Riello RS 45/M BLU Quick start guide

Installation, use and maintenance instructions
20098687 (2) - 02/2017
Forced draught gas burners
Progressive two-stage or modulating operation
CODE MODEL TYPE
3897304 - 3897306 RS 45/M BLU 827 T2
3897305 - 3897307 RS 45/M BLU 827 T2
GB

Translation of the original instructions

1
20098687
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 5
2.1 Information about the instruction manual.................................................................................................................... 5
2.1.1 Introduction.................................................................................................................................................................. 5
2.1.2 General dangers.......................................................................................................................................................... 5
2.1.3 Other symbols............................................................................................................................................................. 5
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 6
2.2 Guarantee and responsibility....................................................................................................................................... 6
3 Safety and prevention................................................................................................................................................................ 7
3.1 Introduction.................................................................................................................................................................. 7
3.2 Personnel training ....................................................................................................................................................... 7
4 Technical description of the burner......................................................................................................................................... 8
4.1 Burner designation...................................................................................................................................................... 8
4.2 Models available.......................................................................................................................................................... 8
4.3 Burner categories........................................................................................................................................................ 9
4.4 Technical data............................................................................................................................................................. 9
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions................................................................................................................................................ 10
4.7 Firing rate .................................................................................................................................................................. 10
4.7.1 Firing rate based on the air density........................................................................................................................... 11
4.8 Test boiler.................................................................................................................................................................. 12
4.8.1 Commercial boilers.................................................................................................................................................... 12
4.9 Burner equipment...................................................................................................................................................... 12
4.10 Burner description..................................................................................................................................................... 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 Positioning the probe - electrode............................................................................................................................... 16
5.7 Securing the burner to the boiler............................................................................................................................... 16
5.8 Combustion head adjustment.................................................................................................................................... 17
5.9 Closing the burner..................................................................................................................................................... 18
5.10 Gas feeding............................................................................................................................................................... 19
5.10.1 Gas feeding line ........................................................................................................................................................ 19
5.10.2 Gas train.................................................................................................................................................................... 20
5.10.3 Gas train installation.................................................................................................................................................. 20
5.10.4 Gas pressure............................................................................................................................................................. 20
5.11 Electrical wiring ......................................................................................................................................................... 22
5.11.1 Supply cables and external connections passage .................................................................................................... 22
5.11.2 Modulating operation................................................................................................................................................. 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 Servomotor................................................................................................................................................................ 24
6.4 Burner start-up .......................................................................................................................................................... 25
6.5 Burner ignition........................................................................................................................................................... 25
6.6 Burner adjustment..................................................................................................................................................... 25
6.6.1 Output upon ignition.................................................................................................................................................. 25
6.6.2 Maximum output........................................................................................................................................................ 25
6.6.3 Minimum output......................................................................................................................................................... 26
6.6.4 Intermediate outputs.................................................................................................................................................. 26
6.7 Final adjustment of the pressure switches................................................................................................................ 27
6.7.1 Air pressure switch.................................................................................................................................................... 27

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Contents
6.7.2 Minimum gas pressure switch....................................................................................................................................27
6.8 Burner operation........................................................................................................................................................28
6.8.1 Burner start-up...........................................................................................................................................................28
6.8.2 Operation...................................................................................................................................................................28
6.8.3 Ignition failure.............................................................................................................................................................28
6.8.4 Burner flame goes out during operation.....................................................................................................................28
6.9 Burner start-up cycle diagnostics...............................................................................................................................29
6.10 Resetting of control box and diagnostics use ............................................................................................................29
6.10.1 Control box reset........................................................................................................................................................29
6.10.2 Visual diagnostics ......................................................................................................................................................29
6.10.3 Software diagnostics..................................................................................................................................................29
6.11 Normal operation / flame detection time ....................................................................................................................30
6.12 Flame presence check...............................................................................................................................................30
6.13 Final checks (with burner operating)..........................................................................................................................31
7 Maintenance ..............................................................................................................................................................................32
7.1 Notes on safety for the maintenance.........................................................................................................................32
7.2 Maintenance programme...........................................................................................................................................32
7.2.1 Maintenance frequency..............................................................................................................................................32
7.2.2 Checking and cleaning...............................................................................................................................................32
7.2.3 Safety components....................................................................................................................................................33
7.3 Opening the burner....................................................................................................................................................34
7.4 Closing the burner......................................................................................................................................................34
8 Faults - Probable causes - Solutions......................................................................................................................................35
A Appendix - Accessories ...........................................................................................................................................................37
B Appendix - Electrical panel layout...........................................................................................................................................39

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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 45/M BLU 827 T2
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 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Declaration of Conformity A.R. 8/1/2004 & 17/7/2009 – Belgium
Manufacturer:
RIELLO S.p.A.
37045 Legnago (VR) Italy
Tel. ++39.0442630111
www.rielloburners.com
Distributed by:
RIELLO NV
Ninovesteenweg 198
9320 Erembodegem
Tel. [phone]
Fax. [phone]
e-mail. [email protected]
URL. www.riello.be
This document certifies that the series of devices specified below is in compliance with the model described in the EC Declaration
of Conformity and has been manufactured and distributed in compliance with the requirements defined in the Legislative Decree of
January 8th 2004 and July 17th 2009.
Type of product: Forced draught gas burners
Model: RS 45/M BLU
Regulation applied: EN 676 and A.R. of January 8th 2004 - July 17th 2009
Controlling organisation:
TÜV Industrie Service GmbH
TÜV SÜD Gruppe
Ridlerstrase, 65
80339 München DEUTSCHLAND
Values measured: Max. CO: 6 mg/kWh
Max. NOx: 65 mg/kWh
Legnago, 01.12.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
EC-0085BM0104 Class 3 (EN 676)

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Declarations
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm-
SchV revision 26.01.2010”.
Product Type Model Output
Forced draught gas burners 827 T2 RS 45/M BLU 90 - 550 kW
Legnago, 01.12.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

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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 DEVICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤This symbol indicates a list.

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Information and general warnings
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 voltageand 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 ambient temperature must all be within the values in-
dicated 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, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties.
➤Personnel must follow all the danger and caution indications
shown on the machine.
➤Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
➤Personnel are obliged to 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 manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from 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
4.2 Models available
Tab. A
4 Technical description of the burner
Range: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Flame control system:
FS1
FS2 Standard (1 stop every 24 h) Continuous operation (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R S 45 M TC 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)
M Mechanical cam
P Proportional air/gas valve
S
L
LS
N
Head: TC Standard head
TL Long head
Emission: C01 or...
MZ
BLU
MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
3/400-230/50 3N / 400V-230V / 50Hz
Designation Power supply voltage Start-up Code
RS 45/M BLU TC 1N 230V 50Hz Direct 3897304
RS 45/M BLU TL 1N 230V 50Hz Direct 3897305
RS 45/M BLU TC 1N 230V 50Hz Direct 3897306
RS 45/M BLU TL 1N 230V 50Hz Direct 3897307

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Technical description of the burner
4.3 Burner categories
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)(Fig. 23 on page 24) with zero pressure in the combustion chamber and at maximum burner out-
put.
(3)
Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
(4)
Blast tube: short - long.
4.5 Electrical data
Tab. D
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I
2H
DE I
2ELL
NL I
2L
- I
2E
- I
2
(43,46 ÷ 45,3 MJ/m
3
(0°C))
FR I
2Er
BE I
2E(R)B
LU - PL I
2E
Model RS 45/M BLU
Output
(1)
Max. kW
Mcal/h 190 - 550 164 - 474
Min. kW
Mcal/h 90 78
Fuel Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output
(2)
-
Gas: G20 / G25 mbar 12.4 / 18.5
Operation – Intermittent (min. 1 stop in 24 hours)
– Progressive two-stage or modulating with kit (see ACCESSORIES)
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels
(3)
Sound pressure
Sound power dB(A) 70 81
Weight
(4)
kg 41 - 43
Model RS 45/M BLU
Main electrical supply 1N ~230V 50Hz
Fan motor Hz
rpm
V
W
A
50
2820
220/240
420
2.9
Ignition transformer V1 - V2
I1 - I2 220/240 V - 1 x 15 kV 45 VA - 25 mA
Absorbed electrical power W max 600
Protection level IP 44

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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the slide
bars.
The dimensions of the open burner are indicated by position H.
Tab. E
(1) Blast tube: short-long
4.7 Firing rate
During operation, burner output varies between:
– a MAXIMUM OUTPUT, selected within area A (Fig. 2);
– and a MINIMUM OUTPUT, that should not be less than the
minimum limit of the diagram.
Fig. 1
D1077
mm A B C D
(1)
E F G H I L M
RS 45/M BLU 476 474 580 240 - 354 160 352 164 810 108 168 1”1/2
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 17.
Fig. 2
D2194
Thermal power
A
Pressure in
combustion head - mbar

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Technical description of the burner
4.7.1 Firing rate based on the air density
The firing rate of the burner indicated in the manual refers to an
ambient temperature of 20°C and an altitude of 0 m. above sea
level. (barometric pressure about 1013 mbar).
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 m
3
of 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:
3 In the firing rate of the burner, mark the work point identified
by:
Qe = equivalent output
H1 = pressure in combustion chamber
point A that must remain within the firing rate.
4 Trace a vertical line from point A) (Fig. 3), and find the maxi-
mum pressure H2 of the firing rate.
5 Multiply H2 by F to obtain the maximum lowered pressure
H3 of the firing rate
If H3 is greater than H1)(Fig. 3), the burner can supply the re-
quired 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 com-
bustion 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
Qe = Q : F (kW)
H3 = H2 x F (mbar)
WARNING
The combustion head should be adjusted in rela-
tion to the equivalent output Qe.
H1r = H1 x ( )
Qr
Q
2
Qe kg/h
mbar
Qe kW
mbar
A
H1
H2
H3
D388
Fig. 3
Altitude Average barometric
pressure
F
Air temperature °C
m. a.s.l. mbar 0 5 10 15 20 25 30 40
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2400
2800
3200
3600
4000
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
755
714
675
635
616
1.087
1.073
1.061
1.050
1.037
1.025
1.013
1.000
0.988
0.977
0.964
0.942
0.919
0.897
0.875
0.852
0.810
0.766
0.724
0.682
0.661
1.068
1.054
1.042
1.031
1.018
1.007
0.995
0.982
0.971
0.959
0.946
0.925
0.902
0.881
0.859
0.837
0.796
0.753
0.711
0.669
0.649
1.049
1.035
1.024
1.013
1.000
0.989
0.977
0.965
0.954
0.942
0.930
0.909
0.886
0.866
0.844
0.822
0.782
0.739
0.699
0.657
0.638
1.031
1.017
1.006
0.995
0.983
0.972
0.960
0.948
0.937
0.926
0.914
0.893
0.871
0.851
0.829
0.808
0.768
0.726
0.687
0.646
0.627
1.013
1.000
0.989
0.978
0.966
0.955
0.944
0.932
0.921
0.910
0.898
0.878
0.856
0.836
0.815
0.794
0.755
0.714
0.675
0.635
0.616
0.996
0.983
0.972
0.962
0.950
0.939
0.928
0.916
0.906
0.895
0.883
0.863
0.842
0.822
0.801
0.781
0.742
0.702
0.664
0.624
0.606
0.980
0.967
0.956
0.946
0.934
0.923
0.913
0.901
0.891
0.880
0.868
0.849
0.828
0.808
0.788
0.768
0.730
0.690
0.653
0.614
0.596
0.948
0.936
0.926
0.916
0.904
0.894
0.884
0.872
0.862
0.852
0.841
0.822
0.801
0.783
0.763
0.743
0.707
0.668
0.632
0.594
0.577

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Technical description of the burner
4.8 Test boiler
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:
Output 407 kW (350 Mcal/h) - diameter 50 cm, length 1.5 m.
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of (Fig. 4)
preliminary checks are recommended.
4.8.1 Commercial boilers
The burner is suitable for operating on both flame inversion boil-
ers as well as on boilers with a combustion chamber with run-off
from the bottom (three flue passes) on which the best results for
low NO
x
emissions are obtained.
The maximum thickness of the boiler front door must not exceed
200 mm (see Fig. 5).
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of (Fig. 4)
preliminary checks are recommended.
4.9 Burner equipment
The burner is supplied complete with:
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for gas train flange. . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M8 x 25. . . . . . . . . . . . . . . . . . . . . . . No. 4
M8 x 25 screws for fixing the burner flange to the boiler . . No. 4
Cable grommets for the electrical wiring . . . . . . . . . . . . . . No. 5
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 4
Length of combustion
chamber - m
D497
Fig. 5
200 mm MAX
D1079

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Technical description of the burner
4.10 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Pipe coupling
5 Minimum air pressure switch (differential type)
6 Flame sensor probe
7 Air pressure test point
8 Gas pressure test point and head fixing screw
9 Screw securing fan to pipe coupling
10 Slide bars for opening the burner and inspecting the com-
bustion head
11 Servomotor controlling the gas butterfly valve and the air
damper valve (by means of an variable profile cam mecha-
nism).
When the burner is not operating the air damper 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.
12 Plate with four hole knock-outs for electrical cable routing
13 Fan air inlet
14 Gas input pipe
15 Gas butterfly valve
16 Boiler fixing flange
17 Flame stability disc
18 Flame inspection window
19 Control box with lockout pilot light and lockout reset button
20 Power switch for:
automatic - manual - off
Button for:
power increase - power reduction
21 Plugs for electrical wiring
22 Air damper
23 Plug-socket on ionisation probe cable
Control box lockout:
➤if the control box 19)(Fig. 6) push-button lights up, it indi-
cates that the burner is in lockout. To reset, press the button.
Fig. 6
D2208
D2193
D1074

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Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner is shipped in cardboard packaging, so it is possible to
move it when it is still packaged with a transpallet 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. 7), 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 possible minimum and maximum
output (see Firing rate).
Warning:. The burner output must be within the boiler's fir-
ing rate;
I the category of the appliance/countries of destination.
5 Installation
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 that
cleaning and maintenance are carried out 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
20-25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the 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.
Fig. 7
R.B.L.
GAS-KAASU
GAZ-AEPIO
0085
RIELLOS.p.A.
I-37045Legnago(VR)
CE
A B C
ED F
HG
G H
I
D7738

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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. 9.
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 must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling.
The lengths L available are:
For boilers with front flue passes 13)(Fig. 12), a protection in re-
fractory material 11) must be inserted between the boiler refrac-
tory 12) and the blast tube 10).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 11)-
12)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
Tab. G
WARNING
➤ The burner is designed to operate only in
positions 1 , 2 , 3 and 4 (Fig. 8).
➤ Installation 1 is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
➤ Installations 2 , 3 and 4 permit 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 5 is prohibited for safety reasons.
2 3 4 51
Fig. 8
D3928
Blast tube Short (mm) Long (mm)
RS 45/M BLU 229 354
mm A B C
RS 45/M BLU 165 224 M 8
Fig. 9
D455

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Installation
5.6 Positioning the probe - electrode
If the probe or electrode is not correctly positioned, you must:
➤ remove the screw 1)(Fig. 10)
➤ take out the inner part 2)(Fig. 10) of the head, and then cali-
brate them.
5.7 Securing the burner to the boiler
Separate the combustion head from the rest of the burner, as
shown in Fig. 12; proceed as follows:
➤ loosen the screw 13) and remove the hood 14);
➤ disengage the articulated coupling 4) from the graduated
sector 5);
➤ remove screws 2) from the two slide bars 3);
➤ remove screw 1) and pull the burner back on slide bars 3) by
about 100 mm;
➤ disconnect the wires from the probe and the electrode and
then pull the burner completely off the slide bars, after
removing the split pin from the slide bar 3).
➤ Fix the flange 9) to the boiler plate interposing the insulating
gasket 6) that has been supplied.
➤ Use the 4 screws supplied, with a tightening torque of 35 -
40 Nm, after protecting their thread with anti-seizing prod-
ucts.
WARNING
Before securing the burner to the boiler, check
(through the opening of the blast tube) that the
probe and electrode are correctly positioned, as in
Fig. 11.
WARNING
Do not rotate the probe: leave it as in Fig. 11 since
if it is located too close to the ignition electrode,
the control box amplifier may be damaged.
WARNING
Respect the dimensions shown in Fig. 11.
Fig. 10
D1082
Fig. 11
Probe Electrode
D1081
Provide an adequate lifting system of the burner.
WARNING
The burner-boiler seal should be airtight; after
starting the burner check that there are no leaks of
no flue gases.

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Installation
5.8 Combustion head adjustment
At this stage of installation the blast tube and the pipe coupling
are secured to the boiler as shown in Fig. 13.
Therefore the adjustment of the combustion head is particularly
easy, an adjustment that depends solely on the maximum power
of the burner.
Therefore, this value must be set before adjusting the combus-
tion head.
There are provisions for three adjustments of the head:
– that of the external air R1;
– that of the central air R2;
– that of the gas R3.
In the diagram (Fig. 14) find the notch to which both the air and
the gas should be adjusted and then:
Adjusting R1 external air
➤ Turn the screw 4)(Fig. 13) until the notch found lines up with
the front surface 5) of the flange.
Gas adjustment R3
➤ Loosen the screws 1) and 4)(Fig. 13) and rotate the ring nut
2) until the notch you have found lines up with the index 3).
Central air adjustment R2
➤ Turn the shutter 5)(Fig. 13) until the notch found lines up
with the screw 4).
➤ Block screws 1) and 4).
Example
Burner output = 400 kW.
The diagram (Fig. 14) shows that for this burner output the ad-
justments are:
– external air: R1 = notch 5.3;
– central air: R1 = notch 2.7;
– gas: R3 = notch 0.7.
Fig. 12
D1080
WARNING
The adjustments indicated can be modified during
the initial start-up.
Fig. 13
D1083
Fig. 14
No. notches
Max. burner output
7
S8877

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Installation
5.9 Closing the burner
With the adjustment of the head completed:
➤ refit the burner 4)(Fig. 15) on the guides 3) at about 100 mm
from the pipe coupling 5) - burner in the position shown in
Fig. 12 on page 17;
➤ insert the probe cable and the electrode cable, then slide the
burner as far as the pipe coupling, with the burner in the
position shown in Fig. 15.
➤ Refit screws 2) on slide bars 3).
➤ Fix the burner to the pipe coupling with the screw 1) and put
back the split pin in one of the two slide bars 3).
➤ Reconnect the articulated coupling 8) to the graduated sec-
tor 7).
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.
Fig. 15
D1085