Riello RS 150/M Quick start guide

Installation, use and maintenance instructions
20054085 (2) - 05/2013
Forced draught gas burners
Progressive two-stage or modulating operation
CODE MODEL TYPE
20044638 - 20044639 RS 150/M 890T
20051315 - 20051316 RS 150/M 890T
GB

Translation of the original instructions

1 20054085
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Burner weight .............................................................................................................................................................. 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rate .................................................................................................................................................................... 9
4.7.1 Firing rate based on the air density............................................................................................................................. 9
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description ..................................................................................................................................................... 11
4.10 Burner equipment...................................................................................................................................................... 11
4.11 Control box (RMG/M 88.62C2).................................................................................................................................. 12
4.12 Servomotor (SQN31.76...)......................................................................................................................................... 13
5 Installation ................................................................................................................................................................................ 14
5.1 Notes on safety for the installation ............................................................................................................................ 14
5.2 Handling .................................................................................................................................................................... 14
5.3 Preliminary checks .................................................................................................................................................... 14
5.4 Operating position ..................................................................................................................................................... 15
5.5 Preparing the boiler ................................................................................................................................................... 15
5.5.1 Boring the boiler plate ............................................................................................................................................... 15
5.5.2 Blast tube length........................................................................................................................................................ 15
5.6 Securing the burner to the boiler............................................................................................................................... 16
5.7 Positioning the probe - electrode............................................................................................................................... 17
5.8 Combustion head adjustment.................................................................................................................................... 17
5.8.1 Air adjustment ........................................................................................................................................................... 17
5.8.2 Gas adjustment ......................................................................................................................................................... 17
5.9 Gas feeding ............................................................................................................................................................... 19
5.9.1 Gas feeding line ........................................................................................................................................................ 19
5.9.2 Gas train.................................................................................................................................................................... 20
5.9.3 Gas train installation.................................................................................................................................................. 20
5.9.4 Gas pressure............................................................................................................................................................. 20
5.10 Electrical wiring ......................................................................................................................................................... 22
5.10.1 Supply cables and external connections passage .................................................................................................... 22
5.11 Calibration of the thermal relay ................................................................................................................................. 23
5.12 Measuring the ionisation current ............................................................................................................................... 23
6 Start-up, calibration and operation of the burner ................................................................................................................. 24
6.1 Notes on safety for the first start-up .......................................................................................................................... 24
6.2 Adjustments prior to ignition ...................................................................................................................................... 24
6.3 Burner start-up .......................................................................................................................................................... 25

20054085 2
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Contents
6.4 Burner ignition............................................................................................................................................................25
6.5 Servomotor adjustment..............................................................................................................................................25
6.6 Adjusting the burner...................................................................................................................................................26
6.6.1 Output upon ignition...................................................................................................................................................26
6.6.2 Maximum output ........................................................................................................................................................26
6.6.3 Minimum output .........................................................................................................................................................27
6.6.4 Intermediate outputs ..................................................................................................................................................27
6.6.5 Maximum gas pressure switch...................................................................................................................................28
6.6.6 Minimum gas pressure switch....................................................................................................................................28
6.6.7 Air pressure switch.....................................................................................................................................................28
6.7 Operation sequence of the burner .............................................................................................................................29
6.7.1 Burner start-up ...........................................................................................................................................................29
6.7.2 Operation ...................................................................................................................................................................29
6.7.3 Ignition failure.............................................................................................................................................................29
6.7.4 Burner flame goes out during operation.....................................................................................................................29
6.8 Stopping of the burner ...............................................................................................................................................30
6.9 Final checks (with burner operating)..........................................................................................................................30
6.9.1 Checking the air and gas pressure on the combustion head.....................................................................................30
7 Maintenance ..............................................................................................................................................................................31
7.1 Notes on safety for the maintenance .........................................................................................................................31
7.2 Maintenance programme ...........................................................................................................................................31
7.2.1 Maintenance frequency..............................................................................................................................................31
7.2.2 Checking and cleaning...............................................................................................................................................31
7.3 Opening the burner ....................................................................................................................................................32
7.4 Closing the burner......................................................................................................................................................32
8 Faults - Possible causes - Solutions.......................................................................................................................................33
8.1 Normal operation / flame detection time ....................................................................................................................35
A Appendix - Accessories ...........................................................................................................................................................36
B Appendix - Electrical panel layout...........................................................................................................................................38

3 20054085
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burners
Model: RS 150/M
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 18.02.2013 Executive Director
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. I. Zinna Mr. R. Cattaneo
In progress

20054085 4
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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
Service 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 DEVICES
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.

5 20054085
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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 Assist-
ance 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 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, 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;
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 estab-
lished 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 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.

20054085 6
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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, diathermic
oil, and to other uses expressly foreseen 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 cham-
ber and the room temperature must all be within the values indi-
cated 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.
must take all the measures necessary to pre-
vent 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.

7 20054085
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Designation Voltage Start-up Code
RS 150/M TC 3/400/50 Direct 20044638
RS 150/M TL 3/400/50 Direct 20044639
RS 150/M TC 3/230/50 Direct 20051315
RS 150/M TL 3/230/50 Direct 20051316
Range: R
Size
Fuel: Natural gas
Gas oil
Gas oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
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 150 MTC
Emission: C01 or... Class 1 EN676
BLU or BLU Class 3 EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with 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 Long head
C02 or MZ Class 2 EN676

20054085 8
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Technical description of the burner
4.3 Burner categories - Countries of destination
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at socket 16)(Fig. 6) with zero pressure in combustion chamber and at maximum burner output.
(3) Noise emission tests carried out as specified in EN 15036-1 with measurement accuracy σ= ± 1.5 dB, in the manufacturer's combustion chamber
with burner operating on test boiler at maximum output.
4.5 Burner weight
The weight of the burner complete with its packaging is shown in
Tab. D.
Tab. D
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L
FR I2Er
BE I2E(R)B
LU - PL I2E
Model RS 150/M
Code 20044638 - 20044639 20051315 - 20051316
Power(1)
Delivery (1)
min - max kW 300/900 - 1850
Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2) -
Gas: G20/G25 mbar 17,5 / 27,1
Operation – Intermittent (min. 1 stop in 24 hours)
– Progressive two-stage or modulating by kit (See Accessories).
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Auxiliary circuit electrical supply 1N ~ 230V 50 Hz
Electrical supply 3 ~ 400V +/-10% 50 Hz 3 ~ 230V +/-10% 50 Hz
Fan motor
rpm
V
kW
A
2920
400
3.0
5.9
2920
230
3.0
10.2
Ignition transformer V1 - V2
I1 - I2
230 V - 1x8 kV
1A - 20mA
Absorbed electrical power kW max 4 4
Protection level IP44
Noise levels (3) Sound pressure dB(A) 83.1
Model kg
RS 150/M 85
Fig. 1
20052173

9 20054085
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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 2.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the slide
bars.
The dimensions of the open burner are indicated by position I.
Tab. E
(1) Blast tube: short-long
4.7 Firing rate
The maximum output should be chosen within area Aof the di-
agram (Fig. 3).
The minimum output must not be lower than the minimum limit
of the diagram.
4.7.1 Firing rate based on the air density
It may happen that a burner has to operate with combustion 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 Tab. F;
2 divide the output “Q” required from the burner by “F” to
obtain the equivalent output “Qe”: Qe = Q : F (kW);
3 In the firing rate of the burner, mark the work point identified
by:
Qe = equivalent output
H1 = pressure in the combustion chamber
point A that must remain within the firing rate
Fig. 2
D731
mm ABCDE F (1) GH I (1) LMNO
RS 150/M 675 370 305 590 840 280-415 189 435 1180-1315 214 134 221 2”
WARNING
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20°C, an
atmospheric pressure of 1013 mbar (approx. 0m
above sea level), and with the combustion head
adjusted as shown on page 17.
Thermal power
Fig. 3
Combustion chamber
pressure - mbar
20047386
Qe kg/h
mbar
Qe
A
H1
H2
H3
D388 kW
mbar
Fig. 4

20054085 10
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Technical description of the burner
4 Trace a vertical line from point A (Fig. 4), and find the max-
imum pressure “H2” of the firing rate.
5Multiply
“H2” by “F” to obtain the maximum lowered pres-
sure “H3” of the firing rate
H3 = H2 x F (mbar).
–If
“H3” is greater than “H1” (Fig. 4), the burner can supply
the required output.
–If
“H3” is less than “H1”, it is necessary to reduce the burner
output.
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. F
4.8 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. 5).
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 manufac-
turer.
The firing rates were established in special test boilers, according
to EN 676 regulations.
In Fig. 5 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 756 kW - diameter 60cm - length 2m.
WARNING
The combustion head should be adjusted in rela-
tion to the equivalent output Qe.
H1r = H1 x
()
Qr
Q
2
Altitude Average baro-
metric pressure F (Air temperature °C)
m. above sea
level 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
Fig. 5
Length of combustion
chamber m
D715

11 20054085
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Technical description of the burner
4.9 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Servomotor controlling the gas butterfly valve and the air
damper valve (by means of an adjustable profile cam mech-
anism).
When the burner is not operating the air gate valve is fully
closed in order to reduce heat dispersion from the boiler due
to the flue draught which draws air from the fan suction inlet.
6 Plug-socket on ionisation probe cable
7 Extensions for slide bars 15)
8 Motor contact maker and thermal relay with reset button
9 Power switch for: automatic - manual - off
Button for: power increase - power reduction
10 Terminal board for electrical wiring
11 Cable grommets for electrical wiring (to be carried out by the
installer)
12 Control box with lockout pilot light and lockout reset button
13 Flame inspection window
14 Minimum air pressure switch (differential operating type)
15 Slide bars for opening the burner and inspecting the com-
bustion head
16 Gas pressure test point and head fixing screw
17 Air pressure test point
18 Flame sensor probe
19 Air damper
20 Fan air inlet
21 Screws to secure fan to pipe coupling
22 Gas input pipe
23 Gas butterfly valve
24 Boiler fixing flange
25 Flame stability disk
26 Bracket for fixing the RWF40 output power regulator (kit)
27 Ignition transformer
28 Suppressor
29 “K1” relay
30 “K2” relay
4.10 Burner equipment
The burner is supplied complete with:
Flange for gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws (M8x25) to fix the flange . . . . . . . . . . . . . . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Extensions 7) for guides 15): TL versions only. . . . . . . . . . No. 2
Screw (M12x35) to fix the burner flange to the boiler. . . . . No. 1
Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 6
20047390

20054085 12
GB
Technical description of the burner
4.11 Control box (RMG/M 88.62C2)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation 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.
For safety and reliability, comply with the following instruc-
tions:
– Avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure the control box is perfectly dry.
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Use
The control box is a control and supervision system of medium
and large capacity forced draught burners, for intermittent opera-
tion (at least one controlled shutdown every 24 hours).
Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Install switches, fuses, earth connection etc. in compliance
with local regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit, make sure the 230V AC mains voltage
cables are run strictly separate from extra low-voltage cables,
to avoid the risk of electrocution.
Electrical wiring of the flame detector
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• Always separate the detector cables from the other cables:
– the line capacity reduces the magnitude of the flame sig-
nal;
– use a separate cable.
• The cable length must not exceed 1m.
• Respect the polarity.
• Insulation resistance:
– must be at least 50Mbetween the ionisation probe and
the earth;
– a dirty detector reduces the insulation resistance, fostering
leakage currents.
• The ionisation probe is not protected against the risk of elec-
trocution. When connected to the electricity supply, the ioni-
sation probe must be protected against any accidental
contact.
• Position the ionisation probe so that the ignition spark cannot
form an arc on the probe (risk of electric overcharge).
Technical data
Tab. G
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!
Mains voltage AC 230V -15% / +10%
Mains frequency 50/60 Hz ±6%
Built-in fuse T6.3H 250V
Energy consumption 20 VA
Weight approx. 260g
Protection level IP20
Safety class I
Tightening torque of M4 screw Max. 0.8 Nm
Allowed cable length
Thermostat
Air pressure switch
CPI
Gas pressure switch
Flame detector
Remote reset
max. 20m at 100 pF/m
max. 1m at 100 pF/m
max. 1m at 100 pF/m
max. 20m at 100 pF/m
max. 1m
max. 20m at 100 pF/m
Environmental conditions
Storage
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60°C
< 95% RH
Fig. 7
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Technical description of the burner
4.12 Servomotor (SQN31.76...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the connection area of the
servomotor, fully disconnect the burner control device from
the power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the servomotor must not be operated,
even if it displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• When assembling the servomotor and connecting the damp-
er, the gears can be disengaged by means of a lever, allow-
ing the drive shaft to be easily adjusted in both directions of
rotation.
Technical data
Tab. H
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actuators.
The servomotor contains electric and electronic
components that must not be disposed of with
normal domestic waste.
Respect all current local legislation.
Operating voltage AC 220 V -15 %...AC 240 V +10 %
AC 100 V -15 %...AC 110 V +10 %
Mains frequency 50/60 Hz ±6%
Energy consumption 6.5 VA
Angular positioning up to 160° (base scale)
Assembly position optional
Protection level IP40, in accordance with DIN 40050
Switching voltage 24...250V AC
Type of motor synchronous
Environmental conditions
Storage
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
Class 3K5
Class 3M2
-20...+70°C
< 95% RH
Fig. 8
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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 9), showing:
A the burner model;
B the burner type;
C the cryptographic year of manufacture;
D the serial number;
E the data for electrical supply and the protection level;
F the electrical power consumption;
G the types of gas used and the relative supply pressures;
H the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate;
I the category of the appliance/countries of destination.
5Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
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 quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25cm 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 burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board 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.
WARNING
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS- KAASU
GAZ-AEPIO X
RIELLOS.p.A.
I-37045Legnago(VR)
A
DEBC
F
I
G H
G H
Fig. 9
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
5.5.2 Blast tube length
The length of the blast tube 12)(Fig. 12) must be selected accord-
ing to the indications provided by the boiler manufacturer, and in
any case must be greater than the thickness of the boiler door
complete with its refractory.
The available lengths are the ones indicated in Tab. I.
Tab. I
For boilers with a front flue gas passes 15)(Fig. 12) or flame in-
version chamber, a protection device in refractory material 13)
must be inserted between the boiler fettling 14) and the blast tube
12).
For boilers with a water-cooled frontal, a refractory lining 13)-14)
is not necessary unless expressly requested by the boiler manu-
facturer.
Tab. J
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 10).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 10
2 3 4 51
D7739
Blast tube Short Long
RS 150/M 280mm 415mm
WARNING
This protective fettling must not compromise the
extraction of the blast tube.
mm ABC
RS 150/M 195 275-325 M12
Fig. 11
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Installation
5.6 Securing the burner to the boiler
Separate the combustion head from the rest of the burner, as
shown in Fig. 12.
To do this, proceed as follows:
loosen the four screws 3) and remove the hood 1);
disengage the articulated coupling 7) from the graduated
sector 8);
remove screws 2) from the two slide bars 5);
remove the 2 screws 4) and pull the burner back on slide
bars 5) by about 100mm;
disconnect the probe and electrode cables, then slide off the
burner completely from the slide bars.
If the probe or electrode is not correctly positioned, you must:
remove the screw 1)(Fig. 13);
take out the inner part 2)(Fig. 13) of the head, and then cali-
brate them.
Once this operation (if necessary) has been carried out, fix the
flange 11)(Fig. 12) to the boiler plate, interposing the insulating
gasket 9)(Fig. 12) supplied.
Use the 4 screws supplied, with a tightening torque of 35 - 40 Nm,
after protecting their thread with anti-seizing products.
Provide an adequate lifting system.
WARNING
Before fixing the burner to the boiler, check
(through the opening of the blast tube) that the
probe and electrode are correctly positioned (see
Fig. 14).
100m
m
1 2 5
11
14
13
12
9
3
8
7
6
15
15
10
3
4
D8688
Fig. 12
WARNING
The seal between burner and boiler must be air-
tight: after the start-up, check there is no leakage
of flue gases into the external environment.
1
2
Fig. 13
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Installation
5.7 Positioning the probe - electrode
5.8 Combustion head adjustment
At this point of the installation, the combustion head is fixed to the
boiler as shown in Fig. 13.
It is therefore especially easy to adjust, and this adjustment de-
pends only on the maximum output of the burner.
You can adjust the air and gas to calibrate the combustion head.
In the diagram of Fig. 15, find the notch at which both air and cen-
tral gas/air should be adjusted.
5.8.1 Air adjustment
Proceed as follows:
rotate the screw 2)(Fig. 16) until the notch you have found
corresponds with the front surface 1) of the flange.
5.8.2 Gas adjustment
Proceed as follows:
loosen the screws 4) and rotate the ring nut 5)(Fig. 16) until
the notch you have found corresponds with the indicator 3);
tighten the screws 4).
Example:
burner output = 1300 kW and combustion chamber pressure
equal to 0 mbar
The diagram (Fig. 15) shows that the gas and air adjustments for
this output are carried out on notch 4.
WARNING
When positioning the probe and electrode, re-
spect the dimensions shown in Fig. 14.
WARNING
Do not rotate the probe: leave it as in Fig. 14.
since if it is located too close to the ignition elec-
trode, the control box amplifier may be damaged.
Fig. 14
Probe Electrode
D613
WARNING
The diagrams show an optimum adjustment for
a type of boiler according to Fig. 5 on page 10.
CAUTION
To facilitate the adjustment, loosen the screw
3)(Fig. 16); adjust, then lock in place.
WARNING
The adjustments indicated can be modified during
the initial start-up.
If the pressure in the combustion chamber is 0
mbar, the adjustments are made with reference to
the dotted line.
Fig. 15
20047394
20047395
AIR ADJUSTMENT
GAS ADJUSTMENT
3
5
4
1
2
Fig. 16
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Installation
Once the combustion head adjustment is completed:
reassemble the burner on the guides 3), about 100mm from
the pipe coupling 4) - burner in the position shown in Fig. 12;
insert the probe and electrode cables, then slide the burner
as far as the pipe coupling - burner in the position shown in
Fig. 17;
connect the socket of the maximum gas pressure switch;
refit the screws 2) on the slide bars 3);
fix the burner to the pipe coupling with the screws 1);
reconnect the articulated coupling 7) to the graduated sector 6).
WARNING
When fitting the burner on the two slide bars, it is
advisable to gently draw out the high voltage ca-
ble and the flame detection probe cable until they
are slightly stretched.
Carry out all the operations described above, then
reassemble the hood and all the burner safety and
protection devices.
Fig. 17
D1325