Riello RS 68/E BLU Quick start guide

Installation, use and maintenance instructions
20068435 (8) - 07/2021
Forced draught gas burners
Progressive two-stage or modulating operation
CODE MODEL TYPE
3897432 - 3897433 RS 68/E BLU 846 T1
3897632 - 3897633 RS 120/E BLU 847 T1
3788032 - 3788033 RS 160/E BLU 843 T1
3899810 - 3899811 RS 200/E BLU 1106 T1
3899840 RS 200/E BLU 1106 T1
GB

Translation of the original instructions

1 20068435
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 5
2.1 Information about the instruction manual .................................................................................................................... 5
2.1.1 Introduction.................................................................................................................................................................. 5
2.1.2 General dangers.......................................................................................................................................................... 5
2.1.3 Other symbols ............................................................................................................................................................. 5
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 6
2.2 Guarantee and responsibility....................................................................................................................................... 6
3 Safety and prevention................................................................................................................................................................ 7
3.1 Introduction.................................................................................................................................................................. 7
3.2 Personnel training ....................................................................................................................................................... 7
4 Technical description of the burner ......................................................................................................................................... 8
4.1 Burner designation ...................................................................................................................................................... 8
4.2 Burner categories........................................................................................................................................................ 9
4.3 Models available.......................................................................................................................................................... 9
4.4 Technical data........................................................................................................................................................... 10
4.5 Electrical data............................................................................................................................................................ 11
4.6 Maximum dimensions................................................................................................................................................ 12
4.7 Firing rates ................................................................................................................................................................ 13
4.7.1 Firing rate on basis of air density .............................................................................................................................. 14
4.8 Test boiler.................................................................................................................................................................. 15
4.9 Burner equipment...................................................................................................................................................... 15
4.10 Burner description ..................................................................................................................................................... 16
4.11 Control box for the air/fuel ratio (REC 27.100A2)...................................................................................................... 17
4.12 Operation sequence of the burner............................................................................................................................. 20
4.12.1 List of phases ............................................................................................................................................................ 21
4.13 Operator panel operation .......................................................................................................................................... 21
4.13.1 Symbols description on the display........................................................................................................................... 21
4.13.2 Buttons description.................................................................................................................................................... 22
4.14 Servomotors (SQM33....) .......................................................................................................................................... 23
5 Installation ................................................................................................................................................................................ 24
5.1 Notes on safety for the installation ............................................................................................................................ 24
5.2 Handling .................................................................................................................................................................... 24
5.3 Preliminary checks .................................................................................................................................................... 24
5.4 Operating position ..................................................................................................................................................... 25
5.5 Preparing the boiler................................................................................................................................................... 25
5.5.1 Introduction................................................................................................................................................................ 25
5.5.2 Boring the boiler plate ............................................................................................................................................... 25
5.5.3 Blast tube length........................................................................................................................................................ 26
5.6 Positioning probe - electrode..................................................................................................................................... 26
5.7 Securing the burner to the boiler............................................................................................................................... 27
5.8 Pre-calibrating the combustion head......................................................................................................................... 28
5.9 Combustion head adjustment.................................................................................................................................... 28
5.10 Burner closing ........................................................................................................................................................... 29
5.11 Gas feeding............................................................................................................................................................... 30
5.11.1 Gas feeding line ........................................................................................................................................................ 30
5.11.2 Gas train.................................................................................................................................................................... 31
5.11.3 Gas train installation.................................................................................................................................................. 31
5.11.4 Gas pressure............................................................................................................................................................. 31
5.12 Electrical wiring ......................................................................................................................................................... 33
5.12.1 Supply cables and external connections passage .................................................................................................... 33
5.13 Calibration of the thermal relay ................................................................................................................................. 34
6 Start-up, calibration and operation of the burner ................................................................................................................. 35
6.1 Notes on safety for the first start-up .......................................................................................................................... 35
6.2 Adjustments prior to ignition ...................................................................................................................................... 35
6.3 Burner start-up .......................................................................................................................................................... 36

20068435 2
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Contents
6.4 Burner adjustment......................................................................................................................................................36
6.4.1 Firing output ...............................................................................................................................................................36
6.4.2 Maximum output ........................................................................................................................................................36
6.4.3 Minimum output .........................................................................................................................................................36
6.5 Final calibration of the pressure switches ..................................................................................................................37
6.5.1 Air pressure switch.....................................................................................................................................................37
6.5.2 Maximum gas pressure switch...................................................................................................................................37
6.5.3 Minimum gas pressure switch....................................................................................................................................38
6.5.4 PVP pressure switch kit .............................................................................................................................................38
6.6 Visualisation and programming mode........................................................................................................................39
6.6.1 Normal mode .............................................................................................................................................................39
6.6.2 Info mode ...................................................................................................................................................................40
6.6.3 Service mode .............................................................................................................................................................41
6.6.4 Parameter mode ........................................................................................................................................................41
6.7 Parameter modification procedure.............................................................................................................................42
6.8 Start-up procedure .....................................................................................................................................................44
6.9 Backup / Restore procedure ......................................................................................................................................46
6.9.1 Backup .......................................................................................................................................................................46
6.9.2 Restore ......................................................................................................................................................................47
6.9.3 Parameter list.............................................................................................................................................................49
6.10 Steady-state operation...............................................................................................................................................53
6.11 Ignition failure.............................................................................................................................................................53
6.12 Burner flame goes out during operation.....................................................................................................................53
6.13 Stopping of the burner ...............................................................................................................................................53
6.14 Final checks (with burner operating)..........................................................................................................................54
7 Maintenance ..............................................................................................................................................................................55
7.1 Notes on safety for the maintenance .........................................................................................................................55
7.2 Maintenance programme ...........................................................................................................................................55
7.2.1 Maintenance frequency..............................................................................................................................................55
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................55
7.2.3 Checking and cleaning...............................................................................................................................................55
7.2.4 Measuring the ionisation current................................................................................................................................56
7.2.5 Checking the air and gas pressure on the combustion head.....................................................................................56
7.2.6 Safety components ....................................................................................................................................................57
7.3 Opening the burner ....................................................................................................................................................58
7.4 Closing the burner......................................................................................................................................................58
8 Faults - Probable causes - Solutions ......................................................................................................................................59
8.1 Error codes list ...........................................................................................................................................................59
A Appendix - Accessories ...........................................................................................................................................................66
B Appendix - Electrical panel layout...........................................................................................................................................68

3 20068435
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Declarations
5
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: RS 68/E BLU
RS 120/E BLU
RS 160/E BLU
RS 200/E BLU
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
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, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
Manufacturer’s Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm-
SchV release 26.01.2010”.
Product Type Model Output
Forced draught gas burners 846 T1 RS 68/E BLU 150 - 860 kW
847 T1 RS 120/E BLU 300 - 1300 kW
843 T1 RS 160/E BLU 300 - 1860 kW
1106 T1 RS 200/E BLU 550 - 2400 kW
CE-0085BS0267 RS 68/E BLU
CE-0085BS0268 RS 120/E BLU
CE-0085BS0266 RS 160/E BLU
CE-0085BT0419 RS 200/E BLU

20068435 4
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Declarations
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer: RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.riello.com
Distributed by: VAN MARCKE HQ
LAR Blok Z 5,
B-8511 Kortrijk (Aalbeke) Belgio
Tel. [phone]
e-mail: [email protected]
URL. www.vanmarcke.com
It is hereby certified that the apparatuses specified below conform with the model of the type described n the CE conformity decla-
ration and they are produced and placed in circulation in conformity with the provisions defined in L.D. dated January 8, 2004 and
July 17, 2009.
Type of product: Forced draught gas burners
Model: RS 68/E BLU
Regulation applied: EN 676 and A.R. dated January 8, 2004 - July 17, 2009
Control body: TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
Measured value: CO max: 5 mg/kWh
NOx max: 61 mg/kWh

5 20068435
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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 Ser-
vice 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 car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal 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 at-
mosphere may be present. An explosive atmos-
phere 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 HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood 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.

20068435 6
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Information and general warnings
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance 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 recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, 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, incor-
rectly 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;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
the use of non-original components, including spare parts,
kits, accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

7 20068435
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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 confi-
dence 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 dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other users 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 room temperature must all be within the values indicated
in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. 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 re-
sponsible for the machine and for the training of the people work-
ing 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, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions 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 com-
promise 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
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures neces-
sary to prevent unauthorised people gaining
access to the machine
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual

20068435 8
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Technical description of the burner
4.1 Burner designation
4 Technical description of the burner
R S 200 E TC FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
Range : R
Size
Fuel : Natural gas
Light oil
Light oil / Natural gas
Adjustment :
Flame control system :
FS1
FS2
Standard (1 stop every 24h)
Continuous operation (1 stop every 72h)
Electrical supply of the system :
3/400/50
3/230/50
Voltage of auxiliaries :
230/50/60
110/50/60
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
S
L
LS
N
Head : TC Standard head
TL Long head
Emission : C01 or ...
MZ
BLU
MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
3/400-230/50 3N / 400V-230V / 50Hz

9 20068435
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Technical description of the burner
4.2 Burner categories
Tab. A
4.3 Models available
Tab. B
Country of destination Gas category
BE I2E(R)
LV I2H
CY, MT I3B/P
BE I3P
LU, PL II2E3B/P
DE II2ELL3B/P
FR II2Er3P
AT, CH, CZ, DK, EE, FI, GR, HU, IS, IT, LT, NO, SE, SI, SK II2H3B/P
ES, GB, IE, PT II2H3P
NL I2L - I2E - I2 (43.46 ÷ 45.3 MJ/m3(0°C))
Designation Voltage Start-up Code
RS 68/E BLU TC 3 ~ 400 / 230V - 50Hz Direct 3897432
RS 68/E BLU TL 3 ~ 400 / 230V - 50Hz Direct 3897433
RS 120/E BLU TC 3 ~ 400 / 230V - 50Hz Direct 3897632
RS 120/E BLU TL 3 ~ 400 / 230V - 50Hz Direct 3897633
RS 160/E BLU TC 3 ~ 400 / 230V - 50Hz Direct 3788032
RS 160/E BLU TL 3 ~ 400 / 230V - 50Hz Direct 3788033
RS 200/E BLU TC 3 ~ 400V - 50Hz Direct 3899810
RS 200/E BLU TL 3 ~ 400V - 50Hz Direct 3899811
RS 200/E BLU TC 3 ~ 230V - 50Hz Direct 3899840

20068435 10
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Technical description of the burner
4.4 Technical data
Tab. C
Tab. D
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(2) Pressure on the pressure switch socket (Fig. 30 at page 35) with zero pressure in the combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output.
The sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy,
as set out in EN ISO 3746.
(4) Blast tube: short-long.
Model RS 68/E BLU RS 120/E BLU RS 160/E BLU
Type 846 T1 847 T1 843 T1
Output (1) Max. kW
Mcal/h
350 ÷ 860
301 ÷ 740
600 ÷ 1300
516 ÷ 1118
930 ÷ 1860
800 ÷ 1600
Min. kW
Mcal/h
150
130
300
258
300
258
Fuel Natural gas: G20 (methane gas) G21 - G22 - G23 - G25
Gas pressure at max. output (2)
- Gas: G20 / G25
mbar
11.7 / 17.5 22.5 / 33.6 17.7 / 26.4
Operation – Intermittent (min. 1 stop in 24 hours)
– Two progressive or modulating stages with kit (see ACCESSORIES)
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 77 88
78.5
89.5
80.5
91.5
Weight (4) kg 77-79 83-85 96-98
Model RS 200/E BLU
Type 1106 T1
Output (1) Max. kW
Mcal/h
1380 ÷ 2400
1187 ÷ 2064
Min. kW
Mcal/h
550
473
Fuel Natural gas: G20 (methane gas) G21 - G22 - G23 - G25 - G31
Gas pressure at max. output (2)
- Gas: G20 / G25
- Gas: G31
mbar
28.0 / 41.8
19.6
Operation – Intermittent (min. 1 stop in 24 hours)
– Two progressive or modulating stages with kit (see ACCESSORIES)
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 83.0 94.0
Weight (4) kg 101-103

11 20068435
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Technical description of the burner
4.5 Electrical data
Tab. E
Tab. F
Tab. G
Model RS 68/E BLU RS 120/E BLU
Type 846 T1 847 T1
Main electrical supply
Control circuit power supply
3 ~ 230/400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
3 ~ 230/400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
Fan motor IE3 Hz
rpm
V
kW
A
50
2890
220/240 - 380/415
1.5
5.9 - 3.4
50
2890
220/240 - 380/415
2.2
8.0 - 4.6
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 2.3 3.0
Protection level IP 44
Model RS 160/E BLU
Type 843 T1
Main electrical supply
Control circuit power supply
3 ~ 230/400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
Fan motor IE3 Hz
rpm
V
kW
A
50
2895
230 - 400
4.5
15.0 - 8.7
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 5.3
Protection level IP 44
Model RS 200/E BLU
Type 1106 T1
Main electrical supply
Control circuit power supply
3 ~ 230/400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
Fan motor IE3 Hz
rpm
V
kW
A
50
2935
230 - 400
5.5
17.7 - 10.2
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 6.5
Protection level IP 44

20068435 12
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Technical description of the burner
4.6 Maximum dimensions
The dimensions of the burner are shown in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the guides.
The dimensions of the open burner are indicated by position I.
Tab. H
(1) Blast tube: short-long
Fig. 1
D1206
mm ABCDE F (1) GH I (1) LMNO
RS 68/E BLU 511 312 215 555 840 255-390 189 430 1161-1296 214 134 221 2”
RS 120/E BLU 553 338 215 555 840 255-390 189 430 1161-1296 214 134 221 2”
RS 160/E BLU 681 366 315 555 872 373-503 222 430 1442-1587 230 141 260 2”
RS 200/E BLU 732 427 305 555 872 373-503 222 430 1442-1587 230 141 260 2”

13 20068435
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Technical description of the burner
4.7 Firing rates
The maximum output is chosen within area A (and B for RS 120/
E BLU) of the diagram (Fig. 2).
The minimum output must not be lower than the minimum limit
of the diagram.
WARNING
to use area B (RS 120/E BLU) as well, the pre-cali-
bration of the combustion head is necessary, as ex-
plained in the paragraph "Pre-calibrating the
combustion head" at page 28.
CAUTION
The firing rate (Fig. 2) of the model RS 200/E BLU
refers to the operation with fuel G20 - G25.
In case G31 is used, the minimum output goes
from 550 to 630 kW.
WARNING
The firing rate (Fig. 2) was obtained considering a
room temperature of 20°C and an atmospheric
pressure of 1013 mbar (approx. 0 m above sea
level), with the combustion head adjusted as
shown at page 28.
Thermal power Thermal power
RS 68/E BLU RS 120/E BLU D9600
Fig. 2
Thermal power Thermal power
RS 160/E BLU
RS 200/E BLU
Combustion chamber
pressure - mbar
Combustion chamber
pressure - mbar
Combustion chamber
pressure - mbar
Combustion chamber
pressure - mbar

20068435 14
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Technical description of the burner
4.7.1 Firing rate on basis of air density
The firing rate of the burner shown in the manual is valid for a
room temperature of 20°C and an altitude of 0m above sea level
(barometric pressure around 1013 mbar).
It may be that a burner has to operate with combustive air at a
higher temperature and/or higher altitudes.
The heating of the air and the increase in altitude produce the
same effect: the expansion of the air volume (i.e. the reduction of
its density).
The delivery of the burner fan remains essentially the same, but
the oxygen per m3of air, and the thrust (discharge head) of the
fan are reduced.
It is therefore important to know if the maximum output requested
from the burner at a determinate combustion chamber pressure
remains within the firing rate of the burner even with the changed
temperature and altitude conditions.
To check it, proceed as follows:
1 find the corrective factor F (relating to the air temperature
and altitude of the system) in the Tab. I.
2 Divide the output Q required from the burner by F to obtain
the equivalent output Qe:
3 In the firing rate of the burner, mark the work point identified
by:
Qe = equivalent output
H1 = pressure in combustion chamber
point A that must remain within the firing rate.
4 Trace a vertical line from point A)(Fig. 3), and find the maxi-
mum pressure H2 of the firing rate.
5 Multiply H2 by F to obtain the maximum lowered pressure
H3 of the firing rate:
If H3 is greater than H1)(Fig. 3), the burner can produce the de-
livery requested.
If H3 is less than H1, it is necessary to reduce the output of the
burner. The reduction in output is accompanied by a reduction in
the combustion chamber pressure:
Qr = reduced output
H1r = reduced pressure
Example, 5% reduction in output:
Qr = Q x 0,95
H1r = H1 x (0,95)2
With the new values - Qr and H1r - repeat steps 2 - 5.
Tab. I
Qe = Q : F (kW)
H3 = H2 x F (mbar)
WARNING
The combustion head should be adjusted in rela-
tion to the equivalent output Qe.
H1r = H1 x ()
Qr
Q
2
Qe kg/h
mbar
Qe kW
mbar
A
H1
H2
H3
D388
Fig. 3
Altitude Average baro-
metric pressure
F
Air temperature °C
m a.s.l. mbar 0 5 10 15 20 25 30 40
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2400
2800
3200
3600
4000
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
755
714
675
635
616
1.087
1.073
1.061
1.050
1.037
1.025
1.013
1.000
0.988
0.977
0.964
0.942
0.919
0.897
0.875
0.852
0.810
0.766
0.724
0.682
0.661
1.068
1.054
1.042
1.031
1.018
1.007
0.995
0.982
0.971
0.959
0.946
0.925
0.902
0.881
0.859
0.837
0.796
0.753
0.711
0.669
0.649
1.049
1.035
1.024
1.013
1.000
0.989
0.977
0.965
0.954
0.942
0.930
0.909
0.886
0.866
0.844
0.822
0.782
0.739
0.699
0.657
0.638
1.031
1.017
1.006
0.995
0.983
0.972
0.960
0.948
0.937
0.926
0.914
0.893
0.871
0.851
0.829
0.808
0.768
0.726
0.687
0.646
0.627
1.013
1.000
0.989
0.978
0.966
0.955
0.944
0.932
0.921
0.910
0.898
0.878
0.856
0.836
0.815
0.794
0.755
0.714
0.675
0.635
0.616
0.996
0.983
0.972
0.962
0.950
0.939
0.928
0.916
0.906
0.895
0.883
0.863
0.842
0.822
0.801
0.781
0.742
0.702
0.664
0.624
0.606
0.980
0.967
0.956
0.946
0.934
0.923
0.913
0.901
0.891
0.880
0.868
0.849
0.828
0.808
0.788
0.768
0.730
0.690
0.653
0.614
0.596
0.948
0.936
0.926
0.916
0.904
0.894
0.884
0.872
0.862
0.852
0.841
0.822
0.801
0.783
0.763
0.743
0.707
0.668
0.632
0.594
0.577

15 20068435
GB
Technical description of the burner
4.8 Test boiler
The firing rates were obtained in special test boilers, according to
EN 676 regulations.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 756 kW (650 Mcal/h) - diameter 60 cm, length 2 m.
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. 4, pre-
liminary checks are recommended.
4.9 Burner equipment
The burner is supplied complete with:
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M10 x 35 to fix the flange . . . . . . . . . . . . . . . . . . . No. 4
Screws M12 x 35 to fix the burner flange to the boiler . . . . No. 4
PVP kit for leak detection (except RS 68/E BLU). . . . . . . . No. 1
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 4
Combustion chamber
lenght - m
D715

20068435 16
GB
Technical description of the burner
4.10 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling
6 Gas servomotor
7 Plug-socket on ionisation probe cable
8 Motor contact maker and thermal relay with reset button
9 Operation on/off switch
10 Terminal board for electrical wiring
11 Operator panel with LCD display
12 Control box for checking flame and air/fuel ratio
13 Clean contact relay
14 Filter to protect against radio disturbance
15 Flame inspection window
16 Ignition transformer
17 Cable grommets for electrical wiring (to be carried out by the
installer)
18 Air servomotor
19 Air pressure switch (differential type)
20 Guides for opening the burner and inspecting the combus-
tion head
21 Gas pressure test point and head fixing screw
22 Air pressure socket
23 Flame sensor probe
24 Air damper
25 Fan air inlet
26 Screws to secure fan to pipe coupling
27 Gas input pipe
28 Gas butterfly valve
29 Boiler fixing flange
30 Flame stability disc
31 Bracket for application of output regulator RWF40
32 Extensions for guides 20) - only for TL versions
25
A
19
31
9
20 521 32130
23
22
29
26
6
13
18
24
12
11
10
17
14 7
Vista da "A"
15
4
27
28
8
1632
Fig. 5
D7923
A
Seen from A

17 20068435
GB
Technical description of the burner
4.11 Control box for the air/fuel ratio (REC 27.100A2)
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 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.
During the programming of the control curves of the air-fuel
ratio, the technician should constantly observe the quality of
the combustion process (for example, using a gas analyser)
and, if the combustion values are too low or if there are dan-
gerous conditions, take the appropriate action, for example
by manually switching off the system.
The plugs of the connection cables or other accessories can
be removed or changed when the system is off.
The connections to the actuators do not provide a safe sepa-
ration of the mains voltage. Before connecting or changing
the actuators, the system should be switched off.
To ensure the safety and reliability of the control box, the follow-
ing instructions must also be followed:
– 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.
Installation notes
Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
Check the electric wiring inside the boiler complies with the
national and local safety regulations.
Phase and neutral should not be exchanged (cause of dan-
gerous malfunctions, loss of protection against electric
shocks, etc..).
Make certain that strain relief of the connected cables is in
compliance with the relevant standards (e.g. as per
EN60730 e EN60 335).
Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
The mechanical connection between the actuators and the
elements for controlling the fuel and air, or other control ele-
ments, should be rigid.
When wiring the unit, make sure that AC 230V mains volt-
age cables are run strictly separate from extra low-voltage
cables to avoid risks of electrical shock hazard.
Mechanical structure
The control box is a system to check the burners, based on a mi-
croprocessor and equipped with components to adjust and mon-
itor medium and large capacity forced draught burners.
The base control box of the control box incorporates the following
components:
– burner adjustment device with system for checking the seal
of the gas valves;
– electronic fuel/air ratio monitoring device with a maximum of
2 actuators;
– Modbus interface.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the display and operating unit and incor-
rect settings of the fuel and / or air actuator posi-
tions can lead to dangerous burner operating
conditions.
Fig. 6
D8266

20068435 18
GB
Technical description of the burner
Electrical connection of flame detector
It is important for signal transmission to be almost totally free
of any disturbances or loss:
always separate the detector cables from the other cables:
– line capacitance reduces the magnitude of the flame sig-
nal.
– Use a separate cable.
Respect the allowed cable lengths.
The ionisation probe is not protected against the risk of elec-
trocution; it must be protected against any accidental con-
tact.
The grounding of the burner must be in compliance with the
rules in force; the grounding of the boiler alone is not
enough.
Position the ignition electrode and the ionisation probe so
that the ignition spark cannot form an arc on the probe (risk
of electric overcharge).
Technical data
Control box Mains voltage AC 230 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power absorption < 30 W (normal)
Safety class I, with components in compliance with II and III, ac-
cording to DIN EN 60730-1
Load on ‘input’
terminals
F1 unit fuse (internal) 6,3 AT
Main fuse of perm. network (external) Max. 16 AT
Undervoltage
– Safety switch-off from operating position to mains
voltage
– Restart when mains voltage picks up
< AC 186 V
> AC 195 V
Input currents and input voltages
– UeMax
–UeMin
– Iemax
–IeMin
UN +10%
UN -15%
1.5 mA peak
0.7 mA peak
Voltage detection
–On
–Off
AC 180...253 V
< AC 80 V
Load on ‘output’
terminals
Total load on the contacts
– Mains voltage
– Total unit input current (safety circuit)
- Fan motor contactor
- Ignition transformer
- Valve
AC 230 V, 50 / 60 Hz
Max. 5 A
Single contact loading
Fan motor contactor
– Rated voltage
– Nominal current
– Power factor
AC 230 V, 50 / 60 Hz
2A
cos> 0.4
Alarm output
– Rated voltage
– Nominal current
– Power factor
AC 230 V, 50 / 60 Hz
1A
cos> 0.4
Ignition transformer
– Rated voltage
– Nominal current
– Power factor
AC 230 V, 50 / 60 Hz
2A
cos> 0.2
Fuel valve
– Rated voltage
– Nominal current
– Power factor
AC 230 V, 50 / 60 Hz
2A
cos> 0.4
Display operation
– Rated voltage
– Nominal current
– Power factor
AC 230 V, 50 / 60 Hz
0,5A
cos> 0.4