Riello RS 300/E BLU Quick start guide

Installation, use and maintenance instructions
Gas burners
Modulating operation
2543947 (2) - 06/2007
CODE MODEL TYPE
3809098 RS 300/E BLU 09098 D
3809097 RS 400/E BLU 09097 D
3809099 RS 500/E LN 09099 D
GB

1
CONTENTS
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of available models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blast tube length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accessibility to the interior of the combustion head . . . . . . . . . . . 7
Position of electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rotation of fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustment before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion air adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Air adjustment for maximum output . . . . . . . . . . . . . . . . . . . . . . .11
Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air/fuel control and power modulation system . . . . . . . . . . . . . . 15
Appendix
Layout of electrical panel board . . . . . . . . . . . . . . . . . . . . . . . . . 16
Key to electrical layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394 “WC - Altitude 329 ft a.s.l.
(2) Pressure at pressure switch test point 20)(A)p.4 with zero pressure in the combustion chamber and maximum burner output.
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
(4) Values referred to Gross calorific Value (GCV).
(5) Values referred to Net calorific Value (NCV).
ACCESSORIES (optional)
•PRESSURE/TEMPERATURE CONTROL PROBE
•KIT SOFTWARE INTERFACE: code 3010388
Note.
Riello S.p.a. declines all responsibility for the addition of safety devices not provided for herein.
MODEL RS 300/E BLU RS 400/E BLU RS 500/E BLU
TYP 09098 D 09097 D 09099 D
OUTPUT (1) HIGH MBtu/hr (4) 5112 ÷ 14390 6817 ÷ 17043 9468 ÷ 19580
kW (5) 1350 ÷ 3800 1800 ÷ 4500 2500 ÷ 5170
LOW MBtu/hr (4) 1893 3030 3787
kW (5) 500 800 1000
FUEL Natural gas
Gas pressure at maximum delivery. (2) “ w.c. 7 / 10.2 13 / 15.2 15 / 22
OPERATION Continuous / Intermittent
STANDARD APPLICATIONS Boilers: water, steam, diathermic oil
AMBIENT TEMPERATUR °F 32 - 104 (0 - 40 °C)
COMBUSTION AIR TEMPERATURE °F max 140 (60 °C)
MAIN POWER SUPPLY (+/- 10%) V/Ph/Hz 460 / 3 / 60
AUXILIARY SUPPLY V/Ph/Hz 110-120 / 3 / 60
FAN MOTOR
(star-delta starting for RS400 and RS500)
rpm
V
HP
A
3410
460
7,5
10
3410
460/795
10
13 - 8
3410
460/795
13
16 - 13
IGNITION TRANSFORMER V1 - V2
I1 - I2
120 V - 1 x 7 kV
1.6 A - 23 mA
ELECTRICAL POWER CONSUMPTION HP - kW max 8 - 6 13.5 - 10 15 - 11
ELECTRICAL PROTECTION NEMA 3
NOISE LEVELS (3) dBA 82 85 88
PARAMETER TO BE CHECKED PROBE
Range Type Code
Temperature - 148...+ 932°F (- 100...+ 500°C) PT 100 3010110
Pressure 0...36.3 PSI (0...2,5 bar)
0...232 PSI (0...16 bar)
Output probe
4...20 mA
3010213
3010214

3
DESIGNATION OF BURNER SERIES RS
Series : R
Size
Fuel : S
L
LS
Natural gas
Light oil
Light oil / Methane
Setting : E Electronic cam
EV Variable speed (with Inverter)
Head : TC Standard head
TL Extended head
Flame control system :
FS1
FS2
Standard (1 stop every 24 h)
Continuos working (1 stop every 72 h)
Electrical supply to the system :
3/400/50
3/230/50
Auxiliary voltage :
230/50/60
110/50/60
R S 300 ETC
Emission : ... Class 1 EN267 - EN676
MZ Class 2 EN267 - EN676
BLU Class 3 EN267 - EN676
MX Class 1 EN267
Class 3 EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
LN
Designation Electrical supply Starting Code
RS 300/E BLU TC 460V-60Hz Direct 3809098
RS 400/E BLU TC 460V-60Hz Star/Delta 3809097
RS 500/E BLU TC 460V-60Hz Star/Delta -
RS 500/E LN TC 460V-60Hz Star/Delta 3809099
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
N Heavy oil
P Air/gas proportioning valve
LIST OF AVAILABLE MODELS
LN Class LOW NOx US

4
BURNER DESCRIPTION (A)
1 Lifting eyebolts
2Fan
3 Fan motor
4 Air gate valve servomotor
5 Gas pressure test point
6 Combustion head
7 Ignition pilot
8 Flame stability disk
9 Electric panel board - cover
10 Servomotor for gas butterlfy valve
11 Air inlet to fan
12 Manifold
13 Thermal insulation screen for securing
burner to boiler
14 Gas butterfly valve
15 Shutter
16 Lever for movement of combustion head
17 Gears for movement of air damper
18 Air pressure switch (differential operating
type)
19 Air pressure test point
20 Maximum gas pressure switch with pressure
test point
21 QRI infrared sensor
22 Hinge for opening burner
23 Air pressure test point pressure test point “+”
24 Air pressure test point pressure test point “-”
The burner can be opened either on the right or
left sides, irrespective of the side from which
fuel is supplied.
When the burner is closed, the hinge can be re-
positioned on the opposite side.
DESCRIPTION OF PANEL BOARD (B)
1 Auxiliary terminal strip
2 Relay outlet - clean contacts
3 Electronic cam transformer
4 Electronic cam setting device
5 Ignition transformer
6 Stop push-button
7 Dial for O - AUTO
8 Signal light for power on
9 Signal light for fan motor overload
10 Signal light for burner failure and lock-out
reset button
11 Display AZL
12 Star-powered/delta-powered starter (RS
400/E BLU - RS 500/E BLU only)
13 Timer
14 Main supply terminal strip
15 Entry for power cables and external leads
N.B.
Two types of burner failure may occur:
Flame control lockout: light 12)(B) on the
panel comes on to report burner lockout.
To reset, press pushbutton 12)(B).
Motor trip: release by pressing the push button
on thermal.
Key to layout (C)
1Electrical supply
2Auxiliary electrical supply
3Fan motor
4Triggering / Safety devices
5Gas train
6Adjustment probes
7Available
(A)
2 3 4 5
14
15
12 13
1
6
78 9
10
11
9 1 17 116 19 615
8
14
20
11
7
10 22
13 512 24 4
3
23
18
2
21
ENTRY FOR POWER CABLES AND EXTERNAL LEADS
D3793
5557 1
34447
6
6
7
7
72
D3801
(C)
(B)

5
PACKAGING - WEIGHT (A) - Approximate
measurements
• The burners stands on a wooden base which
can be lifted by fork-lifts. Outer dimensions of
packaging are indicated in (A).
• The weight of the burner complete with pack-
aging is indicated in Table (A).
STANDARD EQUIPMENT
1 - Flange gasket
4 - Flange fixing screws M 16 x 50
1 - Thermal insulation screen
4 - Screws to secure the burner flange to the
boiler: M 18 x 70
2 - Spacers (see Fig. C page 8)
1 - Pressure switch (for leak detection control)
1 - Instruction booklet
1 - Spare parts list
MAX. DIMENSIONS (B) -Approximate
measurements
The maximum dimensions of the burner are
given in (B). Bear in mind that inspection of the
combustion head requires the burner to be
opened by rotating the rear part on the hinge.
The overall dimensions of the burner when open
are indicated by L and R.
(A)
inch A B C lbs
RS 300/E BLU 7711/64“37
1/64“38 3/16“496
RS 400/E BLU 7711/64“37
1/64“38 3/16“520
RS 500/E BLU 7711/64“37
1/64“38 3/16“551
inch A B C D E F G H L R S
RS 300/E BLU 523/16“20
1/2“6 7/16“12 5/16“23 5/32“DN80 2811/32“34 9/64“46 1/4“41 17/32“12 19/32“
RS 400/E BLU 523/16“20
1/2“6 7/16“12 5/16“23 5/32“DN80 301/2“34 9/64“46 1/4“41 17/32“12 19/32“
RS 500/E BLU 523/16“20
1/2“6 7/16“14 17/32“23 5/32“DN80 301/2“34 9/64“46 1/4“41 17/32“12 19/32“
(B)
D3099
D36

6
FIRING RATES (A)
MAXIMUM OUTPUT must be selected in the
hatched area of the diagram.
MINIMUM OUTPUT must not be lower than the
minimum limit shown in the diagram:
Important: The FIRING RATE area values have
been obtained considering a surrounding tem-
perature of 68°F (20°C), and an atmospheric
pressure of 394 “WC (approx. 329 ft above sea
level) and with the combustion head adjusted as
shown on page 8.
MODEL NCV GCV
RS 300/E BLU 500 kW 1893 MBtu/hr
RS 400/E BLU 800 kW 3030 MBtu/hr
RS 500/E BLU 1000 kW 3787 MBtu/hr
(A) D3775
0
2
4
6
8
10
12
14
16
18
20
mbar
22
24
MBtu/h
9
8
7
6
5
4
3
2
0
1
w.c.
9
8
7
6
5
4
3
2
w.c.
0
1
MBtu/h
0 5000 10000 15000 17500
0 56005200
24
22
mbar
20
18
16
14
12
10
8
6
4
2
0
kW
4800440040003600320028002400200016001200800400
05600
5200
kW
4800
4400
400036003200
2800
2400
20001600
1200
800
400
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
6000
NCV
GCV
RS 500/E BLU
RS 400/E BLU
RS 300/E BLU
RS 300/E BLU
RS 400/E BLU
RS 500/E BLU
MBtu/hr
MBtu/hr
W.C. W.C.
GCV
NCV
mbar
mbar
Combustion chamber pressureCombustion chamber pressure
Burner power output (referred to NCV)
Burner power output (referred to GCV)
0 2000 6000 80004000 12000 1400010000 16000 18000 20000

7
INSTALLATION
BOILER PLATE (A)
Drill the combustion chamber locking plate as
shown in (A). The position of the threaded holes
can be marked using the thermal screen sup-
plied with the burner.
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected
according to the indications provided by the
manufacturer of the boiler, and in any case it
must be greater than the thickness of the boiler
door complete with its fettling.
For boilers with front flue passes 1) or flame
inversion chambers, protective fettling in refrac-
tory material 5) must be inserted between the
boiler fettling 2) and the blast tube 4).
This protective fettling must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front the
refractory fettling 2)-5)(B) is not required unless
it is expressly requested by the boiler manufac-
turer.
SECURING THE BURNER TO THE
BOILER (B)
• Create a suitable hoisting system by hooking
onto the rings 3)(B), removing the fastening
screws 7) securing the cover 8) first.
• Slip the thermal protection (standard equip-
ment) onto the blast tube 4) (B).
• Place entire burner on the boiler hole
(arranged previously, see fig. (A), and fasten
with the screws given as standard equipment.
The coupling of the burner-boiler must be air-
tight.
ACCESSIBILITY TO THE INTERIOR OF
THE COMBUSTION HEAD (C)
• Open burner at hinge as illustrated in fig. C
after releasing the tie rod of the head move-
ment lever 1) and removing the 4 fastening
screws 2).
• Disconnect the wire 3) from the electrode.
Disconnect the tube of ignition pilot 6).
• Unscrew the under part of the elbow 4) until it
comes free of its slot.
• Extract the internal part 5) of the combustion
head.
5
36 4 1
2
inch A B C
RS 300-400/E BLU 1325/32“17
51/64“45/64W
RS 500/E BLU 153/4“17
51/64“45/64W
(A)
(B)
(C)
D455
D3090
D3819

8
POSITION OF ELECTRODES (A)
Make sure that the electrode and the ignition
pilot are positioned as shown in figure (A).
COMBUSTION HEAD SETTING (B)
In addition to varying air flow depending on the
output requested, the air gate valve servomotor
4)(A) pag. 4 - by means of a lifting assembly -
varies the setting of the combustion head.
This system allows an optimal setting even at a
minimum firing rate.
For the same servomotor rotation, combustion
head opening can be varied by moving the tie
rod onto holes 1-2-3, fig. (B).
The choice of the hole (1-2-3) to be used is de-
cided on the basis of diagram (D) against the re-
quired maximum output.
Setting is pre-arranged in the plant for the maxi-
mum run (hole 3).
When dealing with boilers featuring a strong
back pressure, if air delivery is insufficient even
with the damper fully open, you can use a differ-
ent setting to that illustrated in diagram (D) - do
this by moving the tie rod onto the next highest
hole numerically speaking, thus increasing the
combustion head’s opening and hence air deliv-
ery.
If combustion requirements require you to move
spacer (1) fig. (C) onto the 1st or 2nd hole of the
gear and, at the same time, the hinge is on the
right, you need to fit the spacers (4) fig. (C)
supplied with the burner.
Proceed as follows (fig. C):
- first unscrew nuts (2), remove tie rod (3),
unscrew spacer (1) and position it on the hole
you want,
- screw the spacers (4) onto spacer (1) and
screw (5) respectively,
- once done, refit the tie rod and nuts.
For operation on flame-reversal
boilers, gas pipes must be adjusted
to hole position 4, see Fig. (E).
ROTATION OF FAN MOTOR
Look at the fan motor's cooling fan from the front
and make sure it turns anticlockwise.
D3409
0
1
2
3
4
6
3
2
1
4
D3777
3
2
1
0
MBtu/h
NCV
19694
17743
18179
16378
16664
15012
15150
13648
13635
12283
12120
10919
10605
9554
9090
8189
7575
6824
6060
5459
4545
40953412
3787
2730
3030
GCV
4545 6060 7575 9090 10605 12120 13635 15150 16664
4095 5459 6824 8189 9554 10919 12283 13648 15012
1
3
2
0
NCV
GCV MBtu/h
1
2
3
4
5
N° Hole
(A)
D3802
(C)
D3093
(D)
D3803
(B)
Max burner output
Max burner output
N° Hole
NCV
GCV
NCV
GCV
MBtu/hr
RS 500/E BLU
RS 400/E BLU
RS 300/E BLU
MBtu/hr
Ignition pilot Electrode
(E)

9
GAS LINE (A)
The gas train is to be connected on the right of
the burner, by flange 1) (A).
If it is necessary to connect it on the left of the
burner, loosen nuts and screws 3) and 4),
remove blind flange 2) together with its gasket
and fit them to flange 1) tightening the nuts and
screws.
Note
Once assembled the gas train, check for leaks.
GAS TRAIN (B)
It must be type-approved according to Stand-
ards and is supplied separately from the burner.
KEY TO LAYOUT (B)
1 - Gas input pipe for main burner
2 - Manual valve
3 - Low gas pressure switch
4 - Safety shut-off valve with SKP10
5 - NO vent valve
6 - Regulating shut off valve with SKP20
7 - Gas input pipe for pilot
8 - Gas adjustment butterfly valve
9 - Burner
10- High gas pressure switch
11- Manual valve (for seal control)
12- Pilot regulator
IMPORTANT
The pressure at the head of the burner from
table (C) - refers to zero in the combustion
chamber; to obtain true pressure, measured by
a U-type manometer, (see fig. (A) page 10) add
the counter-pressure of the boiler.
Note
See the accompanying instructions for the
adjustment of the gas train.
(A)
(B)
Main
gas supply
10
2
3
45
6
11
Vent
Pilot
gas supply
212
5
4
7
Vent
9
8
1
4
NCV
kW
Combustion
Head
mbar
Gas
butterfly +
Adaptor
mbar
GCV
MBtu/hr
Combustion
Head
“WC
Gas
butterfly +
Adaptor
“WC
RS 300/E BLU
1350 8.4 1.6 5112 3.3 0.63
1500 9.4 2.0 5680 3.7 0.79
2000 12.4 3.5 7574 4.9 1.38
2500 13.7 5.4 9467 5.4 2.13
3000 15.0 7.8 11361 5.9 3
3500 20.2 10.6 13254 7.9 4.2
3800 23.0 13.0 14390 9 5.1
RS 400/E BLU
1800 5.8 2.8 6816 2.3 1.1
2000 7.6 3.5 7574 3 1.38
2500 11.9 5.4 9467 4.7 2.13
3000 16.3 7.8 11361 6.4 3
3250 18.5 9.2 12307 7.3 3.62
3500 21.1 10.6 13254 8.3 5.17
4000 27.6 13.9 15148 10.8 5.47
4500 33.0 18.0 17042 13 7
RS 500/E BLU
2500 11.2 4.6 9467 4.4 1.81
3000 15.4 6.7 11361 62.64
3500 19.5 9.1 13254 7.7 3
4000 24.7 11.8 15148 9.7 3.82
4500 30.0 15.0 17042 11.8 4.64
5000 35.9 18.5 18935 14.1 5.55
5200 38.0 20.0 19692 15 5.9
(C)
D3095
D3776
P1
P4