................................................................................................................ 11
4.8 Test boiler.................................................................................................................................................................. 12
4.9 Burner equipment...................................................................................................................................................... 12
4.10 Burner description ..................................................................................................................................................... 13
4.11 Electrical panel description........................................................................................................................................ 14
4.12 Control box RFG0-A22.............................................................................................................................................. 15
4.13 Servomotor (SQN31...).............................................................................................................................................. 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 Introduction................................................................................................................................................................ 18
5.5.2 Boring the boiler plate ............................................................................................................................................... 18
5.5.3 Blast tube length........................................................................................................................................................ 19
5.6 Positioning the probe - electrode............................................................................................................................... 19
5.7 Securing the burner to the boiler............................................................................................................................... 20
5.8 Combustion head pre-calibration .............................................................................................................................. 21
5.9 Combustion head adjustment.................................................................................................................................... 21
5.10 Closing the burner..................................................................................................................................................... 22
5.11 Gas supply ................................................................................................................................................................ 23
5.11.1 Gas feeding line ........................................................................................................................................................ 23
5.11.2 Gas train.................................................................................................................................................................... 24
5.11.3 Gas train installation.................................................................................................................................................. 24
5.11.4 Gas pressure............................................................................................................................................................. 24
5.12 Electrical connections................................................................................................................................................ 26
5.12.1 Supply cables and external connections passage .................................................................................................... 27
5.13 Calibration of the thermal relay ................................................................................................................................. 28
5.14 Motor rotation ............................................................................................................................................................ 28
6 Start-up, calibration and operation of the burner ................................................................................................................. 29
6.1 Notes on safety for the first start-up .......................................................................................................................... 29
6.2 Adjustments prior to ignition ...................................................................................................................................... 29
6.3 Servomotor adjustment ............................................................................................................................................. 30
6.4 Burner start-up .......................................................................................................................................................... 30
6.5 Burner ignition ........................................................................................................................................................... 30
6.6 Adjusting the burner .................................................................................................................................................. 31

20152093 2
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Contents
6.7 Final adjustment of the pressure switches.................................................................................................................33
6.7.1 Air pressure switch.....................................................................................................................................................33
6.7.2 Maximum gas pressure switch...................................................................................................................................33
6.7.3 Minimum gas pressure switch....................................................................................................................................33
6.8 Burner operation ........................................................................................................................................................34
6.8.1 Burner start-up ...........................................................................................................................................................34
6.8.2 Steady state operation ...............................................................................................................................................34
6.8.3 Ignition failure.............................................................................................................................................................34
6.8.4 Final checks (with burner operating)..........................................................................................................................34
7 Maintenance ..............................................................................................................................................................................35
7.1 Notes on safety for the maintenance .........................................................................................................................35
7.2 Maintenance programme ...........................................................................................................................................35
7.2.1 Maintenance frequency..............................................................................................................................................35
7.2.2 Safety test - with no gas supply .................................................................................................................................35
7.2.3 Checking and cleaning...............................................................................................................................................35
7.2.4 Safety components ....................................................................................................................................................36
7.3 Opening the burner ....................................................................................................................................................37
7.4 Closing the burner......................................................................................................................................................37
8 LED indicator and special function.........................................................................................................................................38
8.1 Description of LED lamps ..........................................................................................................................................38
8.2 Check mode function .................................................................................................................................................38
8.3 Flame control lock-out or emergency stop condition .................................................................................................38
8.4 LED lamps: burner operating status ..........................................................................................................................39
9 Problems - Causes - Remedies signalled by LED indicators ...............................................................................................40
A Appendix - Accessories ...........................................................................................................................................................45
B Appendix - Electrical panel layout...........................................................................................................................................47

3 20152093
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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) Italy
Product: Forced draught gas burners
Model: RS 200/M BLU
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Devices Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU 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. BImSchV revision 26.01.2010”.
Product Type Model Output
Forced draught gas burners 1106T RS 200/M BLU 500 - 2400 kW
Legnago, 21.04.2018 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini
CE-0085BT0414 RS 200/M BLU

20152093 4
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Declarations
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.rielloburners.com
Distributed by: RIELLO NV
Waverstraat 15
9310 Moorsel (Aalst)
Tel. [phone]
Fax. [phone]
e-mail. [e-mail]
URL. www.riello.be
This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration
of Conformity and has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of
January 8th 2004 and July 17th 2009.
Type of product: Forced draught gas burners
Model: RS 200/M BLU
Regulation applied: EN 676 and A.R. of January 8th 2004 - July 17th 2009
Controlling organisation: TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
Values measured: Max. CO: 5 mg/kWh
Max. NOx: 61 mg/kWh
Legnago, 21.04.2018 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini

5 20152093
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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
Centre 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
Table Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not
carried out correctly, cause serious injury, death
or long-term health risks.
ATTENTION
This symbol indicates operations which, if not
carried out correctly, may cause serious injury,
death or long-term health risks.
CAUTION
This symbol indicates operations which, if not
carried out correctly, may cause damage to the
machine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not
carried out correctly, lead to electric shocks with
lethal 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
atmosphere may be present. An explosive
atmosphere 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.
IMPORTANT
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20152093 6
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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
Assistance 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
recommends 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
sale 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,
incorrectly 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
established 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
responsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
ATTENTION
Failure to observe the information given in this
manual, operating negligence, incorrect
installation and carrying out of non authorised
modifications will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

7 20152093
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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 safety
technical rules 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
confidence 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
dangerous.
Specifically:
it can be applied to boilers operating with water, steam,
diathermic 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
chamber and the ambient temperature must all be within the
values indicated in the instruction manual.
Modification of the burner to alter its performance and
destinations is not allowed.
The burner must be used in exemplary technical safety
conditions. 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
responsible for the machine and for the training of the people
working 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 observe all the danger and caution
indications shown on the machine.
Personnel must not carry out, on their own initiative,
operations or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence
compromise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
ATTENTION
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to
prevent unauthorised people gaining access
to the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident
prevention systems are noticed, along with
any presumed danger situation;
personnel must always use the personal
protective equipment envisaged by legislation
and follow the indications given in this
manual.

20152093 8
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Technical description of the burner
4.1 Burner designation
4.2 Burner categories
Tab. A
4 Technical description of the burner
Series: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R S 200 MTC FS1 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
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
S
L
LS
N
Head: TC Standard head
TL Extended head
Emission: C01 or ...
MZ
BLU
MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
3/400-230/50 3N / 400V-230V / 50Hz
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous operation - use only with flame
detection electrode (ionisation)
Country of destination Gas category
BE I2E(R)
LV I2H
CY, MT I3B/P
BE I3P
LU, PL II2E3B/P
DE II2ELL3B/P
FR II2Er3P
AT, CH, CZ, DK, EE, FI, GR, HU, IS, IT, LT, NO, SE, SI, SK II2H3B/P
ES, GB, IE, PT II2H3P
NL I2E - I2(43.46 ÷ 45.3 MJ/m3(0°C))

9 20152093
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Technical description of the burner
4.3 Models available
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 (Fig. 29 on page 29) 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 output.
The sound power is measured using the "Free Field" method, required by the EN 15036 standard, and according to an “Accuracy: Category 3”
measurement, as described in EN ISO 3746.
4.5 Electrical data
Tab. D
Designation Power supply voltage Start-up Code
RS 200/M BLU TL 3 ~ 230 / 400V - 50Hz Direct 20145799
Model RS 200/M BLU
Type 1106T
Output (1) Max. kW
Mcal/h
1380 ÷ 2400
1187 ÷ 2064
Min. kW
Mcal/h
550
473
Fuel Natural gas: G20 (methane) G21 - G22 - G23 - G25 - G31
Gas pressure at max. output (2)
- Gas: G20 / G25 / G31
mbar 28 / 35.6 / 19.6
Operation – Intermittent (min. 1 stop in 24 hours)
– Progressive two-stage or modulating by kit (see ACCESSORIES).
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power
dB(A) 80.5
91.5
Model RS 200/M BLU
Type 1106T
Main electrical supply
Auxiliary circuit electrical supply
3 ~ 400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
Fan motor IE3 Hz
rpm
V
kW
A
50
2935
400
5.5
10.2
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electric power kW max 5.9
Protection level IP 44

20152093 10
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Technical description of the burner
4.6 Maximum dimensions
The dimensions of the burner are given in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the slide
bars.
The maximum dimensions of the open burner are indicated by
the value I.
Tab. E
(1) Blast tube: short-long
4.7 Firing rates
The maximum output is to be chosen within area A of the
diagram (Fig. 2).
The minimum output must not be lower than the minimum limit
of the diagram.
Fig. 1
D1702
mm ABCDE F (1) GH I (1) LMNO
RS 200/M BLU 732 427 329 573 863 373-503 221 430 1442-1587 228 141 261 Rp2
CAUTION
Model firing rate (Fig. 2) refers to operation on
G20 - G25.
If using G31, the minimum output goes from 550
to 630 kW.
ATTENTION
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 21.
-2
Mcal / h
kW
0
2
4
6
8
10
12
14
A
2400
2100
22001400 1600 1800 20001000 1200800 600
1900
1700
1500
13001100
900
700500
D9599
Thermal power
Pressure in the chamber
chamber - mbar
Fig. 2

11 20152093
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Technical description of the burner
4.7.1 Firing rate according to air density
The burner firing rate specified in the manual applies for an
ambient temperature of 20 °C and an altitude of 0 m a.s.l.
(barometric pressure of approx. 1013 mbar).
The burner may have to operate at a higher altitude and/or with
combustion air at a higher temperature.
Both air heating and increased altitude cause air volume
expansion, i.e. air density is reduced.
Burner fan flow rate remains basically the same but oxygen
content per cu. m of air is reduced as well as the fan push (head).
Therefore, it is important to know whether burner required
maximum output at a certain pressure in the combustion
chamber remains within the burner firing rate also under different
temperature and altitude conditions.
To check this, proceed as follows:
1 find the correction factor F concerning air temperature and
altitude for the system in Tab. F.
2 Divide output Q requested from the burner by F to obtain the
equivalent output Qe:
3 Within burner firing rate, mark the point identified by:
Qe = equivalent output
H1= pressure in combustion chamber
point A that must remain within the firing rate.
4 Draw a vertical line from point A)(Fig. 3), and calculate the
maximum pressure H2 of the firing rate.
5 Multiply H2 by F to obtain the reduced maximum pressure
H3 of the firing rate:
If H3 is higher than H1)(Fig. 3), the burner can output the
requested flow rate.
If H3 is lower than H1, burner output must be reduced. Output
reduction is also combined with a reduction of the pressure in the
combustion chamber:
Qr = reduced output
H1r = reduced pressure
Example, 5% output reduction:
Qr = Q x 0.95
H1r = H1 x (0.95)2
Using the new Qr and H1r values, repeat steps 2-5.
Tab. F
Qe = Q : F (kW)
H3 = H2 x F (mbar)
ATTENTION
The combustion head must be adjusted according
to equivalent output Qe.
H1r = H1 x ()
Qr
Q
2
Qe kg/h
mbar
Qe kW
mbar
A
H1
H2
H3
D388
Fig. 3
Altitude
Average
barometric
pressure
F
Air temperature °C
m a.s.l. mbar 0 5 10 15 20 25 30 40
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2400
2800
3200
3600
4000
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
755
714
675
635
616
1.087
1.073
1.061
1.050
1.037
1.025
1.013
1.000
0.988
0.977
0.964
0.942
0.919
0.897
0.875
0.852
0.810
0.766
0.724
0.682
0.661
1.068
1.054
1.042
1.031
1.018
1.007
0.995
0.982
0.971
0.959
0.946
0.925
0.902
0.881
0.859
0.837
0.796
0.753
0.711
0.669
0.649
1.049
1.035
1.024
1.013
1.000
0.989
0.977
0.965
0.954
0.942
0.930
0.909
0.886
0.866
0.844
0.822
0.782
0.739
0.699
0.657
0.638
1.031
1.017
1.006
0.995
0.983
0.972
0.960
0.948
0.937
0.926
0.914
0.893
0.871
0.851
0.829
0.808
0.768
0.726
0.687
0.646
0.627
1.013
1.000
0.989
0.978
0.966
0.955
0.944
0.932
0.921
0.910
0.898
0.878
0.856
0.836
0.815
0.794
0.755
0.714
0.675
0.635
0.616
0.996
0.983
0.972
0.962
0.950
0.939
0.928
0.916
0.906
0.895
0.883
0.863
0.842
0.822
0.801
0.781
0.742
0.702
0.664
0.624
0.606
0.980
0.967
0.956
0.946
0.934
0.923
0.913
0.901
0.891
0.880
0.868
0.849
0.828
0.808
0.788
0.768
0.730
0.690
0.653
0.614
0.596
0.948
0.936
0.926
0.916
0.904
0.894
0.884
0.872
0.862
0.852
0.841
0.822
0.801
0.783
0.763
0.743
0.707
0.668
0.632
0.594
0.577

20152093 12
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Technical description of the burner
4.8 Test boiler
The firing rates were obtained in special test boilers, according to
standard EN 676.
In Fig. 4 you can see the diameter and length of the test
combustion chamber.
Example:
Output 756 kW (650 Mcal/h) - diameter 60 cm, length 2 m.
Although combination is guaranteed when boiler has a CE type-
approval, preliminary tests are recommended for boilers or
furnaces having a combustion chamber size much different than
the one specified in Fig. 4.
4.9 Burner equipment
The burner is supplied complete with:
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Seal for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M10 x 40. . . . . . . . . . . . . . . . . . . . . . No. 4
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Stud bolts to fix the burner flange to the
boiler: M16 x 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
M16 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Extensions for slide bars 16)(Fig. 5 on page 13)
(models having a long blast tube) . . . . . . . . . . . . . . . . . . . No. 2
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 4
Length of combustion
chamber - m
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Technical description of the burner
4.10 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling with flange for boiler fixing
6 Servomotor controlling the gas butterfly valve and the air
damper, by means of a variable profile cam mechanism.
When the burner is not operating the air damper is fully
closed in order to reduce heat dispersion from the boiler due
to the flue draught, which draws air from the fan suction inlet
7 Plug-socket on ionisation probe cable
8 Extensions for slide bars 16)
9 Motor contact maker and thermal relay with reset button
10 A switch for:
automatic-manual-off operation
A button for:
output increase - decrease
11 Terminal board
12 Cable grommets for electrical wiring (to be carried out by the
installer)
13 Electrical control box with lockout pilot light and reset button
14 Flame inspection window
15 Minimum air pressure switch (differential 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 damper
21 Air inlet to fan
22 Screws to secure fan to pipe coupling
23 Gas input pipe
24 Gas butterfly valve
25 Flame stability disc
26 Sockets for electric connections
27 Lifting rings
Fig. 5
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Technical description of the burner
4.11 Electrical panel description
1 Plug-socket on ionisation probe cable
2 Motor contact maker and thermal relay with reset button
3 A switch for: automatic-manual-off operation
A button for: output increase - decrease
4 Terminal board for electrical connection
5 Cable grommets for electrical wiring (to be carried out by the
installer)
6 Air pressure switch (differential type)
7 Sockets for electric connections
8 Ignition transformer
9 Control box base
10 Filter to protect against radio disturbance
11 Bracket to apply the RWF kit for modulating operation
Fig. 6
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Technical description of the burner
4.12 Control box RFG0-A22
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).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation
operations, assistance, etc.), ensure the wiring is in order
and that the parameters are correctly set, then make the
safety checks.
Falls and collisions can negatively affect the safety
functions. In this case, the control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following
instructions:
– avoid conditions that can favour the development of
condensate 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.
Use
The control box is a control and supervision system of medium
and large capacity forced draught burners for intermittent
operation (at least one controlled shutdown every 24 hours).
Installation notes
• Check that the electrical wiring inside the boiler complies with
the national and local safety regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with
neighbouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as
possible from the control box and the other cables.
• When wiring the unit, make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
Technical data
Tab. G
Electrical wiring of the flame detector
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:
– The capacitive reactance of the line reduces the size of the
flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
• The ionisation probe is not protected against the risk of
electrocution. When connected to the electricity supply, the
ionisation probe must be protected against any accidental
contact.
• Position the ignition electrode and the ionisation probe so
that the ignition spark cannot form an arc on the probe (risk
of electric overcharge).
ATTENTION
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. The
Manufacturer cannot assume any responsibility
for damage resulting from unauthorised work!
Mains voltage AC 230 V -15 % / +10 %
Mains frequency 50 / 60 Hz
Primary fuse (external) Refer to the electric system
Weight approx. 1.1 kg
Power absorption approx. AC 7 VA
Protection level IP40
Safety class II
Environmental conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K2
Class 1M2
-40...+60 °C
< 90% RH (non-condensing)
Fig. 7
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Technical description of the burner
4.13 Servomotor (SQN31...)
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
terminals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety
functions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• When assembling the servomotor and connecting the
damper, the gears can be disengaged by means of a lever,
allowing the drive shaft to be easily adjusted in both
directions of rotation.
Technical data
Tab. H
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the
actuators.
Operating voltage AC 220...240V, 50 Hz –15 % / +10 %
AC 220 V, 60 Hz –15 % / +10 %
Switching capacity of
auxiliary devices and
limit switches
10 (3) A, AC 24...250 V
Angle
positioning up to 160° (full scale)
Assembly position option
Protection level IP 54, DIN 40050
Safety class I
Weight approx. 0.8 kg
Actuator motor synchronous motor
Power absorption 6.5 VA
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-1
Class 1K2
Class 1M2
-20...+60 °C
< 95% RH
Fig. 8
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to handle the burner (still packaged) with a pallet 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. 9), 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 relevant supply pressures;
H the data of the burner possible minimum and maximum
output (see Firing rate).
Warning. The burner output must be within the firing rate of
the boiler;
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.
ATTENTION
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and
regulations of the laws in force.
DANGER
The combustion air inside the boiler must be free
from hazardous mixes (e.g.: chloride, fluoride,
halogen); if present, it is highly recommended to
carry out cleaning and maintenance more
frequently.
ATTENTION
Burner handling operations can be highly
dangerous if not carried out with the greatest
attention: distance unauthorised personnel, check
integrity and suitability of the means available.
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
quickly move if the burner should fall).
During handling, keep the load at no 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
burner will be installed.
CAUTION
After removing all the packaging, check the
integrity of the contents. In the event of doubt, do
not use the burner; contact the supplier.
The packaging elements (wooden cage or
cardboard 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.
ATTENTION
A burner label that has been tampered with,
removed or is missing, along with anything else
that prevents the definite identification of the
burner makes any installation or maintenance
work difficult
Fig. 9
R. B. L.
GAS- KAASU
GAZ- AEPIO
0085
RIELLO S.p .A.
I- 37045 Legnago (VR)
CE
ABC
EDF
HG
GH
I
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Introduction
The burners are suitable for operating both on boilers with flame
inversion chambers (*) (the long head model being
recommended in this instance) and on boilers having a
combustion chamber with bottom outflow (three passes), on
which the lowest NOxemissions are obtained.
The boiler front door maximum thickness A)(Fig. 11), complete
with refractory, must not exceed:
Tab. I
(*) A kit for reducing CO is available for boilers with flame
inversion chambers, if necessary See Accessories.
The kit includes 5 gas tubes, identical to another 5 already
present in the burner head.
In standard conditions, burner head is equipped with a
second set of tubes, letting gas out in a different direction
compared to the previous tubes.
Using the kit, this second set of tube is replaced so that in the
end all tubes are the same.
After installing the kit, check its effectiveness by measuring
flue gas and CO.
5.5.2 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 12.
The position of the threaded holes can be marked using the
thermal insulation screen supplied with the burner.
Tab. J
ATTENTION
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 10).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the
correct operation of the appliance.
Installation 5are forbidden for safety
reasons.
2 3 4 51
Fig. 10
D7739
Blast tube A (mm)
RS 200/M BLU 250
mm ABC
RS 200/M BLU 230 325-368 M 16
Fig. 11
A
D1079
Fig. 12
D455