Riello RS 45 BLU Quick start guide

Installation, use and maintenance instructions
20191684 (1) - 07/2021
Forced draught gas burner
Two-stage operation
CODE MODEL
20191662 RS 45 BLU
GB

Translation of the original instructions

1 20191684
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Contents
1 Information and general warnings............................................................................................................................................ 3
1.1 Information about the instruction manual .................................................................................................................... 3
1.1.1 Introduction.................................................................................................................................................................. 3
1.1.2 General dangers.......................................................................................................................................................... 3
1.1.3 Other symbols ............................................................................................................................................................. 3
1.1.4 Delivery of the system and the instruction manual...................................................................................................... 4
1.2 Guarantee and responsibility....................................................................................................................................... 4
2 Safety and prevention................................................................................................................................................................ 5
2.1 Introduction.................................................................................................................................................................. 5
2.2 Personnel training ....................................................................................................................................................... 5
3 Technical description of the burner ......................................................................................................................................... 6
3.1 Burner designation ...................................................................................................................................................... 6
3.2 Models available.......................................................................................................................................................... 6
3.3 Technical data ............................................................................................................................................................. 7
3.4 Electrical data.............................................................................................................................................................. 7
3.5 Maximum dimensions.................................................................................................................................................. 8
3.6 Burner equipment........................................................................................................................................................ 8
3.7 Firing rates .................................................................................................................................................................. 9
3.8 Test boiler.................................................................................................................................................................. 10
3.8.1 Commercial boilers.................................................................................................................................................... 10
3.9 Burner description ..................................................................................................................................................... 11
3.10 Electrical panel description........................................................................................................................................ 12
3.11 Control box RMG88................................................................................................................................................... 13
3.12 Servomotor SQN.. ..................................................................................................................................................... 14
4 Installation ................................................................................................................................................................................ 15
4.1 Notes on safety for the installation ............................................................................................................................ 15
4.2 Handling .................................................................................................................................................................... 15
4.3 Preliminary checks .................................................................................................................................................... 15
4.4 Operating position ..................................................................................................................................................... 16
4.5 Preparing the boiler ................................................................................................................................................... 16
4.5.1 Boring the boiler plate ............................................................................................................................................... 16
4.5.2 Blast tube length........................................................................................................................................................ 16
4.5.3 Securing the burner to the boiler ............................................................................................................................... 16
4.6 Access to head internal part...................................................................................................................................... 17
4.7 Positioning the probe - electrode............................................................................................................................... 17
4.8 Combustion head adjustment.................................................................................................................................... 18
4.9 Gas supply ................................................................................................................................................................ 19
4.9.1 Gas feeding line ........................................................................................................................................................ 19
4.9.2 Gas train.................................................................................................................................................................... 20
4.9.3 Gas train installation.................................................................................................................................................. 20
4.9.4 Gas pressure............................................................................................................................................................. 20
4.10 Electrical connections................................................................................................................................................ 22
4.11 Motor rotation ............................................................................................................................................................ 23
5 Start-up, calibration and operation of the burner ................................................................................................................. 24
5.1 Notes on safety for the first start-up .......................................................................................................................... 24
5.2 Adjustments prior to ignition ...................................................................................................................................... 24
5.3 Burner start-up .......................................................................................................................................................... 24
5.4 Burner ignition ........................................................................................................................................................... 25
5.5 Burner adjustment ..................................................................................................................................................... 25
5.5.1 Output upon ignition .................................................................................................................................................. 25
5.5.2 Output in 2nd stage ................................................................................................................................................... 25
5.5.3 Output in 1st stage .................................................................................................................................................... 26
5.5.4 Intermediate outputs.................................................................................................................................................. 26

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Contents
5.6 Pressure switch adjustment .......................................................................................................................................27
5.6.1 Air pressure switch.....................................................................................................................................................27
5.6.2 Minimum gas pressure switch....................................................................................................................................27
5.6.3 Flame presence check...............................................................................................................................................27
5.7 Servomotor adjustment..............................................................................................................................................28
5.8 Burner operation ........................................................................................................................................................29
5.8.1 Burner start-up ...........................................................................................................................................................29
5.8.2 Full-running operation - System equipped with TR remote control ............................................................................29
5.8.3 Ignition failure.............................................................................................................................................................29
5.9 Burner start-up cycle diagnostics...............................................................................................................................30
5.9.1 Resetting of control box and diagnostics use ............................................................................................................30
5.9.2 Control box reset........................................................................................................................................................30
5.9.3 Visual diagnostics ......................................................................................................................................................30
5.9.4 Software diagnostics..................................................................................................................................................30
6 Maintenance ..............................................................................................................................................................................31
6.1 Notes on safety for the maintenance .........................................................................................................................31
6.2 Maintenance programme ...........................................................................................................................................31
6.2.1 Maintenance frequency..............................................................................................................................................31
6.2.2 Safety test - with no gas supply .................................................................................................................................31
6.2.3 Checking and cleaning...............................................................................................................................................31
6.2.4 Combustion control (gas)...........................................................................................................................................32
6.2.5 Safety components ....................................................................................................................................................32
6.3 Opening the burner ....................................................................................................................................................33
6.4 Closing the burner......................................................................................................................................................33
7 Faults - Possible causes - Solutions.......................................................................................................................................34
A Appendix - Accessories ...........................................................................................................................................................36
B Appendix - Electrical panel layout...........................................................................................................................................37

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Information and general warnings
1.1 Information about the instruction manual
1.1.1 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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 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
1.1.4 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.
1.2 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
2.1 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.
2.2 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:
2 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
3.1 Burner designation
3.2 Models available
3 Technical description of the burner
Designation Voltage Start-up Code
RS 45 BLU TC 1/230/50-60 Hz Direct 20191662
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 45 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
BLU

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Technical description of the burner
3.3 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. 5) 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.
3.4 Electrical data
Tab. B
Model RS 45 BLU
Output (1) 2nd stage kW 190 - 600
164 - 517
Mcal/h
1st stage (min.) kW
Mcal/h
90
78
Fuel Natural gas: G20 - G25
G20 G25
- Net calorific value kWh/Nm3
Mcal/Nm3
10
8.6
8.6
7.4
- Absolute density kg/Nm30.71 0.78
- Max delivery Nm3/h 60 69.8
- Pressure at maximum delivery (2) mbar 29 43.5
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) 70 81
Approval GB/T 36699
Model RS 45 BLU
Electrical supply 1N ~ 230 V 50-60 Hz
Fan motor rpm
W
V
A
2800
420
230
2.6
Motor capacitor F12.5
Ignition transformer V1 - V2
I1 - I2
220-240 V - 1 x 15 kV
45 VA - 25 mA
Electrical power consumption W max 760
Protection level IP 44

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Technical description of the burner
3.5 Maximum dimensions
The dimensions of the burner are given in Fig. 1.
Tab. C
(1) Blast tube: short-long
3.6 Burner equipment
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Seal for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M8 x 25. . . . . . . . . . . . . . . . . . . . . . . No. 4
Thermal flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws to fix the burner flange to the boiler M8 x 25 . . . . . No. 4
Plugs for electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . No. 3
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 6
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
mm BCDEE1FHLNP T-T(1) U - U (1)
RS 45 BLU 164 108 140 352 425 11/2” 456 476 167 578 230 - 365 806
P
T-T(1)B
D
N
E
C
F
L
H
E1
U-U(1)
Fig. 1
20152188

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Technical description of the burner
3.7 Firing rates
The burners RS 45 BLU 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 45 BLU = 90 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.
Fig. 2
RS 45 BLU 20153186
Thermal power - kW
Pressure in the chamber
pressure - mbar

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Technical description of the burner
3.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the
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 400 kW: diameter 50 cm - length 1.5 m.
3.8.1 Commercial boilers
The burner is suitable for operating on both flame inversion boil-
ers as well as on boilers with a combustion chamber with run-off
from the bottom (three flue passes) on which the best results for
low NOxemissions are obtained.
The maximum thickness of the boiler front door must not exceed
200 mm (see Fig. 4).
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of (Fig. 3)
preliminary checks are recommended.
Fig. 3
Combustion chamber
m
D497
Fig. 4
200 mm MAX
D1079

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Technical description of the burner
3.9 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Control box with lockout pilot light and lockout reset button
5 Flame sensor probe
6 Air pressure socket
7 Gas pressure test point and head fixing screw
8 Screws securing fan to sleeve
9 Slide bars for opening the burner and inspecting the
combustion head
10 Servomotor controlling the gas butterfly valve and the air
damper (by means of a variable profile cam mechanism).
When the burner is stopped, the air damper will be
completely closed to reduce heat loss due to the flue
draught, which tends to draw air from the fan air inlet
11 Areas for passage of electric cables
12 Air inlet to fan
13 Gas input pipework
14 Gas butterfly valve
15 Boiler mounting flange
16 Flame stability disc
17 Flame inspection window
18 Fan motor
19 Air damper
Two types of burner lockout may occur:
CONTROL BOX LOCKOUT:
if the control box button (red LED) 4)(Fig. 5) lights up, it indicates
that the burner is locked out. To reset, hold the push button down
for between 1 and 3 seconds.
12
11
13 14 15
16
10
18
19
4 17
5
1
2
36
7
8 9
Fig. 5
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Technical description of the burner
3.10 Electrical panel description
1 Ionisation probe connector
2 Control box base
3 Two switches:
- one for “on - off burner”
- one for “1st - 2nd stage”
4 Filter to protect against radio disturbance
5 Ignition transformer
6Relay
7 Air pressure switch
8 Sockets for electrical connection
7
1
8
2
4
6
3
5
Fig. 6
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Technical description of the burner
3.11 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 opera-
tions, 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 func-
tions.
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 conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
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 opera-
tion. Riello S.p.A. cannot assume any responsibil-
ity 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. 260g
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. 7
S8906

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Technical description of the burner
3.12 Servomotor SQN..
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. 8
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Installation
4.1 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.
4.2 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.
4.3 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)
Attention. The burner output must be within the boiler's
firing rate;
I the category of the appliance/countries of destination.
4 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.
A B
CD
E F
G
I I I I I I I I
G
I
H
H
Fig. 9
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Installation
4.4 Operating position
4.5 Preparing the boiler
4.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the
thermal insulation screen supplied with the burner.
Tab. D
4.5.2 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 13) or flame inversion chamber,
a protection in refractory material 11) must be inserted between
the boiler fettling 12) and the blast tube 10).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 11)-
12)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
4.5.3 Securing the burner to the boiler
Separate the combustion head from the rest of the burner
(Fig. 12):
Remove the cover.
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.
ATTENTION
The burner is set up 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 4permit 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.
Fig. 10
2 3 4 51
D3928
mm D1 DF Ø
RS 45 BLU 165 224 M 8
mm RS 45 BLU
Standard 230
Elongated 365
Ø
45
45
DF
D1
Fig. 11
20149117
Provide an adequate lifting system.
ATTENTION
The seal between burner and boiler must be
airtight.
Fig. 12
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Installation
4.6 Access to head internal part
In order to reach inside the combustion head (Fig. 13) proceed as
follows:
remove the screw 1) and the internal part 2).
Fix the flange 9)(Fig. 12) to the plate of the boiler interposing
the insulating flange gasket 6)(Fig. 12) 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.
4.7 Positioning the probe - electrode
If in the previous check the position of the probe or electrode was
not correct, remove the screw 1)(Fig. 13) extract the inner part
2)(Fig. 13) of the head, and adjust them.
Fig. 13
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. 14.
ATTENTION
Do not rotate the probe but leave it as in Fig. 14; if
it is too close to the ignition electrode, it could
damage the control box amplifier.
ATTENTION
Respect the dimensions shown in Fig. 14.
3
mm
7mm
2mm
5
mm
Fig. 14
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Installation
4.8 Combustion head adjustment
Installation operations are now at the stage where the blast tube
and sleeve are secured to the boiler as shown in Fig. 15.
It is therefore particularly easy to adjust the combustion head.
Air adjustment (Fig. 15 - Fig. 16)
Rotate the screw (1) until the notch on the lamina (2) corresponds
with the surface of the plate (3).
Example:
RS 45 BLU burner, output = 300 kW.
From diagram (Fig. 16) you can see that, for the MAX output of
300 kW, the air should be adjusted at notch 3, subtracted from
the value of the pressure in the chamber.
In this case, the loss of pressure in the combustion head is shown
in paragraph on page 20.
NOTE:
If the pressure in the chamber is equal to 0 mbar, the air is adjust-
ed with reference to the broken line of the diagram Fig. 16.
Central air adjustment
In case the application needs a particular setup, it is possible
to modify the central air delivery using the ring nut
4)(Fig. 15) up to the notch indicated in diagram (Fig. 17).
In order to carry out this operation, unscrew the screws
5)(Fig. 15) and rotate the ring nut 4)(Fig. 15).
At the end, tighten the screws 5)(Fig. 15) again.
Once you have finished adjusting the head, reassemble the
burner 4)(Fig. 18) on the guides 3)(Fig. 18) at about 100mm
from the pipe coupling 5)(Fig. 18) - burner in the position
shown in Fig. 12 - insert the cable of the probe and the cable
of the electrode, then slide the burner as far as the pipe cou-
pling, burner in the position shown in Fig. 18.
Refit screws 2)(Fig. 18) on guides 3)(Fig. 18).
Fix the burner to the pipe coupling with the screw 1)(Fig. 18).
ATTENTION
When fitting the burner on the two slide bars, it is
advisable to gently draw out the high tension ca-
ble and flame detection probe cable until they are
slightly stretched.
ATTENTION
The adjustments indicated can be modified during
the initial start-up.
Fig. 15
20151933
Max burner output
Combustion head setting
Fig. 16
No. notches 20152659
Central air adjustment
Max burner output
Fig. 17
20152663
No. notches
Fig. 18
20152666