Riello RS 310/E FGR Quick start guide

Installation, use and maintenance instructions
20155699 (3) - 08/2021
Forced draught gas burners
Modulating operation
CODE MODEL
20155654 RS 310/E FGR
20155657 RS 410/E FGR
20160534 RS 510/E FGR
20155659 RS 610/E FGR
GB

Original instructions

1 20155699
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Contents
1 Declarations................................................................................................................................................................................ 4
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 Models available.......................................................................................................................................................... 8
4.3 Technical data ............................................................................................................................................................. 9
4.4 Electrical data.............................................................................................................................................................. 9
4.5 Burner weight ............................................................................................................................................................ 10
4.6 Maximum dimensions................................................................................................................................................ 11
4.7 Firing rates ................................................................................................................................................................ 12
4.8 Test boiler.................................................................................................................................................................. 13
4.9 Burner equipment...................................................................................................................................................... 13
4.10 Burner description ..................................................................................................................................................... 14
4.11 Electrical panel description........................................................................................................................................ 15
4.12 Control box for the air/fuel ratio (BT330) ................................................................................................................... 16
4.13 Burner operating sequence ....................................................................................................................................... 17
4.14 Servomotor (662R5...)............................................................................................................................................... 18
4.15 Calibration of the thermal relay ................................................................................................................................. 18
5 Installation ................................................................................................................................................................................ 19
5.1 Notes on safety for the installation ............................................................................................................................ 19
5.2 Handling .................................................................................................................................................................... 19
5.3 Preliminary checks .................................................................................................................................................... 19
5.4 Operating position ..................................................................................................................................................... 20
5.5 Preparing the boiler ................................................................................................................................................... 20
5.5.1 Boring the boiler plate ............................................................................................................................................... 20
5.5.2 Blast tube length........................................................................................................................................................ 20
5.6 Securing the burner to the boiler............................................................................................................................... 20
5.7 Access to head internal part...................................................................................................................................... 21
5.8 Probe-electrode position ........................................................................................................................................... 22
5.9 Gas butterfly valve..................................................................................................................................................... 22
5.10 Combustion head adjustment.................................................................................................................................... 23
5.11 FGR duct system....................................................................................................................................................... 24
5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 25
5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 25
5.12 Gas pressures ........................................................................................................................................................... 26
5.12.1 Gas feeding line ........................................................................................................................................................ 26
5.12.2 Gas train.................................................................................................................................................................... 27
5.12.3 Gas train installation.................................................................................................................................................. 27
5.12.4 Gas pressure............................................................................................................................................................. 28
5.13 Electrical wiring ......................................................................................................................................................... 29
5.13.1 Supply cables and external connections passage .................................................................................................... 29
6 Start-up, calibration and operation of the burner ................................................................................................................. 30

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Contents
6.1 Notes on safety for the first start-up ...........................................................................................................................30
6.2 Adjustments prior to ignition.......................................................................................................................................30
6.3 Burner start-up ...........................................................................................................................................................30
6.4 FGR commissioning...................................................................................................................................................31
6.5 Air / fuel adjustment ...................................................................................................................................................32
6.5.1 Air adjustment for maximum output ...........................................................................................................................32
6.5.2 Air/fuel adjustment and output modulation system ....................................................................................................32
6.5.3 Burner adjustment......................................................................................................................................................32
6.5.4 Output upon ignition...................................................................................................................................................32
6.5.5 Maximum output ........................................................................................................................................................32
6.5.6 Minimum output .........................................................................................................................................................32
6.6 Final adjustment of the pressure switches.................................................................................................................33
6.6.1 Air pressure switch.....................................................................................................................................................33
6.6.2 Maximum gas pressure switch...................................................................................................................................33
6.6.3 Minimum gas pressure switch....................................................................................................................................34
6.6.4 PVP pressure switch kit .............................................................................................................................................34
6.7 Final checks (with burner operating)..........................................................................................................................34
7 Operating control and display .................................................................................................................................................35
7.1 UI300 user interface...................................................................................................................................................35
7.2 Menu functions...........................................................................................................................................................35
7.3 Main menu .................................................................................................................................................................36
7.4 INFO menu path ........................................................................................................................................................36
7.4.1 Burner details.............................................................................................................................................................36
7.4.2 Recall fault history......................................................................................................................................................37
7.4.3 Software version ........................................................................................................................................................37
7.4.4 Display of check sums ...............................................................................................................................................38
7.4.5 Serial number.............................................................................................................................................................38
7.4.6 Positions of actuators.................................................................................................................................................38
7.4.7 Check digital inputs/outputs .......................................................................................................................................39
7.4.8 Digital outputs ............................................................................................................................................................40
7.5 MANUAL menu path ..................................................................................................................................................41
7.5.1 Fault indication...........................................................................................................................................................41
7.6 SETTINGS menu path ...............................................................................................................................................42
7.6.1 Program sequence.....................................................................................................................................................42
7.7 PASSWORD menu path ............................................................................................................................................48
7.8 DATASET PROCESSING menu path .......................................................................................................................48
7.9 Other displays ............................................................................................................................................................49
8 Options ......................................................................................................................................................................................50
8.1 Firing-rate controller module LCM100 .......................................................................................................................50
8.1.1 Range Limits ..............................................................................................................................................................50
8.1.2 Enter set-point of firing-rate controller........................................................................................................................50
8.1.3 Operating Description ................................................................................................................................................51
8.1.4 Control by atmospheric conditions and external set-point presetting ........................................................................51
8.1.5 set-point changeover .................................................................................................................................................52
8.1.6 Start-up sequence......................................................................................................................................................52
8.1.7 Thermostat and control range....................................................................................................................................53
8.1.8 Control range .............................................................................................................................................................53
8.1.9 Checking of the safety limiter.....................................................................................................................................53
8.1.10 Control mode .............................................................................................................................................................54
8.1.11 Aides for setting .........................................................................................................................................................55
8.1.12 External/manual firing-rate presetting (terminals 16 - 19) ..........................................................................................56
8.1.13 DIP switch ..................................................................................................................................................................56
8.1.14 LED ............................................................................................................................................................................57
9 Maintenance ..............................................................................................................................................................................58
9.1 Notes on safety for the maintenance .........................................................................................................................58
9.2 Maintenance programme ...........................................................................................................................................58
9.2.1 Maintenance frequency..............................................................................................................................................58
9.2.2 Safety test - with gas feeding closed .........................................................................................................................58

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Contents
9.2.3 Checking and cleaning .............................................................................................................................................. 58
9.2.4 QRI flame sensor ...................................................................................................................................................... 59
9.2.5 Checking the air and gas pressure on the combustion head .................................................................................... 59
9.2.6 Safety components.................................................................................................................................................... 59
9.3 Opening the burner ................................................................................................................................................... 60
9.4 Closing the burner ..................................................................................................................................................... 60
10 Faults - Possible causes - Solutions ...................................................................................................................................... 61
10.1 List of fault code ........................................................................................................................................................ 61
A Appendix - Accessories........................................................................................................................................................... 65
B Appendix - Electrical panel layout.......................................................................................................................................... 66

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Declarations
Declaration of Conformity in accordance with ISO / IEC 17050-1
These products are in compliance with the following Technical Standards:
• EN 12100
• EN 676
According to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
1 Declarations

5 20155699
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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 COVER
AND ALL THE SAFETY AND PROTECTION DE-
VICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20155699 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 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.

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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 uses expressly foreseen by the manufactur-
er;
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.

20155699 8
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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
Version FS1
Designation Voltage Start-up Code
RS 310/E FGR FS1 3/400/50 Diretto 20128711
RS 410/E FGR FS1 3/400/50 Diretto 20128715
RS 510/E FGR FS1 3/400/50 Stella/Triangolo 20128716
RS 610/E FGR FS1 3/400/50 Stella/Triangolo 20128724
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 310 ETC FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
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
Emission: C01 - ...
C02 - MZ
C03 - BLU
C03 - MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
FGR: Induced Flue Gas Recirculation
FGR

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Technical description of the burner
4.3 Technical data
Tab. B
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point of the pressure switch 5)(Fig. 5) 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.
4.4 Electrical data
Tab. C
Model RS 310/E FGR RS 410/E FGR RS 510/E FGR RS 610/E FGR
Power(1)
Delivery (1)
min - max kW 400/1200 ÷ 3630 500/1500 ÷ 4450 680/1800 ÷ 5250 1000/2200 ÷ 6250
Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2)
Gas: G20/G25 mbar 50.1/74.7 53.1/79.2 59.7/89.1 77.6/115.8
Operation FS1: Intermittent (min. 1 stop in 24 hours)
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 78 89
80
91
82.5
93.5
85
96
WARNING
In order to reduce the nitrogen oxides NOx in case
of FGR system, the maximum burner capacity ob-
tained, changes within the limits agreed with the
Riello Technical Dept. for the specific application.
DIRECT START UP
Model RS 310/E FGR RS 410/E FGR
Main electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2920
220-240 / 380-415
7.5
25.2/14.5
2930
230/400
9.2
28.6/16.5
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 9.1 10.6
Protection level IP 54
STAR - TRIANGLE START UP
Model RS 510/E FGR RS 610/E FGR
Main electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2920
400/690
12
21/12.2
2915
400/690
15
26.8/15.5
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 13.9 16.9
Protection level IP 54

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Technical description of the burner
4.5 Burner weight
The weight of the burner complete with its packaging is shown in
Tab. D .
Tab. D
Model kg
RS 310/E FGR 265
RS 410/E FGR 265
RS 510/E FGR 265
RS 610/E FGR 295
Fig. 1
20091888

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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 turned on the hinge.
The maximum dimensions of the open burner are indicated by
the L and R positions.
The l position is reference for the refractory thickness of the boiler
door.
Tab. E
Fig. 2
20131490
mm A B C D E F* G H I L M N O P** R S
RS 310/E 1178 465 178 306 520 DN65 1185 790 346 1015 615 528 290 177 890 DN100
RS 410/E 1178 517 178 313 520 DN65 1140 790 340 1015 615 528 290 177 890 DN100
RS 510/E 1260 517 178 313 520 DN65 1140 790 360 1015 620 528 290 177 890 DN125
RS 610/E 1260 517 178 336 520 DN65 1215 790 365 1015 632 528 290 177 890 DN150
WARNING
*The gas adaptor is set also for DN 80 bore.
** Maximum position for the extraction of the ser-
vomotor cover.

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Technical description of the burner
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the diagram area
(Fig. 3).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
Tab. F
Model kW
RS 310/E FGR 400
RS 410/E FGR 500
RS 510/E FGR 680
RS 610/E FGR 1000
WARNING
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 23.
Fig. 3
Thermal power – kW
400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800
0
2
4
6
8
10
12
14
16
18
5200 5600 6000 6400 6800
-2
20
Pressure in
combustion chamber - mbar
20058566
RS 310/E
RS 410/E
RS 510/E
RS 610/E

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Technical description of the burner
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. 4).
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 set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 4 you can see the diameter and length of the test combus-
tion chamber.
Example: RS 510/E
Output 5000 kW - diameter 100 cm - length 5 m
4.9 Burner equipment
Gasket for gas train adaptor. . . . . . . . . . . . . . . . . . . . . . . . No. 1
Adaptor for gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws for fixing the gas train adaptor: M 16 x 70 . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M 18 x 60 screws to secure the burner flange
to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Cable grommets kit for optional electrical wiring input . . . . No. 1
M16 nuts to fix the gas elbow to the pipe coupling. . . . . . . No. 8
Stud bolts M16X60 to fix the gas elbow
to the pipe coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gas pipe (RS 310/E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 6
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
20057548 Fig. 4
Combustion chamber
m

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Technical description of the burner
4.10 Burner description
1 Lifting rings
2Fan
3Fanmotor
4 Air damper servomotor
5 Combustion head gas pressure test point
6 Combustion head
7 Ignition electrode
8 Flame stability disk
9 Electrical panel casing
10 Gas butterfly valve servomotor
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas butterfly valve
15 Shutter
16 Combustion head movement screw
17 Lever for controlling the dampers with graduated scale
18 Probe for flue gas temperature
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 ignition pilot
22 Hinge for opening the burner
23 Pressure test point for air pressure switch “+”
24 Combustion head air pressure test points
25 Gas train adapter
26 Indication for checking the rotation direction of the purging
motor
27 Flame inspection window
28 UV sensor
29 Servomotor for flue gas
30 Flange inlet for flue gas
31 Ignition pilot valves
32 Air cooling intake
Fig. 5
22 28
24
12
5
13
10
26 3
2
23
32
1 1
4
69
11 14
1516
17
19
20
27
29
21 7
30
8
25
31
18
20131495
The burner can be opened to the right or to the left
without links to the fuel supply side.
WARNING
To open the burner see section “Access to head
internal part” on page 21.

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Technical description of the burner
4.11 Electrical panel description
1 Earth terminal
2 Supply cables and external connections passage
3 Main terminal supply board
4 Auxiliary circuits fuse (includes a spare fuse)
5 Air pressure switch
6 Ignition transformer
7 Free contact relay
8 Direct start up line contactor
9 Star/delta start-up line contactor
10 Thermal relay (with reset button)
11 Delta contactor (star/delta start up)
12 Star contactor (star/delta start up)
13 Auxiliary contacts
14 Timer for delta/star start-up
15 Electronic cam
16 ON/OFF selector
17 Operator panel with LCD display
18 LCM 100 module
Fig. 6
8
10
10
14
13
11
12
9
2
5
3
1
4
15
17
7
16
1
18
6
1
2
1
20131500

20155699 16
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Technical description of the burner
4.12 Control box for the air/fuel ratio (BT330)
Warnings
For the safety and reliability of the equipment, also follow these
guidelines.
After commissioning and after each maintenance action
check the exhaust gas values across the entire power
range!
Qualified specialist staff are required to carry out all activities
(assembly, installation, servicing, etc.).
Before working in the connection area, switch off the power
supply to the plant from all poles. Ensure that it cannot be
switched back on and that the plant is voltage-free. There is
a risk of electric shock when the plant is not switched off.
Place and secure the protection against contact on the
BT300 and on all connected electrical parts. The cover must
fulfil the design, stability and protection requirements of EN
60730.
After each activity (e.g. assembly, installation, servicing,
etc.) check wiring and parameters to make sure it is in good
working condition.
If the equipment is dropped or suffers impact, you should no
longer commission it. The safety functions may also be
impaired but fail to show any obvious external damage.
When the ratio curves are being programmed, the adjuster
will continually monitor the quality of the plant's combustion
(e.g. using an exhaust gas analysis station). In the event that
the combustion values are inadequate or the conditions are
potentially harmful, the adjuster will take suitable action, e.g.
switch off the system manually.
These operating instructions describe many possible appli-
cations and functions and should be used as guidelines.
Carry out functional tests on the test bench and/or in the
plant application to ensure correct functioning and document
the results.
Condensation and humidity are to be avoided. If necessary,
make sure that the installation is sufficiently dry before you
switch it on.
Avoid static charge having a destructive effect in case of
touching the device's electronic components.
Technical data
Tab. G
WARNING
To avoid accidents, material and/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!
The operators must be aware that the incorrect
setting of the visualisation and operation control
box, and of the positions of the fuel and/or air ac-
tuators, can cause dangerous conditions during
burner operation.
Model BT330
Mains voltage 230 V +10/-15 % 50-60 Hz
Power absorption max. 30 VA
Cables length:
- Control load
- external reset button
- fuel valve
- other lines
Max. 20 m
Max. 20 m
Max. 10 m
Max. 20 m
Weight 1 kg
Environmental conditions:
- Climatic conditions
- Mechanical conditions
- Temperature range
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electric safety IP40 (casing)
IP20 (terminals)
Fig. 7
20127488

17 20155699
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Technical description of the burner
4.13 Burner operating sequence
Key to layout (Fig. 8)
Tab. H
Key to layout (Fig. 8)
FGR FGR release
X01 Gas valve 1
X02 Gas valve 2
X03 Pilot valve
X04 Ignition transformer
X05 Gas pressure > min.
X06 Gas safety circuit
X07 Boiler safety circuit
X08 Air pressure switch
X10 Burner ON
X20+X21 Flame signal
X24 Fault
X25 Fan ON
X32 Air servomotor
X33 Fuel servomotor
X34 FGR servomotor
Fig. 8
X07
X06
X10
X05
X08
X20+X21
FGR
X32
X33
X34
X04
X03
X01
X02
X25
X24
S9612
Any condition
t1 Waiting time for safety circuits consent
(boiler fuel)
t2 Opening time of the gas valve (with
sealing control active)
2.4 s
t3 Servomotor opening time 30/60 s
t4 Activation time FGR servomotor 0 - t5
t5 Pre-purge time adjustable
t6 Pre-ignition time adjustable
t7 Ignition flame safety time 3 s
t8 Flame stabilization time adjustable
t9’ Safety time 2nd stage 3 s
t10 Modulation phase
t11 Adjustment time
t12 Opening time of the gas valve (with
sealing control active)
3 s
t13 Post-purge time adjustable
t15 Post-combustion time adjustable
t16 Checking time for flame extinction 5 s
t17 Checking time for gas valve (with seal-
ing control active)
30 s

20155699 18
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Technical description of the burner
4.14 Servomotor (662R5...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the servomotor connection
area, 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 unit must not be operated, even if it
displays no evident damage.
Installation notes
The static torque is reduced when the electrical supply of the
actuator is switched off.
Technical data
4.15 Calibration of the thermal relay
The thermal relay serves to avoid damage to the motor due to an
excessive absorption increase or if a phase is missing.
For calibration 2), see the table in the wiring diagram.
To reset, in case of an intervention of the thermal relay, press the
“RESET” button 1) of Fig. 10.
The red “TEST” button 3) opens the NC (95-96) contact and
stops the motor.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actua-
tors.
WARNING
Assembly notes
The connection between the actuator command
shaft and the control element must be rigid, with-
out any mechanical play.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
WARNING
Avoid condensate, ice and water leaks from form-
ing!
Model 662R5...
Adjustment time 5 sec / 90°
Rotation direction from
0° to 90° left - by the motor shaft side
Nominal torque (max) 3 Nm
Holding torque (max) 3 Nm
Weight 1,4 kg circa
Degree of protection IP54 according to DIN EN 60529-1
Environmental conditions:
- climatic condition
- mechanical condition
- temperature range
Classe 3K5 (DIN EN 60721-3)
Classe 3M5 (DIN EN 60721-3)
-20...+60 °C (dew not allowed)
Electric safety Protection class 2
according to DIN EN 60730
D8271 Fig. 9
CAUTION
The automatic reset (Position “A” button 1) can be
dangerous. This operation is not anticipated in the
burner's operation, leave it always on “H”. There-
fore do not position the “RESET” button 1) on
“A”.
Fig. 10
20073932
3
1
2
RESET
HA
TEST
95 96 97 98