Riello RS 68/E FGR Quick start guide

Installation, use and maintenance instructions
20171652 (3) - 03/2021
Forced draught gas burners
Modulating operation
CODE MODEL
20171510 RS 68/E FGR
20171514 RS 120/E FGR
GB

Original instructions

1 20171652
GB
Contents
1 Information and general warnings............................................................................................................................................ 3
1.1 Information about the instruction manual .................................................................................................................... 3
1.1.1 Introduction.................................................................................................................................................................. 3
1.1.2 General dangers.......................................................................................................................................................... 3
1.1.3 Other symbols ............................................................................................................................................................. 3
1.1.4 Delivery of the system and the instruction manual...................................................................................................... 4
1.2 Guarantee and responsibility....................................................................................................................................... 4
2 Safety and prevention................................................................................................................................................................ 5
2.1 Introduction.................................................................................................................................................................. 5
2.2 Personnel training ....................................................................................................................................................... 5
3 Technical description of the burner ......................................................................................................................................... 6
3.1 Burner designation ...................................................................................................................................................... 6
3.2 Models available.......................................................................................................................................................... 6
3.3 Burner categories ........................................................................................................................................................ 7
3.4 Technical data ............................................................................................................................................................. 7
3.5 Electrical data.............................................................................................................................................................. 7
3.6 Maximum dimensions.................................................................................................................................................. 8
3.7 Burner equipment........................................................................................................................................................ 8
3.8 Firing rates .................................................................................................................................................................. 9
3.9 Test boiler.................................................................................................................................................................... 9
3.9.1 Commercial boilers.................................................................................................................................................... 10
3.10 Burner description ..................................................................................................................................................... 10
3.11 Electrical panel description........................................................................................................................................ 11
3.12 Control box for the air/fuel ratio (BT330) ................................................................................................................... 12
3.13 Burner operating sequence ....................................................................................................................................... 13
3.14 Servomotor (662R5...)............................................................................................................................................... 14
4 Installation ................................................................................................................................................................................ 15
4.1 Notes on safety for the installation ............................................................................................................................ 15
4.2 Handling .................................................................................................................................................................... 15
4.3 Preliminary checks .................................................................................................................................................... 15
4.4 Operating position ..................................................................................................................................................... 16
4.5 Preparing the boiler ................................................................................................................................................... 16
4.5.1 Boring the boiler plate ............................................................................................................................................... 16
4.5.2 Blast tube length........................................................................................................................................................ 16
4.6 Positioning electrode ................................................................................................................................................. 17
4.7 Securing the burner to the boiler............................................................................................................................... 17
4.8 Combustion head adjustment.................................................................................................................................... 18
4.9 FGR duct system....................................................................................................................................................... 19
4.9.1 Flue gas recirculation line sizing ............................................................................................................................... 20
4.9.2 Calculating the percentage of recirculated flue gas .................................................................................................. 20
4.10 Burner closing ........................................................................................................................................................... 20
4.11 Gas feeding ............................................................................................................................................................... 21
4.11.1 Gas feeding line ........................................................................................................................................................ 21
4.11.2 Gas train.................................................................................................................................................................... 22
4.11.3 Gas train installation.................................................................................................................................................. 22
4.11.4 Gas pressure............................................................................................................................................................. 23
4.12 Electrical wiring ......................................................................................................................................................... 24
4.12.1 Supply cables and external connections passage .................................................................................................... 24
4.13 Calibration of the thermal relay ................................................................................................................................. 25
5 Start-up, calibration and operation of the burner ................................................................................................................. 26
5.1 Notes on safety for the first start-up .......................................................................................................................... 26
5.2 Adjustments prior to ignition ...................................................................................................................................... 26
5.3 Burner start-up .......................................................................................................................................................... 27
5.4 Final calibration of the pressure switches ................................................................................................................. 27
5.4.1 Air pressure switch.................................................................................................................................................... 27
5.4.2 Maximum gas pressure switch.................................................................................................................................. 28
5.4.3 Minimum gas pressure switch ................................................................................................................................... 28
5.4.4 PVP pressure switch kit............................................................................................................................................. 28
6 E-display control ...................................................................................................................................................................... 29
6.1 User interface UI300 ................................................................................................................................................. 29

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Contents
6.2 Menu features ............................................................................................................................................................29
6.3 Main menu .................................................................................................................................................................30
6.4 INFO menu path ........................................................................................................................................................30
6.4.1 Consulting the fault history.........................................................................................................................................30
6.5 Password access procedure......................................................................................................................................31
6.6 Unlock procedure.......................................................................................................................................................32
6.7 Start-up procedure .....................................................................................................................................................32
6.7.1 Adjusting the servomotors .........................................................................................................................................35
6.8 Backup / Restore Procedure......................................................................................................................................36
6.8.1 Backup .......................................................................................................................................................................36
6.8.2 Restore ......................................................................................................................................................................37
6.9 Commissioning of flue gas recirculation system ........................................................................................................38
6.10 Steady state operation ...............................................................................................................................................38
6.11 Ignition failure.............................................................................................................................................................39
6.12 Burner flame goes out during operation.....................................................................................................................39
6.13 Stopping of the burner ...............................................................................................................................................39
6.14 Final checks (with burner operating)..........................................................................................................................39
7 Maintenance ..............................................................................................................................................................................40
7.1 Notes on safety for the maintenance .........................................................................................................................40
7.2 Maintenance programme ...........................................................................................................................................40
7.2.1 Maintenance frequency..............................................................................................................................................40
7.2.2 Safety test - with gas feeding closed .........................................................................................................................40
7.2.3 Checking and cleaning...............................................................................................................................................40
7.2.4 Checking the air and gas pressure on the combustion head.....................................................................................41
7.2.5 Safety components ....................................................................................................................................................41
7.3 Opening the burner ....................................................................................................................................................42
7.4 Closing the burner......................................................................................................................................................42
8 Faults - Probable causes - Solutions ......................................................................................................................................43
8.1 List of fault codes .......................................................................................................................................................43
A Appendix - Accessories ...........................................................................................................................................................47
B Appendix - Electrical panel layout...........................................................................................................................................48

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Information and general warnings
1.1 Information about the instruction manual
1.1.1 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.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

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Information and general warnings
1.1.4 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.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion date, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregular-
ity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
the use of non-original components, including spare parts,
kits, accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

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Safety and prevention
2.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other users expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion chamber
and the room temperature must all be within the values indicated
in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
2.2 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:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures neces-
sary to prevent unauthorised people gaining
access to the machine
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual

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Technical description of the burner
3.1 Burner designation
3.2 Models available
Tab. A
3 Technical description of the burner
Range : R
Size
Fuel : Natural gas
Light oil
Light oil / Natural gas
Adjustment :
Heavy oil
E Electronic cam
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
S
L
LS
N
Emission : C01 or ...
MZ
BLU
MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
Flame control system :
FS1
FS2
Standard (1 stop every 24h)
Continuous operation (1 stop every 72h)
Electrical supply of the system :
3/400/50
3/230/50
Voltage of auxiliaries :
230/50/60
110/50/60
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Head : TC Standard head
TL Long head
3/400-230/50 3N / 400V-230V / 50Hz
FGR : Induced flue gas recirculation
R S 120 E TL FS1 3/400/50 230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
FGR
Designation Voltage Start-up Code
RS 68/E FGR TL FS1 3 ~ 400V - 50Hz Direct 20171510
RS 120/E FGR TL FS1 3 ~ 400V - 50Hz Direct 20171514

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Technical description of the burner
3.3 Burner categories
Tab. B
3.4 Technical data
Tab. C
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(2) Pressure on the pressure switch socket (Fig. 28 on page 26) 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.
3.5 Electrical data
Tab. D
Country of destination Gas category
AT - CH - CZ - DK - EE - ES - FI - FR - GB - GR - HU - IE
IT - LT - LV - NL - NO - PT - RO - SE - SI - SK I2H
DE - LU - PL - RO I2E
Model RS 68/E FGR RS 120/E FGR
Output (1) Max. kW
Mcal/h
350 ÷ 880
301 ÷ 757
600 ÷ 1180
516 ÷ 1015
Min. kW
Mcal/h
195
168
300
258
Fuel Natural gas: G20 (methane gas)
Gas pressure at max. output (2)
- Gas: G20
mbar
13.8 19.0
Operation – Intermittent (min. 1 stop in 24 hours)
– Modulating
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) 80.5
91.5
83.0
94.0
Weight kg 85 90
Model RS 68/E FGR RS 120/E FGR
Main electrical supply
Control circuit power supply
3 ~ 400V +/-10% 50Hz
1N ~ 230V +/-10% 50Hz
Fan motor IE3 rpm
V
kW
A
2890
380/415
1.5
3.4
2890
380/415
2.2
4.6
Ignition transformer V1 - V2
I1 - I2
230 V - 2 x 5 kV
1.9 A - 35 mA
Absorbed electrical power kW max 2.1 2.9
Protection level IP 44

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Technical description of the burner
3.6 Maximum dimensions
The dimensions of the burner are shown in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the guides.
The dimensions of the open burner are indicated by position I.
(1) Blast tube: short-long
(*) Maximum depth of the boiler door including the depth of the burner
flange insulating gasket.
Tab. E
3.7 Burner equipment
The burner is supplied complete with:
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M10x35 to fix the gas train flange . . . . . . . . . . . . . No. 4
Screws M12x35 to fix the burner flange to the boiler . . . . . No. 4
PVP kit for leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Nozzle M10-D6 (RS68/E). . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 1
PT-T(1)
I(1)*
I*
D
N
C
R3
E
F
R 1
R4
B
L
G M
H
U-U(1)
20187047
mm B C D E F G H I - I (1) L M N P R1 R3 R4
RS 68/E FGR 218 131 189 426 2” 308 640 204 - 339 734 426 220 929 DN65 518 196,5
RS 120/E FGR 218 131 189 426 2” 328 640 204 - 339 754 426 220 929 DN65 518 196,5
mm T - T (1) U - U (1)
RS 68/E FGR 255 - 390 1237 - 1447
RS 120/E FGR 255 - 390 1237 - 1447

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Technical description of the burner
3.8 Firing rates
The maximum output is chosen within area A) of the diagram
(Fig. 2).
The minimum output must not be lower than the minimum limit
of the diagram.
3.9 Test boiler
The firing rates were obtained in special test boilers, according to
EN 676 regulations. Fig. 3 indicates the diameter and length of
the test combustion chamber.
Example:
Output 756 kW (650 Mcal/h) - diameter 60 cm, length 2 m.
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of Fig. 3, pre-
liminary checks are recommended.
WARNING
The firing rate (Fig. 2) was obtained considering a
room temperature of 20°C and an atmospheric
pressure of 1013 mbar (approx. 0 m above sea
level), with the combustion head adjusted as
shown at page 18.
Fig. 2
Thermal power
Combustion chamber
pressure - mbar
RS 68/E FGR
Thermal power
Combustion chamber
pressure - mbar
kW
-1
0
1
2
3
4
5
6
7
8
9
10
11
400 500 600 700 800
Mcal/h
400 600
900
1000
300
1100
-2
1300
1200
12
13
14
500 900
700 800 1000 1100
A
300
kW
A
-1
0
1
2
3
4
5
6
7
8
9
10
11
200 300 400 500 600 700
Mcal/h
200 300 400 500 600
800 900
700 800
-2
100
100
20172323
RS 120/E FGR
Fig. 3
Combustion chamber
length - m
D715
Thermal power

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Technical description of the burner
3.9.1 Commercial boilers
The burners are suitable for operation on either flame-inversion
boilers or boilers with combustion chambers featuring flow from
the base (three flue passes) on which the best results are ob-
tained in terms of low NOx emissions.
The burner-boiler match is assured where the boiler is EC type-
approved; for boilers and furnaces with combustion chambers
featuring dimensions differing considerably from those given in
the diagram, it is advisable to perform preliminary tests.
* The maximum depth of the boiler door is referred to dimension
“I” (Fig. 1 on page 8).
3.10 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling
6 Gas servomotor
7 Flame sensor
8 Lifting rings
9 Flue gas recirculation servomotor
10 Flue gas recirculation butterfly valve
11 Extensions for guides 20)
12 Connector G1/4
13 Flame stability disc
14 Boiler fixing flange
15 Gas butterfly valve
16 Gas input pipe
17 Screws to secure fan to pipe coupling
18 Air servomotor
19 Fan air inlet
20 Guides for opening the burner and inspecting the combus-
tion head
21 Gas pressure test point and head fixing screw
22 Air pressure test point
23 Air damper
24 Fan motor
Fig. 4
D1079
*
13
1
3
5
21
14
22
17
6
10
19
9
23
18
20
12
11
88
24
2
4
15
7
16
Fig. 5
20178163

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Technical description of the burner
3.11 Electrical panel description
1 Fan motor thermal relay and contactor
2 Ignition transformer
3 Suppressor
4 ON/OFF operation selector
5 Air pressure switch (differential type)
6 External connections passage by the installer
7 Terminal strip supply for electrical connection
8 Display
9 Relay with clean contacts
10 Electrical control box
11 Auxiliary circuits fuse
2
3
64
7
8
5
1
10
11 9
Fig. 6
20172257

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Technical description of the burner
3.12 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. F
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the operating unit and incorrect settings
of the fuel and / or air actuator positions can lead
to dangerous burner operating conditions.
Model BT330
Power supply 230 V +10/-15% 50-60 Hz
Power consumption max. 30 VA
Cable 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
- mechanic conditions
- temperature range
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C
(condensation is prohibited)
Electronic safety IP40 (housing)
IP20 (terminals)
Fig. 7
S9619

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Technical description of the burner
3.13 Burner operating sequence
Key to layout (Fig. 8)
Tab. G
Key to layout (Fig. 8)
FGR FGR release
X01 Gas valve 1
X02 Gas valve 2
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
20172248
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

20171652 14
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Technical description of the burner
3.14 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.
After any operation (mounting, installation and service, etc.),
check that the wiring is in order, so do the security checks.
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
Tab. H
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actuators.
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
Condensation, the formation of ice and the entry
of water are prohibited!
Model 662R5...
Floating time 5 sec / 90°
Direction of rotation
0° to 90° left - seen from the drive shaft
Rated torque (max) 3 Nm
Static torque (max) 3 Nm
Weight about 1,4 kg
Type of protection IP54 as per DIN EN 60529-1
Environmental conditions:
- climatic conditions
- mechanic conditions
- temperature range
Class 3K5 (DIN EN 60721-3)
Class 3M5 (DIN EN 60721-3)
-20...+60 °C
(condensation is prohibited)
Electrical safety Protection class 2
as per DIN EN 60730
D8271
Fig. 9

15 20171652
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Installation
4.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
4.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 10), showing:
A the burner model
B the category of the appliance/countries of destination
C the cryptographic year of manufacture
D the serial number
E the data for electrical supply and the protection level
F the electrical power consumption
G the types of gas used and the relative supply pressures
H the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate.
4 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 to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 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.
R.H.E.
GAS-KAASU
GAZ-AEPIO
CE
A C
ED F
HG
B
Fig. 10
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Installation
4.4 Operating position
4.5 Preparing the boiler
4.5.1 Boring the boiler plate
Drill holes in the plate shutting off the combustion chamber, as il-
lustrated in Fig. 12.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
4.5.2 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 refractory.
The lengths L available are:
Tab. I
For boilers with front flue passes 13)(Fig. 15 on page 17), or
flame inversion chambers, a protection in refractory material 11)
must be inserted between the boiler refractory 12) and the blast
tube 10).
This protection must not compromise the extraction of the blast
tube.
For boilers with a water-cooled frontal, a refractory cover is not
necessary 11)-12)(Fig. 15 on page 17), unless expressly re-
quested by the boiler manufacturer.
Tab. J
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 11).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
2 3 4 51
Fig. 11
D7739
Blast tube Short (mm) Long (mm)
RS 68-120/E FGR 255 390 mm D1 DF Ø
RS 68-120/E FGR 195 275 - 325 M 12
Ø
45
45
DF
D1
Fig. 12
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17 20171652
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Installation
4.6 Positioning electrode
The following is required to perform the check:
remove the screw 1)(Fig. 13);
extract the inner part 2) of the head, and adjust them.
4.7 Securing the burner to the boiler
Separate the combustion head from the rest of the burner, as in
Fig. 15; proceed as follows:
loosen the 4 screws 3) and remove the hood 1);
remove the screws 2) from the two guides 5);
disconnect the plug 14);
disconnect the socket from the maximum gas pressure
switch;
remove the two screws 4);
unscrew the nut 15) and disconnect the pilot tube;
pull back the burner on the guides 5) by about 100 mm;
disconnect the electrode lead, then unthread the burner
completely from the guides;
fix the flange 9) to the boiler plate, interposing the insulating
gasket 8) supplied;
use the 4 screws supplied, with a tightening torque of 35 - 40
Nm, after protecting their thread with anti-seize products.
WARNING
Before fixing the burner to the boiler, check the
correct positioning of the electrodes as in Fig. 14.
2
1
Fig. 13
20186164
5mm 16.5mm
5mm mm18
Fig. 14
20187923
RS 68/E FGR
RS 120/E FGR
Provide an adequate lifting system of the burner.
WARNING
The seal between burner and boiler must be air-
tight; after the start-up, check there is no leakage
of flue gases into the external environment.
13
13
100 mm
12
11
10
8
3
14
4
3
1
25
9
Fig. 15
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Installation
4.8 Combustion head adjustment
At this point of the installation, the combustion head is fixed to the
boiler as shown in Fig. 13. It is therefore especially easy to adjust,
and this adjustment depends only on the maximum output of the
burner.
In the diagram (Fig. 17) find the notch at which to adjust both air
and central gas/air.
External air R1 adjustment
Rotate the screw 4)(Fig. 16) until the notch you have found
corresponds with the front surface 5) of the flange.
t
NOTE:
he diagram (Fig. 17) indicates the optimum adjustment for a
type of boiler according to Fig. 3 on page 9.
WARNING
To facilitate adjustment, loosen the screw 6),
adjust and then lock.
6 4 5
Fig. 16
20186050
WARNING
The adjustments indicated can be modified during
the initial start-up.
Fig. 17
Max burner output
No. notches
(R1)RS 68 (R1)RS 120
20136052