Riello RS 28 Quick start guide

Installation, use and maintenance instructions
20144599 (1) - 02/2018
Forced draught gas burners
Progressive two-stage operation
CODE MODEL TYPE
3783302 RS 28 809 T1
3784402 RS 38 810 T1
3784403 RS 38 810 T1
3784502 RS 38 810 T1
3784503 RS 38 810 T1
3784702 RS 50 811 T1
3784703 RS 50 811 T1
GB

Translation of the original instructions

1 20144599
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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 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Burner equipment........................................................................................................................................................ 9
4.8 Firing rates ................................................................................................................................................................ 10
4.9 Test boiler.................................................................................................................................................................. 11
4.9.1 Commercial boilers.................................................................................................................................................... 11
4.10 Burner description ..................................................................................................................................................... 12
4.11 Control box RMG88................................................................................................................................................... 13
4.12 Servomotor SQM....................................................................................................................................................... 14
5 Installation ................................................................................................................................................................................ 15
5.1 Notes on safety for the installation ............................................................................................................................ 15
5.2 Handling .................................................................................................................................................................... 15
5.3 Preliminary checks .................................................................................................................................................... 15
5.4 Operating position ..................................................................................................................................................... 16
5.5 Preparing the boiler ................................................................................................................................................... 16
5.5.1 Boring the boiler plate ............................................................................................................................................... 16
5.5.2 Blast tube length........................................................................................................................................................ 16
5.5.3 Securing the burner to the boiler............................................................................................................................... 16
5.6 Access to head internal part...................................................................................................................................... 17
5.7 Positioning the probe - electrode............................................................................................................................... 17
5.8 Combustion head adjustment.................................................................................................................................... 18
5.9 Gas supply ................................................................................................................................................................ 19
5.9.1 Gas feeding line ........................................................................................................................................................ 19
5.9.2 Gas train.................................................................................................................................................................... 20
5.9.3 Gas train installation.................................................................................................................................................. 20
5.9.4 Gas pressure............................................................................................................................................................. 20
5.10 Electrical connections................................................................................................................................................ 22
5.11 Thermal relay adjustment (RS 38-50 THREE-PHASE)............................................................................................. 23
6 Start-up, calibration and operation of the burner ................................................................................................................. 24
6.1 Notes on safety for the first start-up .......................................................................................................................... 24
6.2 Adjustments prior to ignition...................................................................................................................................... 24
6.3 Burner start-up .......................................................................................................................................................... 24
6.4 Burner ignition ........................................................................................................................................................... 25
6.5 Burner adjustment ..................................................................................................................................................... 25
6.5.1 Output upon ignition .................................................................................................................................................. 25

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Contents
6.5.2 Output in 2nd stage....................................................................................................................................................25
6.5.3 Output in 1st stage.....................................................................................................................................................26
6.5.4 Intermediate outputs ..................................................................................................................................................26
6.6 Pressure switch adjustment .......................................................................................................................................27
6.6.1 Air pressure switch.....................................................................................................................................................27
6.6.2 Gas minimum pressure switch...................................................................................................................................27
6.6.3 Flame presence check...............................................................................................................................................27
6.7 Servomotor adjustment..............................................................................................................................................28
6.8 Burner operation ........................................................................................................................................................29
6.8.1 Burner start-up ...........................................................................................................................................................29
6.8.2 Full-running operation - System equipped with TR remote control............................................................................29
6.8.3 Ignition failure.............................................................................................................................................................29
6.9 Burner start-up cycle diagnostics...............................................................................................................................30
6.9.1 Resetting of control box and diagnostics use ............................................................................................................30
6.9.2 Control box reset........................................................................................................................................................30
6.9.3 Visual diagnostics ......................................................................................................................................................30
6.9.4 Software diagnostics..................................................................................................................................................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 Safety test - with no gas supply .................................................................................................................................31
7.2.3 Checking and cleaning...............................................................................................................................................31
7.2.4 Combustion control (gas)...........................................................................................................................................32
7.2.5 Safety components ....................................................................................................................................................32
7.3 Opening the burner ....................................................................................................................................................33
7.4 Closing the burner......................................................................................................................................................33
8 Faults - Possible causes - Solutions.......................................................................................................................................34

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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 and type: RS 28
RS 38
RS 50
809 T1
810 T1
811 T1
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.
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
CE-0085AP0733
CE-0085AP0734
CE-0085AP0735

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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
Tab. 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.
This symbol indicates a list.

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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
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,
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.

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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
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.

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Technical description of the burner
4.1 Burner designation
4.2 Models available
4 Technical description of the burner
Designation Voltage Start-up Code
RS 28 TC 1/230/50 Direct 3783302
RS 38 TC 1/230/50 Direct 3784402
RS 38 TL 1/230/50 Direct 3784403
RS 38 TC 3/230-400/50 Direct 3784502
RS 38 TL 3/230-400/50 Direct 3784503
RS 50 TC 3/230-400/50 Direct 3784702
RS 50 TL 3/230-400/50 Direct 3784703
Series: R
Size
Fuel: Natural gas
Oil
Gas oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 hours)
Continuous working (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R S 28 TC
Emission: C1 or... Class 1 EN676
C02 or MZ Class 2 EN676
C03 or BLU Class 3 EN676
3/230/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam and 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 Extended head

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Technical description of the burner
4.3 Burner categories - Countries of destination
4.4 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at test point 7) (Fig. 4) with zero pressure in 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 with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measurement, as described in EN ISO
3746.
(4) Blast tube: short-long
4.5 Electrical data
Tab. B
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L - I2E - I2 (43.46 ÷ 45.3 MJ/m3 (0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E
MODEL RS 28 RS 38 RS 38 RS 50
TYPE 809 T1 810 T1 810 T1 811 T1
OUTPUT (1) 2nd stage kW 163 - 325
140 - 280
232 - 440
200 - 378
232 - 440
200 - 378
295 - 600
254 - 516
Mcal/h
1st stage min. kW
Mcal/h
81
70
105
90
105
90
115
99
FUEL NATURAL GAS: G20 - G25 - G31
G20 G25 G20 G25 G20 G25 G20 G25
- Net calorific value kWh/Nm3
Mcal/Nm3
10
8.6
8.6
7.4
10
8.6
8.6
7.4
10
8.6
8.6
7.4
10
8.6
8.6
7.4
- Absolute density kg/Nm30.71 0.78 0.71 0.78 0.71 0.78 0.71 0.78
- max delivery Nm3/h 32 38 44 51 44 51 58 68
- pressure at maximum delivery (2) mbar 7.5 11.1 6.6 9.7 6.6 9.7 7.2 10.6
OPERATION • Intermittent (min. 1 stop in 24 hours).
• Two-stage (high and low flame) and one-stage (all - nothing)
STANDARD USE 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) 68 79
70
81
70
81
72
83
Model RS 28 RS 38 RS 50
ELECTRICAL SUPPLY 1 Ph 1N ~ 230 V 50 Hz 1N ~ 230 V 50 Hz
ELECTRICAL SUPPLY 3 Ph -3 ~ 230 - 400V ~ +/-10% 50Hz
FAN MOTOR rpm
W
V
A
2800
250
220 - 240
2.1
2800
420
220 - 240
2.9
2800
450
220/240-380/415
1.7 - 1
2800
650
220/240-380/415
3 - 1.7
MOTOR CAPACITOR F/V 8/450 12.5/450
IGNITION TRANSFORMER V1 - V2
I1 - I2
230 V - 1 x 8 kV
1A - 20 mA
230 V - 1 x 8 kV
1A - 20 mA
ELECTRICAL POWER
CONSUMPTION
W max 370 600 560 750
PROTECTION LEVEL IP 44

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Technical description of the burner
4.6 Maximum dimensions
The dimensions of the burner are given in Fig. 1.
Note that to inspect the combustion head the burner must be
moved backward and turned upward. The maximum dimension
of the burner, without casing, when open is given by
measurement I.
Tab. C
(1) Blast tube: short-long
4.7 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Seal for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M 8 x 25 . . . . . . . . . . . . . . . . . . . . . . No. 4
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to fix the burner flange to the boiler:
M 8 x 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Cable grommets for the electrical wiring . . . . . . . . . . . . . . . No. 4
(RS 28 and RS 38 single-phase)
Cable grommets for the electrical wiring . . . . . . . . . . . . . . . No. 6
(RS 38 three-phase and RS 50)
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
mm ABC D (1) EFGH I L M
RS 28 476 474 580 216 - 351 140 352 164 810 108 168 1”1/2
RS 38 476 474 580 216 - 351 140 352 164 810 108 168 1”1/2
RS 50 476 474 580 216 - 351 152 352 164 810 108 168 1”1/2
Fig. 1
D495

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Technical description of the burner
4.8 Firing rates
The burners RLS 28- 38 - 50 can work in two ways: one-stage or
two-stage.
The MAXIMUM OUTPUT is chosen within area A.
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RS 28 = 81 kW
RS 38 = 105 kW
RS 50 = 115 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 18.
Pressure in the chamber
pressure - mbar
Thermal power - kW
Fig. 2
RS 28 D3612
Pressure in the chamber
pressure - mbar
Thermal power - kW
RS 38
Pressure in the chamber
pressure - mbar
Thermal power -
kW
RS 50

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Technical description of the burner
4.9 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
manufacturer.
The firing rates were set in relation to special test boilers,
according to EN 676 regulations.
In Fig. 3 you can see the diameter and length of the test
combustion chamber.
Example:
Output 350 kW: diameter 50 cm - length 1.5 m.
4.9.1 Commercial boilers
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 commercial boiler that has
not been EC approved (CE mark) and/or its combustion chamber
dimensions are clearly smaller than those indicated in diagram
(Fig. 3), consult the manufacturers.
Fig. 3
Combustion chamber
m
D715

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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 Pipe coupling
5 Minimum air pressure switch (differential type)
6 Flame sensor probe
7 Air pressure test point
8 Gas pressure test point and head fixing screw
9 Screw securing fan to sleeve
10 Slide bars for opening the burner and inspecting the
combustion head
11 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 minimise heat dispersion from the boiler
due to the flue draught which draws air from the fan suction
inlet.
12 Plate with four hole knock-outs for electrical cable routing
13 Air inlet to fan
14 Gas input pipe
15 Gas butterfly valve
16 Boiler fixing flange
17 Flame stability disc
18 Flame inspection window
19 Plug-socket on ionisation probe cable
20 Motor contactor and thermal relay with reset button (RS 38
three-phase - RS 50)
21 Motor capacitor (RS 28 - RS 38 single-phase)
22 Control box with lockout pilot light and reset button
23 Two electric switches:
- one for “burner on - off”
- one for “1st - 2nd stage”
24 Plugs for electrical wiring
25 Air damper
Two types of burner lockout may occur:
CONTROL BOX LOCKOUT:
if the control box button (red LED) 22)(Fig. 4) lights up, it
indicates that the burner is locked out.
To reset, hold the pushbutton down for between 1 and 3 seconds.
MOTOR LOCKOUT (RS 38 three-phase - RS 50):
Release by pressing the button on thermal relay 20)(Fig. 4).
Fig. 4
D492
D3045
D3026

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Technical description of the burner
4.11 Control box RMG88...
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.
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.
Press the reset button of the burner lockout command or the
reset button (by applying a force of not more than 10 N),
without the aid of tools or sharp objects.
For the safety and reliability of the control box, 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.
Technical data
Mechanical structure
The control box is made of plastic to resist knocks, heat and
flame propagation.
The control box contains the following components:
• a microprocessor that controls the program sequence, and a
relay for controlling the load
• an electronic flame signal amplifier
• a built-in reset button with 3 signalling colours (LED) for status
and error messages
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box RMG88... is a safety device!
Avoid opening or modifying it, or forcing its
operation. Riello S.p.A. cannot assume any
responsibility for damage resulting from
unauthorised interventions!
Mains voltage AC 220...240 V +10 % / -15 %
Mains frequency 50 / 60 Hz ± 6%
Power absorption 20 VA
Protection level IP20
Safety class I
Weight approx. 260 g
Cable length
Thermostat cable
Air pressure switch
Gas pressure switch
Remote reset
CPI
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 20 m at 100 pF/m
Max. 1 m at 100 pF/m
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95 % r.h.
Fig. 5
S8906

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Technical description of the burner
4.12 Servomotor SQM..
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
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.
Fully disconnect the burner from the mains when working
near terminals and servomotor connections.
Condensation and exposure to water are not allowed.
For safety reasons, the servomotor must be checked after
long periods of non-use.
•
Technical data
ATTENTION
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the
servomotor.
Mains voltage 220 V -15% +10% ... 240 V + 10%
Mains frequency 50 / 60 Hz +/- 6%
Power absorption 8 VA
Motor Synchronous
Drive angle Varying between 0° and 90°
Protection level IP XX
Cable connection terminal board for 0.5mm2 (min.)
and 2.5mm2 (max.)
Rotation direction Anticlockwise
Rated torque (max.) 2 Nm
Holding torque 1 Nm
Operation time 12 s. at 90°
Weight approx. 550 kg
Environmental conditions:
Operation
Transport and storage
-20....+60° C
-20...+60°C
Fig. 6
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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. 7), 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 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.
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).
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
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. 7
R. B. L.
GAS- KAASU
GAZ- AEPI O
0085
RI EL LO 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 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 9.
The position of the threaded holes can be marked using the
thermal insulation screen supplied with the burner.
Tab. D
5.5.2 Blast tube length
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 range of lengths available, L (mm),
is as follows:
Tab. E
For boilers with front flue passes 15) or flame inversion chamber,
a protection in refractory 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 with a water-cooled front piece, a refractory lining 13)-
14)(Fig. 10) is not necessary, unless expressly requested by the
boiler manufacturer.
5.5.3 Securing the burner to the boiler
Separate the combustion head from the rest of the burner
(Fig. 10):
Remove screw 14) and extract cover 15).
Disengage the articulated coupling 4) from the graduated
sector 5)
Remove the screws 2) from the two slide bars 3).
Remove the screw 1) and draw the burner back on the slide
bars 3) by about 100mm.
Disconnect the probe and electrode cables and then slide
the burner completely out of the slide bars, after removing
the split pin from the slide bar 3).
ATTENTION
The burner is set up to operate only in
positions 1, 2, 3 and 4 (Fig. 8).
Installation 1 is 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 5 are forbidden for safety
reasons.
Fig. 8
2 3 4 51
D3928
mm A B C
RS 28 160 224 M 8
RS 38 160 224 M 8
RS 50 160 224 M 8
mm RS 28 RS 38 RS 50
Standard 216 216 216
Elongated 351 351 351
Fig. 9
D455
Provide an adequate lifting system.
ATTENTION
The seal between burner and boiler must be
airtight.
Fig. 10
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Installation
5.6 Access to head internal part
In order to reach inside the combustion head (Fig. 11) proceed as
follows:
remove the screw 1) and the internal part 2).
Fix the flange 9)(Fig. 10) to the plate of the boiler interposing the
insulating flange gasket 6)(Fig. 10) supplied with the unit. 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 airtight.
5.7 Positioning the probe - electrode
If in the previous check the position of the probe or electrode was
not correct, remove the screw 1) (Fig. 11) extract the inner part
2)(Fig. 11) of the head, and adjust them.
Fig. 11
D501
ATTENTION
Before securing the burner to the boiler, check
(through the opening of the blast tube) that the
probe and electrode are correctly positioned, as in
Fig. 12.
ATTENTION
Do not rotate the probe but leave it as in Fig. 12; if
it is too close to the ignition electrode, it could
damage the control box amplifier.
ATTENTION
Respect the dimensions shown in Fig. 12.
PROBE ELECTRODE RS 28-38 ELECTRODE RS 50
Fig. 12
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Installation
5.8 Combustion head adjustment
At this point of the installation, the combustion head is fixed to the
boiler as shown in Fig. 11.
It is therefore especially easy to adjust, and this adjustment
depends only on the maximum output of the burner.
2 combustion head adjustments are available:
–air
–gas
In the diagram of Fig. 14, find the notch at which both air and
central gas/air should be adjusted.
Air adjustment
Turn the screw 4)(Fig. 13) until the notch found lines up with
the front surface 5) of the flange.
Gas adjustment
Loosen the screws 1)(Fig. 13) and rotate the ring nut 2) until
the notch you have found corresponds with the indicator 3).
Block the 3 screws 4).
Example:
RS 38 burner output = 337 kW (290 Mcal/h).
The diagram (Fig. 14) shows that the gas and air adjustments for
this output are carried out on notch 3.
NOTE:
The diagram indicates the optimum adjustment for a type of boiler
according to Fig. 3 on page 11.
ATTENTION
To facilitate the adjustment, loosen the screw 6)
(Fig. 13), adjust, then block.
ATTENTION
The adjustments indicated can be modified during
the initial start-up.
Fig. 13
D502
Fig. 14
No. notches
Burner output in 2nd stage
D503