Riello RS 410/EV FGR Quick start guide

Installation, use and maintenance instructions
20162733 (2) - 08/2021
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20162652 RS 410/EV FGR S029T2
20162653 RS 510/EV FGR S030T2
20162655 RS 610/EV FGR S031T2
GB

Translation of the original instructions

1 20162733
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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.......................................................................................................................................................... 8
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions................................................................................................................................................ 10
4.7 Firing rates ................................................................................................................................................................ 11
4.8 Test boiler.................................................................................................................................................................. 12
4.9 Burner equipment...................................................................................................................................................... 12
4.10 Burner description ..................................................................................................................................................... 13
4.11 Electrical panel description........................................................................................................................................ 14
4.12 Control box for the air/fuel ratio (LMV51...) ............................................................................................................... 15
4.13 Servomotor................................................................................................................................................................ 17
5 Installation ................................................................................................................................................................................ 18
5.1 Notes on safety for the installation ............................................................................................................................ 18
5.2 Handling .................................................................................................................................................................... 18
5.3 Preliminary checks .................................................................................................................................................... 18
5.4 Operating position ..................................................................................................................................................... 19
5.5 Preparing the boiler ................................................................................................................................................... 19
5.5.1 Boring the boiler plate ............................................................................................................................................... 19
5.5.2 Blast tube length........................................................................................................................................................ 19
5.6 Securing the burner to the boiler............................................................................................................................... 19
5.7 Access to head internal part...................................................................................................................................... 20
5.8 Probe-electrode position ........................................................................................................................................... 21
5.9 Gas butterfly valve..................................................................................................................................................... 21
5.10 Combustion head adjustment.................................................................................................................................... 22
5.11 FGR duct system....................................................................................................................................................... 23
5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 24
5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 24
5.12 Gas pressures ........................................................................................................................................................... 25
5.12.1 Gas feeding line ........................................................................................................................................................ 25
5.12.2 Gas train.................................................................................................................................................................... 26
5.12.3 Gas train installation.................................................................................................................................................. 26
5.12.4 Gas pressure............................................................................................................................................................. 27
5.13 Electrical wiring ......................................................................................................................................................... 28
5.13.1 Supply cables and external connections passage .................................................................................................... 29
6 Start-up, calibration and operation of the burner ................................................................................................................. 30
6.1 Notes on safety for the first start-up .......................................................................................................................... 30
6.2 Adjustments prior to ignition ...................................................................................................................................... 30

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Contents
6.3 Burner start-up ...........................................................................................................................................................31
6.4 FGR commissioning...................................................................................................................................................32
6.5 Air / fuel adjustment ...................................................................................................................................................33
6.5.1 Air adjustment for maximum output ...........................................................................................................................33
6.5.2 Air/fuel adjustment and output modulation system ....................................................................................................33
6.5.3 Burner adjustment......................................................................................................................................................33
6.5.4 Output upon ignition...................................................................................................................................................33
6.5.5 Maximum output ........................................................................................................................................................33
6.5.6 Minimum output .........................................................................................................................................................33
6.6 Final adjustment of the pressure switches.................................................................................................................34
6.6.1 Air pressure switch.....................................................................................................................................................34
6.7 Final checks (with burner operating)..........................................................................................................................34
7 Maintenance ..............................................................................................................................................................................35
7.1 Notes on safety for the maintenance .........................................................................................................................35
7.2 Maintenance programme ...........................................................................................................................................35
7.2.1 Maintenance frequency..............................................................................................................................................35
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................35
7.2.3 Checking and cleaning...............................................................................................................................................35
7.2.4 Safety components ....................................................................................................................................................36
7.2.5 Voltage on the QRI sensor.........................................................................................................................................37
7.2.6 Checking the air and gas pressure on the combustion head .....................................................................................37
7.2.7 Checking the air and gas pressure on the combustion head .....................................................................................37
7.3 Checking the position of the rpm sensor....................................................................................................................37
7.4 Opening the burner ....................................................................................................................................................38
7.5 Closing the burner......................................................................................................................................................38
8 Faults - Probable causes - Solutions ......................................................................................................................................39
A Appendix - Accessories ...........................................................................................................................................................40
B Appendix - Electrical panel layout...........................................................................................................................................41

3 20162733
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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 and type: RS 410/EV FGR
RS 510/EV FGR
RS 610/EV FGR
S029T2
S030T2
S031T2
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Such products are marked as follows:
CE- 0123CU1034 (Class 4 prEN 676:2016)
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
0085

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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.
IMPORTANT
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

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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.

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Technical description of the burner
4.1 Burner designation
4 Technical description of the burner
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 410 EV TC 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
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 FS1/FS2*
WARNING
*The burner leaves the factory set up for FS1 op-
eration. If FS2 operation is required, see the man-
ual of the electronic cam.

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Technical description of the burner
4.2 Models available
Tab. A
4.3 Burner categories - Countries of destination
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Ambient 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. 4 on page 13) 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.
Designation Voltage Start-up Code
RS 410/EV FGR FS1/FS2 3/400/50 Inverter 20162652
RS 510/EV FGR FS1/FS2 3/400/50 Inverter 20162653
RS 610/EV FGR FS1/FS2 3/400/50 Inverter 20162655
Gas category Destination country
I2H SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO
I2ELL DE
I2E - I2(43,46 ÷ 45,3 MJ/m3(0°C)) NL
I2Er FR
I2E(R)B BE
I2E LU - PL
Model RS 410/EV FGR RS 510/EV FGR RS 610/EV FGR
Power(1)
Delivery (1)
min - max kW 595/1210 ÷ 3820 660/1800 ÷ 4800 912/2220 ÷ 5850
Fuels Natural gas: G20 (methane gas)
Gas pressure at max. output (2)
Gas: G20 mbar 45 70 61
Operation
FS1: Intermittent (min. 1 stop in 24 hours)
FS2: Continuous (min 1 stop 72 hours)
The burner leaves the factory set for the intermittent operation
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) 80 91
82.5
93.5
85
96
Weight of the burner complete with
its packaging kg 265 265 295
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.