Riello RS4D User manual

Installation, use and maintenance instructions
Instrucciones de instalación, uso y mantenimiento
20141174 (3) - 11/2020
Forced draught gas burners
Quemadores de gas con aire soplado
Two-stage operation
Funcionamiento a dos llamas
CODE - CÓDIGO MODEL - MODELO TIPO - TYPE
3761866 RS4D ===
3762016 - 3762058 RS5D 922T1
20052615 RS5D 922T1
3761991 RS5DF ===
GB
ES

Translation of the original instructions
Traducción de las instrucciones originales

1 20141174
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Index
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Background ................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 7
4.4 Technical data............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Preparing the boiler..................................................................................................................................................... 9
4.7.1 Boring the boiler plate ................................................................................................................................................. 9
4.8 Firing rate .................................................................................................................................................................. 10
4.9 Test boiler.................................................................................................................................................................. 11
4.9.1 Commercial boilers.................................................................................................................................................... 11
4.10 Burner description ..................................................................................................................................................... 12
4.11 Burner equipment...................................................................................................................................................... 12
4.12 Electrical control box ................................................................................................................................................. 13
5 Installation ................................................................................................................................................................................ 14
5.1 Notes on safety for the installation ............................................................................................................................ 14
5.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 14
5.3 Handling .................................................................................................................................................................... 14
5.4 Preliminary checks .................................................................................................................................................... 15
5.5 Operating position ..................................................................................................................................................... 15
5.6 Securing the burner to the boiler............................................................................................................................... 16
5.7 Burner adjustment RS4D - RS5D - RS5D TL - RS5DF............................................................................................. 17
5.7.1 Combustion head adjustment.................................................................................................................................... 17
5.7.2 Removing the head assembly................................................................................................................................... 17
5.7.3 Reassembling the head assembly ............................................................................................................................ 17
5.7.4 Air damper servomotor adjustment ........................................................................................................................... 18
5.8 Positioning the probe - electrode............................................................................................................................... 18
5.9 Gas feeding............................................................................................................................................................... 19
5.9.1 Gas feeding line ........................................................................................................................................................ 19
5.9.2 Train electrical supply................................................................................................................................................ 19
5.9.3 Gas pressure............................................................................................................................................................. 20
5.10 Electrical wiring ......................................................................................................................................................... 21
5.10.1 Electrical system carried out by the factory............................................................................................................... 22
5.11 Operating programme ............................................................................................................................................... 23
5.12 Table of times............................................................................................................................................................ 24
5.12.1 Operations status indication...................................................................................................................................... 24
5.12.2 Fault diagnostics - lockouts ....................................................................................................................................... 25
5.12.3 Checking the gas pressure switch............................................................................................................................. 26
5.12.4 Checking the air pressure switch .............................................................................................................................. 26
5.12.5 Shut-down test .......................................................................................................................................................... 26
5.12.6 Intermittent operation ................................................................................................................................................ 26
5.12.7 Recycle and limit of repetitions.................................................................................................................................. 26
5.12.8 Presence of an extraneous light or parasite flame .................................................................................................... 26
5.12.9 Duration of ignition transformer discharge ................................................................................................................ 27
5.12.10 Reset by button and remotely of the burner .............................................................................................................. 27

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Index
5.12.11 Protection reset..........................................................................................................................................................27
5.12.12 Reset push-button anomaly .......................................................................................................................................27
5.12.13 External lockout signal (S3) .......................................................................................................................................27
5.12.14 Hour counter functioning (B4) ....................................................................................................................................27
5.12.15 Monitoring the power supply voltage .........................................................................................................................27
5.12.16 Frequency supply error ..............................................................................................................................................27
5.12.17 Internal voltage anomaly............................................................................................................................................27
5.12.18 Checking the fan motor..............................................................................................................................................27
5.12.19 Checking the faults of the 1st and 2nd stage valve and the motor ............................................................................28
5.12.20 EEprom check............................................................................................................................................................28
5.12.21 Ionisation current .......................................................................................................................................................28
5.12.22 Post-purging...............................................................................................................................................................28
5.12.23 Continuous purging....................................................................................................................................................28
5.12.24 Lockout log.................................................................................................................................................................29
5.12.25 Logging of burner operating parameters....................................................................................................................29
5.12.26 Admissible lengths of the external connections to the burner....................................................................................29
5.12.27 Long pre-purging........................................................................................................................................................29
5.13 Programming menu ...................................................................................................................................................30
5.13.1 General notes ............................................................................................................................................................30
5.13.2 Block diagram for entering the menu .........................................................................................................................30
5.13.3 Shut-down test ...........................................................................................................................................................31
5.13.4 Post-purging and continuous purging ........................................................................................................................31
5.13.5 Intermittent operation .................................................................................................................................................31
5.13.6 Setting the opening delay of the 2nd stage................................................................................................................31
5.13.7 Setting a long pre-purging..........................................................................................................................................31
5.13.8 Displaying the lockout log ..........................................................................................................................................32
5.13.9 Resetting the programming menu parameters and the lockout log ..........................................................................32
5.14 Lockout types.............................................................................................................................................................33
6 Start-up, calibration and operation of the burner ..................................................................................................................34
6.1 Notes on safety for the first start-up...........................................................................................................................34
6.2 Adjustments prior to ignition.......................................................................................................................................34
6.3 Gas pressure switch ..................................................................................................................................................34
6.4 Air pressure switch.....................................................................................................................................................34
6.5 Combustion adjustment .............................................................................................................................................34
7 Maintenance ..............................................................................................................................................................................35
7.1 Notes on safety for the maintenance .........................................................................................................................35
7.2 Maintenance programme ...........................................................................................................................................35
7.2.1 Maintenance frequency..............................................................................................................................................35
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................35
7.2.3 Checking and cleaning...............................................................................................................................................35
7.2.4 Safety components ....................................................................................................................................................36
7.3 Opening the burner ....................................................................................................................................................36
8 Faults - Possible causes - Solutions.......................................................................................................................................37
8.1 Start-up problems ......................................................................................................................................................37
8.2 Operating faults..........................................................................................................................................................38
A Appendix - Accessories ...........................................................................................................................................................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 burner
Model: RS4D - RS5D - RS5DF
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
The RS5D and RS5D TL products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001: 2015.
Legnago, 21.04.2018 General Manager
RIELLO S.p.A. - Burners Department
Research and Development Director
RIELLO S.p.A. - Burners Department
Eng. U. Ferretti Eng. F. Comencini
CE-0085BN0325

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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 Cen-
tre 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 appliance;
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;
use of non-original components, including spare parts, kits,
accessories and optionals;
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 Background
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.
Namely:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses 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 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, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties.
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4.3 Burner categories - Countries of destination
Tab. B
NOTE:
only for Switzerland: Swiss regulations, those of the SVGW for
the use of gas, Canton and local regulations, as well as Fire Ser-
vices regulations (VKF).
4 Technical description of the burner
Designation Combustion head Voltage Code
RS4D TC 1/230/50 3761866
RS5D TC 1/230/50 3762016
RS5D TC 1/230/50 3762058
RS5D TL 1/230/50 20052615
RS5DF TC 1/230/50 3761991
Range:
Size
Fuel: Natural gas
LPG
Variations:
Electrical power 1/230/50
1/220/60
R S 5 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
1/230V/50Hz
1/220V/60Hz
F Light industrial process
M Progressive two-stage or modulating
D Two-stage
S
SP
Head: TC Standard head
TL Extended head
of the system:
Standard Emission
Low NOx
R
B
TCD
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2E - I2(43.46 - 45.3 MJ/m3(0°C))
FR I2Er
BE I2E(R)B
LU - PL I2E

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Technical description of the burner
4.4 Technical data
Tab. C
(1) Reference conditions: Temperature 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.
(2) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an accurate “Accuracy: Category 3” measurement, as
described in EN ISO 3746.
4.5 Electrical data
Tab. D
Model RS4D RS5D - RS5D TL - RS5DF
Thermal power (1) kW
Mcal/h
110/140 ÷ 246
94.6/120.4 ÷ 211.6
160/208 ÷ 345
137.6/178.8 ÷ 296.7
Fuel Gas G20 NCV 8 12 kWh/m3 – 7.000 10.340 kcal/m3
Pressure: min. 20 mbar – max. 100 mbar
Operation Intermittent (FS1)
Use Boilers: water and diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 40
Noise levels (2) Sound pressure
Sound power dB(A) 67 78
70
81
Weight kg 20 18 - 20
Model RS4D RS5D - RS5D TL RS5DF
Electrical power 1 230V 50 Hz 1~ 230V 50 Hz 1~ 220/230V 50 Hz 1~ 220/230V 60 Hz
Fan motor rpm
Hz
A
2720
50
1,9
2720
50
1,9
2720
50
1,9
3320
60
2,3
Ignition transformer Primary 230V
Secondary 18 kV / 11 mA
Capacitor F8,0
Absorbed electric power kW 0,53 0,45 0,45 0,62
Protection level IP40

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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the flange and burner are given in
Fig. 1.
Tab. E
4.7 Preparing the boiler
4.7.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 2.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
Tab. F
FA
GH
L
M
I
DE
B
C
T
Fig. 1
S9695
Model A B C D E F G H I ø L M T
RS4D 300 345 392 150 150 480 278 300 225 203 216 137 286 17
RS5D 300 345 392 150 150 503 278 300 225 203 216 137 286 17
RS5D TL 300 345 392 150 150 660 278 300 382 360 216 137 286 17
RS5DF 300 345 392 150 150 503 278 300 225 203 216 137 286 17
Model A B C D E F
RS4D 218 80,5 203 170 200 137
RS5D 218 80.5 203 170 200 137
RS5D TL 218 80.5 203 170 200 137
RS5DF 218 80.5 203 170 200 137
Fig. 2
20098188

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Technical description of the burner
4.8 Firing rate
The burner output is chosen from within the diagram area (Fig. 5).
WARNING
The firing rate value (Fig. 5) 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.
Heat output
Fig. 3
RS4D
Pressure in the combustion
chamber – mbar
4,8
1,6
0,8
2,4
3,2
4,0
D4692
kcal/h
0
100 150 200
100.000 150.000 200.000
kW250
A
AIn order to guarantee the working with an output of
220 - 246 kW, remove the blank deadening to free the
supplementary slits of the air inlet on the cover (see Fig. 4).
S7025
Fig. 4

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Technical description of the burner
4.9 Test boiler
The firing rate has been defined on test boilers according to EN
676 standard.
4.9.1 Commercial boilers
The burner-boiler matching is assured if the boiler conforms to
EN 303 and the combustion chamber dimensions are similar to
those shown in the diagram EN 676.
For applications where the boiler does not conform to EN 303, or
where the combustion chamber is much smaller than the dimen-
sions given in EN 676, please consult the manufacturers.
Heat output
Fig. 5
RS5D - RS5D TL - RS5DF
Pressure in the combustion
chamber – mbar
D4357
130.000 290.000
kW150
kcal/h
4.8
1.6
0
170 190 210 230 250 270 290 310 350
3.2
170.000 210.000 250.000
8.0
330
6.4

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Technical description of the burner
4.10 Burner description
1 Air pressure switch
2 6 pole socket for gas train
3 Control box with 7 pole socket incorporated
4 Reset button with lock-out signal
5 Head assembly support
6 Flange with insulating gasket
7 Air damper servomotor
8Flametube
9 4-pole socket for 2nd stage
10 Motor
11 Capacitor
12 Combustion head regulating rod
13 Air damper
14 Ionisation probe
15 Gas distributor
4.11 Burner equipment
Flange with insulating gasket . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws and nuts for fixing the flange to the boiler . . . . . . . No. 4
Screw and nut for flange . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Remote reset connection . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
4-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
7-pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Remote reset kit
The burner has a remote reset kit (RS) consisting of a connection
and a push-button operating at a distance of 20 metres max.
In order to install it, remove the safety lockout device installed at
the factory and insert the lockout supplied with the burner (see
electrical diagram).
Fig. 6
D7112
9
2
3
4
5
13
6
7
10
12
1411
1
8
15
RS4D - RS5D - RS5D TL - RS5DF

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Technical description of the burner
4.12 Electrical control box
The control box is a control and supervision system for forced
draught burners, for intermittent operation (at least one controlled
shutdown every 24 hours).
Important notes
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection
area, fully disconnect the system from the power supply
(omnipolar separation).
Protection against electrocution from the control box and all
connected electric components is obtained with the correct
assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions. In this case, the control box must not be operated,
even if it displays no evident damage.
For safety and reliability, comply with the following instruc-
tions:
- Avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure the control box is perfectly dry.
- Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Installation notes
• Check the electric wiring inside the boiler complies with the
national and local safety regulations.
• Install switches, fuses, earth connection etc. in compliance
with local regulations.
• Do not confuse the powered conductors with the neutral
ones.
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the H.V. ignition cables separately, as far as possi-
ble from the control box and the other cables.
• When wiring the unit, make sure the 230V AC mains voltage
cables are run strictly separate from extra low-voltage cables,
to avoid the risk of electrocution.
To remove the control box from the burner it is necessary to (Fig.
7):
disconnect all the connectors connected to it, all the plugs,
the high voltage cables, and the earth wire (TB);
unscrew the screw (A) and pull the control box in the direc-
tion of the arrow.
To install the control box it is necessary to:
tighten the screw A) with a tightening torque of 1 - 1.2 Nm;
reconnect all previously disconnected connectors, making
sure to connect the 7 pin power plug as the final step.
NOTE:
The burners have been approved for intermittent operation.
This means that they must stop once every twenty four
hours to permit the electrical control box to check its effi-
ciency at start up. The boiler limit thermostat (TL) normally
ensures the stopping of the burner. If this is not the case, it
is necessary to apply a timer switch in series to the limit
thermostat (TL) that turns off the burner at least once every
24 hours.
Electrical wiring of ionisation probe
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• Always separate the probe cables from the other cables:
- the line capacity reduces the magnitude of the flame sig-
nal;
- use a separate cable.
• The cable length must not exceed 1 m.
• Respect the polarity
• Insulation resistance:
- must be at least 50 Mbetween the ionisation probe and
the earth;
- a dirty detector reduces the insulation resistance, fostering
leakage currents.
• The ionisation probe is not protected against the risk of elec-
trocution. When connected to the electricity supply, the ioni-
sation probe must be protected against any accidental
contact.
• Position the ionisation probe so that the ignition spark cannot
form an arc on the probe (risk of electric overcharge).
Technical data
Tab. G
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
or modifying it, or forcing its operation. The Man-
ufacturer cannot assume any responsibility for
damage resulting from unauthorised work!
Mains voltage AC 210...230 V -15 % / +10 %
Mains frequency 50/60 Hz ±5 %
Built-in fuse T4A 250V
Energy consumption 40 VA
Protection level IP00
Fig. 7
E9275
A

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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 Instructions to avoid burnout or bad combustion of the burner
1 The burner can not be installed outside as it is suitable for
operation in closed rooms only.
2 The premises the burner operates in must have openings
for the air need for the combustion. To be sure about this,
you have to control CO2and CO in the exhaust gases with
all the windows and doors closed.
3 If there are air extractors in the premises the burner works,
make sure that there are openings for air to be taken in that
are big enough to ensure the required air change; In any
case, check that when the burner stops the extractors do
not draw hot fumes from pipes through the burner.
4 When the burner is stopped, the smoke pipe must be kept
open and a natural draft created in the combustion chamber.
If the smoke pipe is closed, the burner must be drawn back
till the extraction of blast tube from the furnace. Before oper-
ating in this way take the voltage off.
5.3 Handling
The transport weight is given in chapter “Technical data” on
page 8.
Observe the permissible ambient temperatures for storage and
transport: -20... + 70 °C, with max. relative air humidity 80%.
5Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
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.
The operator must use the required equipment
during installation.

15 20141174
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Installation
5.4 Preliminary checks
Control of the supply
Control of burner characteristics
Check the identification label of the burner (Fig. 8), 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 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.
5.5 Operating position
CAUTION
After removing all the packaging, check the integ-
rity of the contents.
In the event of doubt, do not use the burner; con-
tact the supplier.
The packaging elements (cardboard box, 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 appro-
priate places.
WARNING
The figure of the label (Fig. 8) is indicative.
Some of the data may be arranged in a different
position.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
R.B.L. TIPO TYP
TYPE
II2ELL 3B/P DE
II2H3B/P
AT,CH,IS
II2H3 GB,IE,IT
N2L3B/P LU
GAS
GAZ
FAM.2
FAM.3
I2E(P)B.I3 BE
II2L3B/P NL
II2Er3P FR
Icc A
Imax A PESO kg RIELLO S.p.A.
I-37048 Legnago (VR)
AB
F
B
G
DE
C
Fig. 8
20098188
WARNING
The burner is set up to operate only in posi-
tions 1, 2, 3,5,6 and 7 (Fig. 9).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
The installation layout illustrated in position 5
is only possible using the “MULTI-BLOC rota-
tion kit”, to be ordered separately.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 4are forbidden for safety rea-
sons.
Fig. 9
D4450
2 3 4
5
1
6 7

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Installation
5.6 Securing the burner to the boiler
To install the burner on the boiler, do the following:
if necessary, widen the insulating gasket holes (Fig. 10), tak-
ing care not to damage them.
The burner can be fixed with the variable position (A) as shown
in Fig. 11.
Tab. H
Fix the flange 5)(Fig. 12) to the door of the boiler 1)(Fig. 12)
placing the insulating gasket 3) in between using the screws
4) and (if necessary) the nuts 2), but keeping one of the two
top screws 4)(Fig. 12) loose.
Insert the combustion head of the burner into the flange
5)(Fig. 12), tighten the flange with the screw 6), then lock the
screw 4)(Fig. 12) which was loose.
Provide an adequate lifting system of the burner.
Model A (mm)
RS4D - RS5D - RS5DF 225 203
RS5D TL 382 360
WARNING
In any event, make sure that the combustion head
crosses the entire thickness of the boiler door.
WARNING
The seal between burner and boiler must be
airtight.
Fig. 10
D5012
Fig. 11
A
D5011
Fig. 12
S7002
S7741
1
4
2
3
5
6

17 20141174
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Installation
5.7 Burner adjustment RS4D - RS5D - RS5D TL - RS5DF
5.7.1 Combustion head adjustment
The ignition should occur at a low output and not higher than 120 kW.
In order to measure the ignition output:
disconnect the connector (CN1) on the ionisation probe
cable (see paragraph “Electrical system carried out by
the factory” on page 22); The burner comes on and goes
into lockout after the safety time (3s).
Perform 10 ignitions with consecutive lockouts.
Read the total quantity of gas burned on the meter.
This quantity must be equal to or lower than:
0.10 Nm3 for G20 (natural gas H)
0.10 Nm3 for G25 (natural gas L)
0.03 Nm3 for G31 (LPG).
It depends on the burner output and is carried out by turning the
adjusting screw 6)(Fig. 13) clockwise or anti-clockwise until the
notch marked on the regulating rod 2)(Fig. 13) lines up with the
outer surface of the head assembly 1)(Fig. 13).
5.7.2 Removing the head assembly
To remove the head assembly (Fig. 13) it is necessary to:
disconnect the connections 3) and 5);
remove the tube 4) and loosen the screws 8);
unscrew and remove the screws 7), remove the head holder
assembly 1) applying a slight rotation to the right.
5.7.3 Reassembling the head assembly
Reassemble with the reverse procedure to that described above,
repositioning the head assembly 1)(Fig. 13) as it was originally.
In (Fig. 14) the head is adjusted to an output of about 230 kW.
The notch 4of the regulating rod lines up with the outer surface
of the head assembly as shown in the diagram.
Example:
The burner is installed in a 210 kW boiler.
Considering an efficiency of 90% the burner should deliver about
230 kW.
The diagram shows that for this output the adjustment must be
made on notch 4.
NOTE:
The diagram is for indication purposes; to ensure the burner
works at peak performance we suggest adjusting the com-
bustion head according to the requirements requested by
the type of boiler.
CAUTION
Take care not to change the setting position on
the elbow-bracket (2)(Fig. 13) when dismantling.
SW1019
Fig. 13
CAUTION
Screw in the screws 7)(Fig. 13) all the way without
locking them.
Lock them with a tightening torque of 3 - 4 Nm.
WARNING
Check that when operating there are no gas leaks
from the screw housings.
If the pressure test point (11) should become
slack accidentally(Fig. 13) we recommend fixing it
correctly ensuring that the hole (F)(Fig. 13) inside
the head assembly 1)(Fig. 13) is facing down-
wards.
150
130
110
170
190
210
230
250
270
290
310
330
350
130,000
110,000
150,000
170,000
190,000
210,000
230,000
250,000
270,000
290,000
0 2 4 6 8 10
kcal/h kW
Set point
20183748
Fig. 14

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Installation
5.7.4 Air damper servomotor adjustment
First stage - CAM I
Cam I (Fig. 15) adjusts, using the micrometric screw, the position
of the 1st stage damper (factory calibration reference value 25°).
Second stage - CAM II and CAM III
Cam II (Fig. 15) adjusts the position of the 2nd stage damper (fac-
tory calibration reference value 50°, do not exceed 65°).
Cam III (Fig. 15) commands the opening of the 2nd stage valve
(factory calibration reference value 35°).
Cam II should always be anticipated by at least 15°.
CAM V
Cam V (Fig. 15) is positioned in the factory (factory calibration ref-
erence value 90°).
Do not tamper with this adjustment for any reason.
5.8 Positioning the probe - electrode
Make sure that the plate 3)(Fig. 16) is always inserted in the
flattening of the electrode 1)(Fig. 16).
Rest the probe insulator 4)(Fig. 16) against the air diffuser
2)(Fig. 16).
Fig. 15
Micrometric screws
D4360
Fig. 16
D6088
3.5 ± 0.3 31 ±0.3 2
3 4
1