Installation, use and maintenance instructions

GB Forced draught gas burners

Progressive two-stage or modulating operation

Code Model Type

3787032 RS 70/E 828 T2

3787033 RS 70/E 828 T2
3787232 RS 100/E 829 T2
3787233 RS 100/E 829 T2
3787432 RS 130/E 830 T2
3787433 RS 130/E 830 T2
3787630 - 3787632 RS 190/E 836 T2
20052617 RS 190/E 836 T2
3789200 - 3789210 RS 250/E MZ 866 T1
3789201 - 3789211 RS 250/E MZ 866 T1
3789230 - 3789240 RS 250/E MZ 866 T1
3789231 - 3789241 RS 250/E MZ 866 T1

2916367 (8) - 09/2013

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: RS 70/E
RS 100/E
RS 130/E
RS 190/E
RS 250/E MZ
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
According to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
such products are marked as follows:

CE-0085AQ0708 (RS 70-100-130/E)

CE-0085BT0657 (RS 190/E)
CE-0085BT0061 (RS 250/E MZ)

Legnago, 30.05.2012
Burners Division Department
RIELLO S.p.A. Eng. I. Zinna

The quality is guaranteed by a quality and management system cer-

tified in accordance with UNI EN ISO 9001.

Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emis-
sion limits specified by German standard “1. BImSchV release 26.01.2010”.
Product Type Model Power
Forced draught gas burner 866 T1 RS 250/E MZ 600-2650 kW
Legnago, 30.05.2012
Burners Division Department
RIELLO S.p.A. Eng. I. Zinna

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Contents

Section Page
1 Information and general warnings 3
1.1 Information about the instruction manual 3
1.2 Guarantee and responsibility 3
2 Safety and prevention 4
2.1 Introduction 4
2.2 Personnel training 4
3 Technical description of the burner 5
3.1 Burner designation 5
3.2 Models available 5
3.3 Burner categories- Countries of destination 5
3.4 Technical data 6
3.5 Electrical data 6
3.6 Burner weight 7
3.7 Overall dimensions 7
3.8 Firing rates 8
3.9 Burner components 9
3.10 Burner equipment 9
3.11 Control box for the air/fuel ratio 10
3.12 Servomotors 11
4 Installation 12
4.1 Notes on safety for the installation 12
4.2 Handling 12
4.3 Preliminary checks 12
4.4 Working position 12
4.5 Securing the burner to the boiler 13
4.6 Combustion head adjustment 15
4.7 Assembly of the gas train 17
4.8 Electrical wiring 18
4.9 Calibration of the thermal relay 19
5 Start-up, calibration and operation of the
20
burner
5.1 Notes on safety for the first start-up 20
5.2 Operations before start-up 20
5.3 Burner start-up 21
5.4 Final calibration of the pressure switches 21
5.5 Operator Panel with LCD display 23
5.6 Visualisation and programming modes 24
5.7 Operation sequence of the burner 29
5.8 Start-up procedure 30
5.9 CALC function 32
5.10 Burner adjustment 32
5.11 Steady state operation 33
5.12 Ignition failure 33
5.13 Burner flame goes out during operation 33
5.14 Stopping of the burner 33
5.15 Measuring the ionisation current 33
5.16 Checking the air and gas pressure on the com- 33
bustion head
5.17 Final checks (with the burner working): 33
5.18 List of parameters 34
6 Faults - Possible causes - Solutions 38
6.1 List of error codes 38
7 Maintenance 42
7.1 Notes on safety for the maintenance 42
7.2 Maintenance programme 42
7.3 Opening the burner 43
7.4 Closing the burner 43
A Appendix - Electrical panel layout 44

B Appendix - Accessories (on request) 50

C Appendix - Gas supply pressure 52

D Appendix - Firing rate on basis of air density 55

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 1 Information and general warnings

1.1 Information about the instruction manual

Introduction DANGER: LIVE COMPONENTS

The instruction manual supplied with the burner:
This symbol indicates operations which, if not
 is an integral and essential part of the product and must not carried out correctly, lead to electric shocks
be separated from it; it must therefore be kept carefully for any with lethal consequences.
necessary consultation and must accompany the burner even DANGER
if it is transferred to another owner or user, or to another sys-
tem. If the manual is lost or damaged, another copy must be
Other symbols
requested from the Technical Assistance Service of
the Area; ENVIRONMENTAL PROTECTION
 is designed for use by qualified personnel; This symbol gives indications for the use of
the machine with respect for the environ-
 offers important indications and instructions relating to the in-
ment.
stallation safety, start-up, use and maintenance of the burner.
 This symbol indicates a list.
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 Abbreviations used
potential danger. Ch. Chapter
Fig. Figure
GENERAL DANGERS Page Page
Sec. Section
The dangers can be of 3 levels, as indicated below. Tab. Table
Maximum danger level!
Delivery of the system and the instruction manual
This symbol indicates operations which, if not
When the system is delivered, it is important that:
carried out correctly, cause serious injury,
 the instruction manual is consigned to the user by the system
death or long-term health risks.
DANGER manufacturer, with the recommendation to keep it in the room
where the heat generator is to be installed.
This symbol indicates operations which, if not  The instruction manual shows:
carried out correctly, may cause serious the serial number of the burner;
injury, death or long-term health risks. the address and telephone number of the nearest Assistance
WARNING
Centre.
 The system supplier must carefully inform the user about:
This symbol indicates operations which, if not - the use of the system,
carried out correctly, may cause damage to - any further tests that may be necessary before the system
the machine and/or injury to people. is started up,
CAUTION
- maintenance and the need to have the system checked at
least once a year by the manufacturer or another specialised
technician.
To ensure a periodic check, recommends the draw-
ing up of a Maintenance Contract.

1.2 Guarantee and responsibility

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

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 2 Safety and prevention

2.1 Introduction

The burners have been designed and built in compliance In particular:

with current regulations and directives, applying the known tech- it can be applied to boilers operating with water, steam, dia-
nical rules of safety and envisaging all the potential danger situ- thermic oil, and to other users expressly named by the man-
ations. ufacturer;
It is necessary, however, to bear in mind that the imprudent and the type and pressure of the fuel, the voltage and frequency
clumsy use of the equipment may lead to situations of death risk of the electrical power supply, the minimum and maximum
for the user or third parties, as well as the damaging of the burner deliveries for which the burner has been regulated, the pres-
or other items. Inattention, thoughtlessness and excessive confi- surisation of the combustion chamber, the dimensions of the
dence often cause accidents; the same applies to tiredness and combustion chamber and the room temperature must all be
sleepiness. within the values indicated in the instruction manual.
 Modification of the burner to alter its performance and desti-
It is a good idea to remember the following: nations is not allowed.
 The burner must only be used as expressly described. Any  The burner must be used in exemplary technical safety con-
other use should be considered improper and therefore dan- ditions. Any disturbances that could compromise safety must
gerous. be quickly eliminated.
 Opening or tampering with the burner components is not al-
lowed, apart from the parts requiring maintenance.
 Only those parts envisaged by the manufacturer can be re-
placed.

2.2 Personnel training

The user is the person, body or company that has acquired the  Personnel must always use the personal protective equip-
machine and intends to use it for the specific purpose. He is re- ment envisaged by legislation and follow the indications given
sponsible for the machine and for the training of the people work- in this manual.
ing around it.  Personnel must follow all the danger and caution indications
shown on the machine.
The user:
 Personnel must not carry out, on their own initiative, opera-
 undertakes to entrust the machine exclusively to suitably
tions or interventions that are not within their province.
trained and qualified personnel;  Personnel are obliged to inform their superiors of every prob-
 must take all the measures necessary to prevent unauthor- lem or dangerous situation that may arise.
ised people gaining access to the machine;  The assembly of parts of other makes, or any modifications,
 undertakes to inform his personnel in a suitable way about the can alter the characteristics of the machine and hence com-
application and observance of the safety instructions. With promise operating safety. The Manufacturer therefore de-
that aim, he undertakes to ensure that everyone knows the clines any and every responsibility for any damage that may
use and safety instructions for his own duties; be caused by the use of non-original parts.
 must inform the Manufacturer if faults or malfunctioning of the
accident prevention systems are noticed, along with any pre-
sumed danger situation.

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 3 Technical description of the burner

3.1 Burner designation

Range : R

Fuel : S Natural gas

L Light oil
LS Light oil / Natural gas
N Heavy oil

Size

Adjustment : E Electronic cam

EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve

Emission : ... Class 1 EN267 (light oil) - EN676 (gas)

MZ Class 2 EN267 (light oil) - EN676 (gas)
BLU Class 3 EN267 (light oil) - EN676 (gas)
Class 1 EN267 (light oil)
MX
Class 3 EN676 (gas)

Head : TC Standard head

TL Long head

Flame control system :

FS1 Standard (1 stop every 24h)
FS2 Continuous operation (1 stop every 72h)

Electrical supply of the system :

3/400/50 3N / 400V / 50Hz
3/230/50 3 / 230V / 50Hz
3/400-230/50 3N / 400V-230V / 50Hz

Voltage of auxiliaries :
230/50/60 230V/50-60Hz
110/50/60 110V/50-60Hz

R S 100 E MZ TC FS1 3/400/50 230/50/60

BASIC DESIGNATION
EXTENDED DESIGNATION

3.2 Models available

Designation Voltage Code Designation Voltage Code

RS 70/E TC 3 ~ 400 / 230V - 50Hz 3787032 RS 190/E TC 3 ~ 400 / 230V - 50Hz 3787630 - 3787632
RS 70/E TL 3 ~ 400 / 230V - 50Hz 3787033 RS 190/E TL 3 ~ 400 / 230V - 50Hz 20052617
RS 100/E TC 3 ~ 400 / 230V - 50Hz 3787232 RS 250/E MZ TC 3 ~ 400 / 230V - 50Hz 3789200 - 3789210
RS 100/E TL 3 ~ 400 / 230V - 50Hz 3787233 RS 250/E MZ TL 3 ~ 400 / 230V - 50Hz 3789201 - 3789211
RS 130/E TC 3 ~ 400 / 230V - 50Hz 3787432 RS 250/E MZ TC 3 ~ 230V - 50Hz 3789230 - 3789240
RS 130/E TL 3 ~ 400 / 230V - 50Hz 3787433 RS 250/E MZ TL 3 ~ 230V - 50Hz 3789231 - 3789241

3.3 Burner categories - Countries of destination

Gas category Country of destination

II2H3B/P AT - CH - CZ - DK - EE - FI - GR - HU - IS - IT - LT - NO - SE - SI - SK - TR
II2H3P ES - GB - IE - PT
II2L3B/P NL
II2Er3P FR
II2ELL3B/P DE
I2E(R) - I3P BE
II2E3B/P LU - PL
I3B/P CY - CZ - MT

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3 Technical description of the burner

3.4 Technical data

Model RS 70/E RS 100/E RS 130/E RS 190/E RS 250/E MZ

Type 828 T2 829 T2 830 T2 836 T2 866 T1
kW 470 - 930 700 - 1340 920 - 1600 1279 - 2290 1250 - 2650
maximum
Mcal/h 404 - 800 602 - 1152 791 - 1376 1100 - 1970 1075 - 2279
Output (1)
kW 150 150 240 470 600
minimum
Mcal/h 129 129 206 405 516
Fuel Natural gas: G20 - G23 - G25
Gas pressure at max. output (2) -
mbar 12.9 / 17.9 11.4 / 17.1 11.7 / 16.8 14.9 / 22.3 19.4 / 29.1
Gas: G20/G25
Operation Intermittent (min. 1 stop in 24 hours)
Standard applications Boilers: water, steam, diathermic oil
Room temperature °C 0 - 40
Combustion air temperature °C max 60
Noise level (3) dBA 75.0 77.0 78.5 83.1 83.0

(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(2) Gas pressure on the pipe coupling test point 21) (Fig. 5) with zero pressure in the combustion chamber and at maximum burner output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum output.

3.5 Electrical data

Motor IE1
Model RS 70/E RS 100/E RS 130/E RS 190/E RS 250/E MZ
Electrical supply 3 ~ 230V / 400V 1N ~ 230V +/-10% 50 Hz (See Ch. 3.2)
Fan motor (rating) rpm 2800 2830 2860 2860 2900
V 230 / 400 230 / 400 230 / 400 230 / 400 230 / 400
kW 1,1 1,5 2,2 4,5 5,5
Operating current A 4,7 - 2,7 6,4 - 3,7 8,5 - 4,9 16 - 9,1 19 - 11
Acceleration current A 33 - 19 48 - 28 68 - 39 126 - 72 144 - 83
V1 - V2 230 V - 1 x 8 kV
Ignition transformer
I1 - I2 1 A - 20 mA
Absorbed electrical power kW max 1,4 1,8 2,6 5,5 6,5
Protection level IP 44
Motor IE2
Model RS 70/E RS 100/E RS 130/E RS 190/E RS 250/E MZ
Electrical supply 3 ~ 230V / 400V 1N ~ 230V +/-10% 50 Hz (See Ch. 3.2)
Fan motor (rating) rpm 2860 2860 2860 2900 2910
V 230 / 400 230 / 400 230 / 400 230 / 400 230 / 400
kW 1,1 1,5 2,2 4,5 5,5
Operating current A 4,1 - 2,4 5,5 - 3,4 7,9 - 4,6 15 - 8,7 18 - 11
Acceleration current A 33 - 19 51 - 30 62 - 36 141 - 81 186 - 107
V1 - V2 230 V - 1 x 8 kV
Ignition transformer
I1 - I2 1 A - 20 mA
Absorbed electrical power kW max 1,4 1,8 2,6 5,5 6,5
Protection level IP 44

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3.6 Burner weight

The weight of the burner complete with its packaging is shown in table.

Model kg
RS 70/E 77 - 79
RS 100/E 80 - 82
RS 130/E 83 - 85
RS 190/E 89 - 91
RS 250/E MZ 124 - 126
D9078
Fig. 1

3.7 Overall dimensions

The dimensions of the burner are shown in Fig. 2.

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.

D731

Fig. 2

mm A B C D E F (1) G H I (1) L M N O
RS 70/E 511 296 215 555 840 250-385 179 430 1161-1296 214 134 221 2”
RS 100/E 527 312 215 555 840 250-385 179 430 1161-1296 214 134 221 2”
RS 130/E 553 338 215 555 840 280-415 189 430 1161-1296 214 134 221 2”
RS 190/E 675 370 305 555 872 372-522 222 436 1328-1478 230 150 223 2”
RS 250/E MZ 732 427 305 555 872 370-520 222 436 1322-1467 230 150 264 2”

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 3 Technical description of the burner

3.8 Firing rates

RS 70/E D9156 RS 190/E D8034

Pressure in combustion
Pressure in combustion

chamber - mbar
chamber - mbar

A A

RS 100/E RS 250/E MZ
Pressure in combustion

Pressure in combustion
chamber - mbar

chamber - mbar
A
A

RS 130/E Fig. 3
Pressure in combustion

The maximum output is chosen within area A of the dia-

chamber - mbar

gram.
The minimum output must not be lower than the minimum
limit of the diagram.
A
Warning
The firing rate was obtained considering an ambient temper-
ature of 20°C and an atmospheric pressure of 1013 mbar
(approx. 0 m above sea level), with the combustion head ad-
justed as shown in Ch. 4.6.

The firing rates were obtained in special

test boilers, according to EN 676 regula-
tions.
Fig. 4 indicates the diameter and length of
the test combustion chamber.
Length of combustion
chamber - m

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
dimensions compared to those shown in
the diagram of Fig. 4, preliminary checks
D715 are recommended.
Fig. 4

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3 Technical description of the burner

3.9 Burner components

RS 190/E

RS 70-100/E
RS 130/E

RS 250/E MZ

D8038

RS 190/E seen from A

RS 250/E MZ

Fig. 5

1 Combustion head 13 Clean contacts relay 22 Air pressure socket

2 Ignition electrode 14 Filter to protect against radio distur- 23 Flame sensor probe
3 Screw for combustion head adjustment bance 24 Air damper
4 Maximum gas pressure switch 15 Flame inspection window 25 Fan air inlet
5 Pipe coupling 16 Ignition transformer 26 Screws to secure fan to pipe coupling
6 Gas servomotor 17 Cable grommets for electrical wiring 27 Gas input pipe
7 Plug-socket on ionisation probe cable (to be carried out by the installer) 28 Gas butterfly valve
8 Motor contact maker and thermal relay 18 Air servomotor 29 Boiler fixing flange
with reset button 19 Air pressure switch 30 Flame stability disc
9 Operation on/off switch (differential type) 31 Bracket for application of output regu-
10 Terminal board for electrical wiring 20 Guides for opening the burner and lator RWF40
11 Operator Panel with LCD display inspecting the combustion head 32 Extensions for guides 20) - only for TL
12 Control box for checking flame and air/ 21 Gas pressure test point and head fix- versions
fuel ratio ing screw

3.10 Burner equipment

The burner is supplied complete with:

 Gas train flange  Extensions 32) for guides 20): TL versions only
 Flange gasket  Disc (for RS 190/E and RS 250/E MZ only)
 6 screws to fix the flange: M10 x 30 for RS 70-100/E -  Small disc (for RS 190/E and RS 250/E MZ only)
RS 130/E - RS 190/E, M10 x 40 for RS 250/E MZ  PVP kit for leak detection (supplied as standard with
 Thermal insulation screen RS 130/E, RS 190/E and RS 250/E MZ, accessory supplied
 4 Screws to fix the burner flange to the boiler: on request for RS 70-100/E - see Appendix B)
M12 x 35 for RS 70-100/E - RS 130/E, M16 x 40 for RS 190/E  Instruction manual
-RS 250/E MZ  Spare parts list
 N° 2 Screws M4 x 7 (for RS 190/E and RS 250/E MZ only)

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3 Technical description of the burner

3.11 Control box for the air/fuel ratio

D8266 Fig. 6

Introduction Technical Data

The control box for the air/fuel ratio (hereafter referred to simply Electrical supply AC 230 V - 15% /
as the control box), that equips the burners of the RS range, car- +10%
ries out a series of integrated functions in order to optimise
Frequency 50/60 Hz +/- 6%
burner functioning, both for single operation and together with
other units (e.g. double furnace boiler or more than one genera- Internal fuse 6.3 A T
tor at the same time). Operation below the nominal value of electrical supply
Minimum operation value on reduction approx. AC 186 V
The basic functions carried out by the control box relate to: of electrical supply below nominal
1. flame control; value
2. the dosage of air and fuel via the positioning (with direct ser- Minimum operation value on increase approx. AC 195 V
vocontrol) of the relative valves, excluding the possible play in in electrical supply towards nominal
the mechanical cam calibration systems; value
3. the modulation of burner output, on the basis of the load Maximum load of the contacts:
requested by the system, maintaining the pressure or temper- Fan motor relay
ature of the boiler at the working values set; Nominal power supply AC 230 V, 50/60 Hz
4. the safety diagnostic of the air and fuel circuits, via which it is Nominal current 2A
possible to easily identify any causes of malfunctioning. Output factor cos > 0.4
Further interfaces and computer communication functions (for Alarm exit
remote control or integration in central supervision systems) are Nominal power supply AC 230V, 50/60 Hz
available according to the system configuration. Nominal current 1A
Output factor cos > 0.4
NOTE Ignition transformer
The first start-up, like every further operation Nominal power supply AC 230 V, 50/60 Hz
for the internal settings of the control box, Nominal current 2A
WARNING
requires access by means of a password and Output factor cos > 0.2
is only to be carried out by personnel of the Fuel valves
Technical Assistance Service who have been Nominal power supply AC 230 V, 50/60 Hz
specifically trained in the internal program- Nominal current 2A
ming of the tool. Output factor cos > 0.4
The information for the first start-up is given Operator Panel
below. Nominal power supply DC 5 V
Protection level IP 40
Input power < 50 mW
Length of cables
Electrical supply line AC 230V max. 100m (100 pF/m)
Display max. 3m (100 pF/m)
Output regulator max. 20m (100 pF/m)
Remote reset button max. 20m (100 pF/m)

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3 Technical description of the burner

3.12 Servomotors

Introduction
The servomotors that equip the burners of the RS range work directly on
the air damper and the gas butterfly valve, without mechanical lever-
ages but via the interposition of an elastic coupling.
They are commanded by the control box, which constantly checks their
position by means of a return signal from the optic sensor inside the ser-
vomotor.
For this reason it is absolutely forbidden to remove
the cover of the servomotors.

WARNING

The position (in degrees) of the servomotors can be seen on the display
of the Operator Panel. See Ch. 5.18, Parameter 922, index “0” for fuel
servomotor, index “1” for air servomotor.

The servomotors are electrically connected to the control box by means

of RAST 2.5 type connectors.
When servicing or replacing the servomotors, take care not to invert
D8271
the connectors. Follow the indications given in the electrical layouts or
the silkscreen printing on the control box cover.

Fig. 7

Technical Data
Fuel Air
servomotor servomotor
Model SQM33.4.. SQM33.5..
Type of motor Stepping motor
Electrical supply AC/DC 24V
IP IP54
Firing rate 0 - 90°
Opening time 0-90° min: 5 s, max.: 120 s depending on the type of control box
Torque 1.2 Nm 3 Nm
Input power 7.5 W 10 W
Rotation Clockwise/anticlockwise (can be selected from the control box)

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 4 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 environment,
proceed with the installation operations.

All the installation, maintenance and disassem- The installation of the burner must be carried out
bly operations must be carried out with the elec- by qualified personnel, as indicated in this man-
tricity supply disconnected. ual and in compliance with the standards and
DANGER WARNING
regulations of the laws in force.

4.2 Handling

The packaging of the burner includes a wooden platform (see Ch. 3.5), so it is possible to move the burner (still packaged) with a
transpallet truck or fork lift truck.

The handling operations for the burner can be highly dangerous if not carried out with the greatest 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
WARNING area to which you can quickly move if the burner should fall).
During the 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.
Before proceeding with the installation operations, carefully clean all around the area where the burner will be installed.
CAUTION

4.3 Preliminary checks

Checking the consignment

After removing all the packaging, check the integrity of the contents. In the event of doubt, do not use the burner; contact the
supplier.

CAUTION
The packaging elements (wooden cage or cardboard 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.

Checking the characteristics of the burner

Check the identification label of the burner, showing: R.B.L. A B C
D E F
 the model (see A in Fig. 8) and type of burner (B); GAS-KAASU G H
 the year of manufacture, in cryptographic form (C); GAZ-AEPIO G H
RIELLOS.p.A.
 the serial number (D); I I-37045 Legnago (VR)
 the data for electrical supply and the protection level (E);
 the electrical input power (F);
Fig. 8
CE 0085
 the types of gas used and the relative supply D7738
pressures (G);
 the data of the burner's minimum and maximum output
A burner label that has been tampered with, re-
possibilities (H) (see Firing rate)
moved or is missing, along with anything else that
Warning. The output of the burner must be within the
prevents the definite identification of the burner and
boiler's firing rate; WARNING makes any installation or maintenance work diffi-
 the category of the device/countries of destination (I).
cult.
4.4 Working position

The burner is designed to operate only in the positions 1 2 3 4 5

1, 2, 3 and 4.
Installation 1 is preferable, as it is the only one that al-
lows the maintenance operations as described in this
manual. Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the combustion
head more difficult.
D7739
Any other position could compromise the correct opera-
tion of the appliance. Installation 5 is prohibited for
safety reasons. Fig. 9

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4 Installation

4.5 Securing the burner to the boiler

Preparing the boiler

Boring the boiler plate

Make holes in the plate shutting off the combustion chamber, as
illustrated in Fig. 10. The position of the threaded holes can be
marked using the thermal insulation screen supplied with the burner.

9
13 12

11

m 10
0m
10
1 2 5

Fig. 10

mm A B C
8
RS 70/E 185 275-325 M 12
13
RS 100/E 185 275-325 M 12
RS 130/E 195 275-325 M 12
RS 190/E 230 325-368 M 16 3
RS 250/E MZ 230 325-368 M 16 4
15
14
D7950
3 Fig. 11

Length of the blast tube

The length of the blast tube must be selected according to the For boilers with front flue passes 13) or flame inversion cham-
indications provided by the manufacturer of the boiler, and in bers, a protection in refractory material 11) must be inserted
any case it must be greater than the thickness of the boiler door between the boiler refractory 12) and the blast tube 10). This
complete with its refractory. The available lengths L are those protection must not compromise the extraction of the blast tube.
indicated in the table below. See Fig. 11.
For boilers with a water-cooled frontal, a refractory lining is not
necessary 11)-12) unless expressly requested by the boiler
Blast tube short long manufacturer.

RS 70/E 250 mm 385 mm

RS 100/E 250 mm 385 mm
RS 130/E 280 mm 415 mm
RS 190/E 372 mm 522 mm
RS 250/E MZ 370 mm 520 mm

6367
13 GB
4 Installation

Securing the burner to the boiler

Before fixing the burner to the boiler, check from the opening of the blast tube that the probe and the electrode are correctly positioned,
as in Fig. 12.
If, in the previous check, the position of the probe or electrode was not correct, remove the screw 1)(Fig. 13), extract the inner part
2)(Fig. 13) of the head, and adjust them.
Do not rotate the probe: leave it as in Fig. 12; if it is located too close to the ignition electrode, the control box amplifier may be damaged.

Probe Electrode

D1209

Fig. 12

Separate the combustion head from the rest of the burner, Fig. 11.
To do this, 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), unscrew the grommet 15);
 disconnect the socket from the maximum gas pressure switch;
 remove the two screws 4);
 pull back the burner on the guides 5) by about 100 mm;
 disconnect the probe and electrode leads, then unthread the
burner completely from the guides.

D7951
Fig. 13

Once this operation has been carried out, fix the flange 9)(Fig. 11) to the boiler plate, interposing the insulating gasket 8)(Fig. 11) sup-
plied.
Use the 4 screws supplied, with a tightening torque of 35 - 40 Nm, after protecting their thread with anti-seize products.
The seal between burner and boiler must be airtight. After the start-up (see Ch. 5.8), check there is no leakage of flue gases into the
external environment.

6367
14 GB
4 Installation

4.6 Combustion head adjustment

At this point of the installation, the combustion head is fixed RS 190/E - RS 250/E MZ RS 70-100/E
to the boiler as shown in Fig. 13. It is therefore especially RS 130/E
easy to adjust, and this adjustment depends only on the max- 1
1
imum output of the burner. 2 Fig. 14
Two adjustments of the head are foreseen: 2
 the air adjustment;
 the gas adjustment.

In the diagram of Fig. 17, find the notch at which to adjust

both air and central gas/air.
Air adjustment 3
Rotate the screw 2) until the notch you have found corre-
sponds with the front surface 1) of the flange, Fig. 14.

Important
To facilitate adjustment, loosen the screw 3) 6
(Fig. 15), adjust and then lock.
CAUTION

Gas adjustment (RS 70-100/E - RS 130/E)

Loosen the screws 4) and turn ring 5) until the notch identi- 5
fied is aligned with index 6). 4
Tighten the 3 screws 4) fully down.
Gas adjustment (RS 190/E - RS 250/E MZ)
When the burner is installed for maximum burner output
 1300 Mcal/h (approx. 1500 kW) fit the discs 1)-2)(Fig. 16), D8039

supplied as part of the standard equipment, removing the Fig. 15

internal tube 3)(Fig. 16). If the mains gas pressure is low, the
head can be left in the standard set-up, limiting the modula-
tion minimum to 450 Mcal/h (approx. 520 kW).
Example
RS 70/E, burner output = 600 kW.
According to diagram Fig. 17 the gas and air adjustments for
this output are carried out on notch 4.
D8084
NOTE
The diagram indicates the optimum adjustment for a type of 1 3 2 Fig. 16
boiler according to Fig. 4.
D9079
No. of Notches

Maximum burner output

D8040

10
9
No. of Notches

8
RS
RS 190/E
190/ E RS 250/E
RS 250/ E MZ
7
6
5
4
3
2
1
0
1100 1300 1500 1700 1900 2100 2300 2500 Mcal / h

1200 1400 1600 1800 2000 2200 2400 2600 2800 kW

Maximum burner output Fig. 17
Note: The adjustments indicated can be modified during the initial start-up.

6367
15 GB
4 Installation

Once the combustion head adjustment is completed:

 reassemble the burner on the guides 3) at about 100 mm When fitting the burner on the two guides, it is
from the pipe coupling 4) - burner in the position shown in advisable to gently draw out the high voltage
Fig. 11; cable and flame detection probe cable until they
 insert the probe and electrode cables, then slide the burner CAUTION are slightly taut.
as far as the pipe coupling - burner in the position shown in
Fig. 18;
 connect the plug of the servomotor 14) (Fig. 11) and tighten
the cable grommet 15) (Fig. 11);
 connect the socket of the maximum gas pressure switch;
 refit the screws 2) on the guides 3);
 fix the burner to the pipe coupling with the screws 1).

Fig. 18 D7975

6367
16 GB
4 Installation

4.7 Assembly of the gas train

 The gas train is type-approved according to standard EN 676 and is sup-

plied separately from the burner, with the code indicated in Appendix B.

 The gas train can enter the burner from the right or left side, depending
on which is the most convenient, see Fig. 19.

 The gas train must be connected to the gas attachment 1)(Fig. 19) with
the flange 2), the gasket 3) and the screws 4) supplied with the burner.

 The gas solenoids must be as close as possible to the burner, to ensure

that the gas reaches the combustion head within the safety time of 3 s.

 Ensure that the maximum pressure necessary for the burner is included
in the calibration field of the pressure adjuster (colour of the spring): gas
D722
train MBC-1900-SE.

See the accompanying instructions for the adjustment of

the gas train.
WARNING
Fig. 19

1 - Gas input pipe

2 - Manual valve
3 - Vibration damping joint
4 - Pressure gauge with pushbutton cock
7 8 11 P1
5 - Filter 4
6A - “Threaded” multibloc including:
- filter (can be replaced) 12
- safety valve
- working valve
10
- pressure adjuster
6B - “Flanged” multibloc including: P2
1 2 3 6A 13
- safety valve
- working valve
- pressure adjuster
L1 L
7 - Minimum gas pressure switch
8 - Valve leak detection control device. 7 8 11 P1
In accordance with the standard EN 676,
leak detection is compulsory for burners with 4
maximum outputs of more than 1200 kW.
9 - Gasket
12
10 - Gasket supplied with burner
11 - Gas adjustment butterfly valve
10
12 - Maximum gas pressure switch
13 - Gas train/burner adaptor 1 2 5
3 P2 6B 9 13
- supplied with burner
- supplied on request separately from the P3
gas train for the flanged versions
L1 L
P1 - Pressure at combustion head D3735

P2 - Upstream pressure of valves/adjuster

P3 - Pressure upstream from the filter
L - Gas train supplied separately with the
code indicated in Appendix B.
L1 - The responsibility of the installer
Fig. 20

The losses of load along the gas supply line are indicated in Appendix C.

6367
17 GB
4 Installation

4.8 Electrical wiring

Notes on safety for the electrical wiring

 The electrical wiring must be carried out with the electrical supply disconnected.
 Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force
in the country of destination. Refer to the electrical layouts given in Appendix A.
 declines all responsibility for modifications or connections different from those shown in the electrical lay-
outs.
 Check that the electrical supply of the burner corresponds to that shown on the identification label and in this man-
ual. See Fig. 8.
 Do not invert the neutral with the phase in the electrical supply line. Any inversion would cause a lockout due to firing
failure.
 The burners RS 70-100-130-190-250/E have been type-approved for intermittent operation. This means they should
compulsorily be stopped at least once every 24 hours to enable the control box to perform checks of its own start-up
efficiency. Normally the boiler's thermostat/pressure switch ensures the stopping of the burner.
If this is not the case, it is necessary to apply in series with IN a timer switch that turns off the burner at least once
every twenty-four hours. Refer to the electrical layouts given in Appendix A.
DANGER
 The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,
made according to current standards. It is necessary to check this fundamental safety requirement. In the event of
doubt, have the electrical system checked by qualified personnel. Do not use the gas tubes as an earthing system
for electrical devices.
 The electrical system must be suitable for the maximum input power of the device,as indicated on the label and in
the manual, checking in particular that the section of the cables is suitable for the input power of the device.
 For the main power supply of the device from the electricity mains:
- do not use adapters, multiple sockets or extensions;
- use an omnipolar switch with an opening of at least 3 mm between the contacts, as indicated by the current safety
standards.
 Do not touch the device with wet or damp body parts and/or in bare feet.
 Do not pull the electric cables.

If the hood is still present, remove it

and proceed with the electrical wiring
according to the layouts shown in
Appendix A.

Use flexible cables according to stand-

ard EN 60 335-1.
All the cables to be connected to the
burner are fed through the grommets.
See Fig. 21.
The use of the cable grommets can
take various forms. By way of example
we indicate the following mode:
1 - Three-phase power supply
2 - Single phase power supply
3 - Consents/safety
4 - Minimum gas pressure switch
5 - Gas valves
6 - Available
Cable grommets used in the factory:
A - Fan motor
B - Maximum gas pressure switch
C - Gas servomotor
D - Air servomotor D7955

Fig. 21

6367
18 GB
4 Installation

4.9 Calibration of the thermal relay

The thermal relay is used to avoid damage to the motor

owing to a strong increase in absorption or the lack of a
phase.
For the calibration, refer to the table given in electrical layout
no. 6 in Appendix A.
If the minimum value of the scale of the thermal relay is
greater than the rating absorption of the motor, protection is
still ensured. This arises when the power supply of the motor 2
is 400 V.
To reset, in the case of an intervention of the thermal relay,
press the button 1) of Fig. 22.

D8267 Fig. 22

6367
19 GB
 5 Start-up, calibration and operation of the burner

5.1 Notes on safety for the first start-up

The first start-up of the burner must be carried out Check the correct working of the adjustment, com-
by qualified personnel, as indicated in this manual mand and safety devices.
and in compliance with the standards and regula-
WARNING WARNING
tions of the laws in force.

5.2 Operations before start-up

 Ensure that the gas supply Company has carried out the supply line vent operations, eliminating air or inert gases from the piping.
 Slowly open the manual valves situated upstream of the gas train.

 Adjust the minimum gas pressure switch (Fig. 23) to the start of the scale.

 Adjust the maximum gas pressure switch (Fig. 24) to the end of the scale.
 Adjust the air pressure switch (Fig. 25) to the start of the scale.

 Adjust the pressure switch for the valve leak detection control device (PVP Kit) (Fig. 26), if present, according to the instructions supplied with the Kit itself.

Minimum gas pressure switch Maximum gas pressure switch Air pressure switch Pressure switch PVP Kit

D3854
D3855 D3856 D3855

Fig. 23 Fig. 24 Fig. 25 Fig. 26

 Check the gas supply pressure by connecting a

pressure gauge to the pressure test point 1)(Fig. 27)
of the minimum gas pressure switch: it must be low-
er than the maximum allowed pressure of the gas
train, as shown on the characteristics label.

An excessive gas pressure can dam-

age the components of the gas train
and lead to a risk of explosion.
DANGER

 Bleed the air from the piping of the gas train, con-
necting a plastic tube to the pressure test point
1)(Fig. 27) of the minimum gas pressure switch.
Take the vent tube outside the building so you can
notice the smell of gas.
 Connect two lamps or testers to the two gas line so-
lenoids to check the exact moment at which voltage
is supplied.
This operation is unnecessary if each of the two so-
lenoids is equipped with an indicator light that sig-
nals voltage passing through.
1
Before starting up the burner, it is good
practice to adjust the gas train so that D8098
ignition takes place in conditions of
WARNING
maximum safety, i.e. with gas delivery at Fig. 27
the minimum.

6367
20 GB
5 Start-up, calibration and operation of the burner

5.3 Burner start-up

Feed electricity to the burner via the disconnecting switch on the

boiler panel.
Close the thermostats/pressure switches and turn the switch of
Fig. 28 to position “1”.
0
Make sure that the lamps or testers connected to
the solenoids, or indicator lights on the solenoids
1
themselves, show that no voltage is present. If volt-
DANGER D7729
age is present, stop the burner immediately and
check the electrical wiring.
Carry out the “Start-up procedure”, as described on page 30.

D7896
Fig. 28

5.4 Final calibration of the pressure switches

Air pressure switch

Adjust the air pressure switch after having performed all other
burner adjustments with the air pressure switch set to the start
of the scale (Fig. 29).
With the burner working at MIN output, insert a combustion
analyser in the stack, slowly close the suction inlet of the fan
(for example, with a piece of cardboard) until the CO value
does not exceed 100 ppm.
Slowly turn the appropriate knob clockwise until the burner D3951
goes into lockout.
Check the indication of the arrow pointing upwards on the grad- Connecting
uated scale (Fig. 29). Turn the knob clockwise again, until the the pressure
value shown on the graduated scale corresponds with the gauge with the
pressure
arrow pointing downwards, and so recovering the hysteresis of
switch in abso-
the pressure switch (shown by the white mark on a blue back-
lute mode
ground, between the two arrows).
Now check the correct start-up of the burner.
If the burner locks out again, turn the knob slightly anticlock-
wise.
During these operations it may be useful to measure the air Connecting
pressure with a pressure gauge. the pressure
The connection of the pressure gauge is shown in Fig. 29. gauge with the
The standard configuration is that with the air pressure switch pressure
connected in absolute mode. Note the presence of a “T” con- switch in dif-
nection, not supplied. RS 70-100-130/E ferential mode
In certain applications in strong depression situations, the con- D8041
nection of the pressure switch does not allow it to change over.
In this case it is necessary to connect the pressure switch in dif-
ferential mode, applying a second tube between the air pres-
sure switch and the fan suction line mouth. In this case also,
the pressure gauge must be connected in differential mode, as
shown in Fig. 29.

Fig. 29
RS 190-250/E

6367
21 GB
5 Start-up, calibration and operation of the burner

Maximum gas pressure switch

Adjust the maximum gas pressure switch after having per-
formed all other burner adjustments with the maximum gas
pressure switch set to the end of the scale (Fig. 30).
With the burner operating at maximum output, reduce adjust-
ment pressure by slowly turning the relative knob anticlockwise
until the burner locks out.
Turn the knob clockwise by 2 mbar and repeat the start-up of
the burner.
If the burner locks out again, turn the knob clockwise again by
1 mbar.
D3856

Fig. 30

Minimum gas pressure switch

Adjust the minimum gas pressure switch after having per-
formed all other burner adjustments with the pressure switch
set to the start of the scale (Fig. 31).
With the burner operating at maximum output, increase adjust-
ment pressure by slowly turning the relative knob clockwise
until the burner locks out.
Then turn the knob anticlockwise by 2 mbar and repeat the
burner start-up to ensure it is regular.
If the burner locks out again, turn the knob anticlockwise again
by 1 mbar.

D3855

Fig. 31

6367
22 GB
5 Start-up, calibration and operation of the burner

5.5 Operator panel with LCD display

Description of the symbols

Lock-out lamp
Lockout
Flame presence
Valve powered
Ignition transformer powered
Fan motor powered
Pre-heater active
only for burners of fuel oil Fig. 33
Request for heat

D8268
Parameters Mode active
Key to units of measurement
Info Mode active
m3 cubic metre
Service Mode active m3/h cubic metre/hour
l litre
l/h litre/hour
Closure of servomotors D8269 % size as percentage
degree of opening of servomotors
Opening of servomotors Fig. 32
The unit of measurement of the size visualised
Units of measurement is identified by the presence of a dash in the
corresponding unit of measurement.
Description of the keys

Key Function
- Adjustment of the fuel servomotor

F (keep F pressed and adjust the value by pressing or )

- Adjustment of the air servomotor

A (keep A pressed and adjust the value by pressing or )

VSD
- Access to Parameters Mode P

(press, at the same time, F and A plus or )

F A
- Enter Parameters Mode
- Reset in the event of a lockout
- Access to a lower level of the menu
- In Service Mode and Info Mode, allows:
* the selection of the parameter (flashing symbol) (press the key for <1 s)
D8273

* access to a lower level of the menu (press the key for 1 - 3 s)

/reset * access to a higher level of the menu (press the key for 3 - 8 s)
* access to another Mode (press the key for > 8 s)
- Reduction of value
- Access to a lower point of the modulation curve
- Scrolling of the parameters list
- Increase of value
- Access to a higher point of the modulation curve
- Scrolling of the parameters list
Exit function (ESC)
ESC
(press and simultaneously)
- Non confirmation of the value
- Access to a higher level of the menu

6367
23 GB
5 Start-up, calibration and operation of the burner

5.6 Visualisation and programming modes

The Operator Panel, and especially the display visualisation, has 4 working modes:
 Normal mode

 Info Mode (InFo)

 Service Mode (Ser)

 Parameters Mode (PArA)

The information for accessing and operating at the various levels is given below.

Normal Mode
Visualises the operation conditions and allows you to modify the operation point of the burner manually.
It does not require any use of the keys of the Operator Panel.
It allows access to the other visualisation and programming modes.
Some examples in the standard conditions are given below.

P
The burner is in the request for heat waiting mode, or the selector “0-1” of Fig. 28 is at
the “0” position.
D7708

m³ m³/h l l/h %

The display visualises the various phases of the start-up, ignition and switch-off of the
P
burner.
In the example alongside, the display indicates that the burner is in phase 30 (see the
D7710

diagram of Fig. 34) and there are 12 s until the next phase.
m³ m³/h l l/h %

P
The burner is working in the requested load position (in the example alongside, 78.4%).
D7711

m³ m³/h l l/h %

P
D7714

m³ m³/h l l/h % The display visualises alternately the error code (in the example alongside, c: 12) and
the relative diagnostic (in the example d: 0).
The system goes into safety mode and the message shown in the next figure appears.
P
D7715

m³ m³/h l l/h %

P
D7712

The burner goes into lockout.

m³ m³/h l l/h % The display visualises alternately the lockout code (in the example alongside c: 4) and
the relative diagnostic (in the example d: 3).
The red lock-out lamp is on.
P
D7713

m³ m³/h l l/h %

6367
24 GB
5 Start-up, calibration and operation of the burner

D7716
m³ m³/h l l/h %
The display visualises alternately an error code and a diagnostic, which does not take
the system into safety mode.
P

D7717
m³ m³/h l l/h %

Reset procedure

P
D7712

m³ m³/h l l/h % The burner is in lockout when the red indicator light on the Operator Panel is switched on
and the display visualises alternately the lockout code (in the example alongside c: 4) and
the relative diagnostic (in the example d: 3).
P
D7713

m³ m³/h l l/h %

To reset, press the “i/reset” key for 1s: the display will show “rESEt”.
P When the key is released, the lockout signal will disappear and the red indicator light will
switch off.
D7746

The control box is reset.

m³ m³/h l l/h %

Manual lockout procedure

If necessary, it is possible to manually block the control box and, consequently, the burner, by pressing the key “i/reset“ simultaneously
with any other key of the Operator Panel.

With the switch 1-0 in Fig. 28 the burner does not stop immediately, but the switch-off phase is activated.
CAUTION

Manual operation procedure

After the adjustment of the burner and the setting of the points on Releasing the key “F”, the
the modulation curve, it is possible to manually check the opera- standard visualisation
tion of the burner along the entire curve. appears, with the current
P load percentage flashing:
Example this means that the burner
D7767

is working in manual mode

(any outside adjustment is
P The burner is working at m³ m³/h l l/h %
the requested load per- excluded and only the
safety devices are active).
D7765

centage: 20%.
m³ m³/h l l/h % Keep the key “F” pressed
P and, with the keys “+” or
Press the key “F” for 1 “–”, increase or decrease
D7768

P second: “LoAd” is dis- the load percentage.

played and the load per- m³ m³/h l l/h %
D7766

centage flashes.
m³ m³/h l l/h % To emerge from Manual mode, press simultaneously the keys
“+” and “-” (esc) for 3 seconds: the burner will work in auto-
matic mode and the output will depend on the thermostat/adjust-
ment pressure switch (TR).

6367
25 GB
5 Start-up, calibration and operation of the burner

From Normal Mode, using the keys of the Operator Panel, it is possible to activate one of the three visualisation/programming modes:

1 Info Mode (InFo)

Visualisation modes
2 Service Mode (Ser)

Programming modes 3 Service Mode (Ser)

Info Mode Service Mode

Visualises the general system information. Visualises the log of errors and some technical information
The list of the parameters that can be visualised is given in regarding the system.
the table below. The list of the parameters that can be visualised is given in
To access this level, press the key “i/reset” for 1 - 3 s. the table below.
Release the key immediately when the display shows “Info”. To access this level, press the “i/reset” key for more than 3 s.
Release the key immediately when the display shows “SEr”.

P P
D8273

D8273

D7719
D7718

/reset /reset
1..3 s m³ m³/h l l/h % >3s m³ m³/h l l/h %

List of the parameters that can be visualised (in the sequence List of the parameters that can be visualised (in the sequence
in which they are visualised) in which they are visualised)
167 Volumetric delivery of fuel in the unit of measurement 954 Flame intensity (%)
selected 121 Manual setting of output
162 Operation time with flame Not defined = automatic operation
163 Operation time 922 Position of the servomotors (expressed in degrees,
164 No. of resettable ignitions symbol )
166 Total no. of ignitions 0 = fuel
113 Identification code of the burner 1 = air
107 Software version 161 Number of errors
102 Control box test date 701 Log of the errors: 701-725.01, Code
103 Identification code of the control box .
.
104 Identification number of the group of parameters set
.
105 Version of the group of parameters 725
143 Reserved
End

Operating procedure in Info and Service Modes

After access to these levels, the display visualises the number of the parameter
(flashing) on the left, and the corresponding value on the right.
If the value is not visualised, press the key “i/reset” for 1 - 3 s.
To return to the Parameters List, press the key “i/reset” for more than 3 s, or press
simultaneously the keys “+” and “-” (esc).
P
To move on to the next parameter, press the key “+” or “i/reset” for less than 1 s. At
the end of the list, the display visualises “End”.
D7720

To move back to the previous parameter, press the key “-”. m³ m³/h l l/h %
To return to the Normal/Standard Visualisation Mode, press the “i/reset” key for
more than 3 s, or press simultaneously keys “+” and “-” (esc). For a moment the
display will show “OPErAte”.

6367
26 GB
5 Start-up, calibration and operation of the burner

Parameters Mode
Visualises and allows you to modify/program the complete list of To access this level, refer to “Access procedure with password”.
parameters, shown in the table on page 34.
Once the access procedure has been carried out, the display will
The factory-set parameters are not visible.
show “PArA” for a few seconds.
The parameters level is subdivided into groups:
100: ParA General parameters P
Information and identification data of the system.

D7722
200: ParA Checks on the Burner
Type of operation, intervention and safety times m³ m³/h l l/h %
of the various phases.
400: Set Air/Fuel modulation curve Select the group of parameters with keys “+“ and “-“, and con-
Setting of Air/Fuel adjustment points firm by pressing the “i/reset” key.
500: ParA Positioning of Servomotors Within the group you have chosen, scroll through the list with the
Choice of positions of the air/fuel servomotors in keys “+“ and “-”. At the end of the list, the display visualises
the various phases. “End“.
600: ParA Servomotors To return to Normal visualisation mode, simultaneously press the
Setting and addressing of the servomotors. keys “+” and “-” (esc) twice.
700: HISt Log of the errors To modify a parameter, refer to “Parameter modification proce-
Choice of different visualisation modes for the dure”.
errors log.
900: dAtA Process information
Visualisation of information for the remote man- All the parameters are checked in the factory.
agement of the burner. Modification/tampering may compromise the good
operation of the burner and cause injury to people
DANGER or damage to things. In any case, modifications
must be carried out by qualified personnel.

Access procedure with password

Once you have confirmed,

the sign “–” will appear.
P P
Press the keys “F” and Continue in the same way
for the other characters.
D7721

D7722

“A” simultaneously for 1s:

for a moment the display After inserting the last
m³ m³/h l l/h % m³ m³/h l l/h %
will show “CodE“, and character of the password,
immediately after you will confirm by pressing the
P see 7 dashes, the first one P key “i/reset”: if the pass-
flashing. word inserted is correct
D7735

D7736

you will see “PArA“ for a

m³ m³/h l l/h % m³ m³/h l l/h % few seconds, then you can
access the various groups
With the keys “+” and “–” of parameters.
P select the first character of With the keys “+” and “–”
the password (letter or select the group you
require.
D7744

number), and confirm by

m³ m³/h l l/h %
pressing the key “i/reset”. If the password inserted is
incorrect, the message
P “Error“ will appear for a
moment.
D7745

It is then necessary to
m³ m³/h l l/h % repeat the procedure.

The password must only be communicated to the

qualified personnel or the Technical Assistance
Service, and must be kept in a safe place.
DANGER

6367
27 GB
5 Start-up, calibration and operation of the burner

Parameter modification procedure Procedure for inserting and adjusting points on the
modulation curve

After accessing the level Nine adjustment/calibration points (P1 - P9) can be inserted in
and group of parameters, the control box for each servomotor, varying their position by de-
the display visualises the grees and, consequently, the quantity of air and fuel introduced.
number of the parameter The ignition point P0 is independent of the minimum modulation
P (flashing) on the left, and value. This means that, in the event of difficulty, it is possible to
the corresponding value on switch on the burner at a value other than the modulation mini-

D7757
the right. mum (P1).
m³ m³/h l l/h % If the value is not visual- To insert or adjust a point, proceed as follows:
ised, press the key “i/
Access the Parameters level (group 400) referring to “Access
reset” for 1 - 3 s.
procedure with password”.
Find below an example of how to modify the parameter relating Using the keys “+” and “-”
to the pre-purging time (No. 225). insert/select the curve
point you want and wait for
Press the key “i/reset“: it to flash: this means that
the value 20 (seconds) will the servomotors are now
P appear. positioned on the values
P
shown on the display and
D7760

Note: the unit of measure- which correspond to the

ment of the time is not vis-

D7747
m³ m³/h l l/h % point previously set.
ualised but is understood It is now possible to insert/
m³ m³/h l l/h %
in seconds. modify the position by
Press the key “+“ and degrees.
increase the value to 25 Warning: the set value
P
seconds (flashing). does not require
confirmation.
D7758

Press the key “i/reset“ to

confirm and store. For the fuel servomotor,
m³ m³/h l l/h %
keep the key “F” pressed
P (the position in degrees
To return to the list of flashes) and press the

D7748
P parameters, press simulta- keys “+” or “-” to increase
neously the keys “+“ and m³ m³/h l l/h % or decrease the value.
D7759

“-“ (esc).
m³ m³/h l l/h % For the air servomotor,
keep the key “A” pressed
P (the position in degrees
flashes) and press the
D7749

keys “+” or “-” to increase

m³ m³/h l l/h % or decrease the value.
Select another point, or exit this area by pressing the keys “+”
and “-” simultaneously (esc).

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5 Start-up, calibration and operation of the burner

5.7 Operation sequence of the burner

Signal ON
Operation
Signal OFF
Start-up Switching off Checking of
Any signal is allowed seal
t1 TSA1

Number of the phase 00 01 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 80 81 82 83 90

Thermostat/pressure switch
safety TS P
Thermostat/pressure switch P
indicator TL

Ionisation probe ION

Air pressure switch PA Pa

INPUT SIGNALS

Minimum gas pressure switch

P
PGmin
Maximum gas pressure switch
PGM
P

Gas pressure switch for leak

P
detection PGVP

Alternative to leak detection CPI

Fan motor MV

Ignition transformer TA
OUTPUT SIGNALS

Shutoff valve

Safety valve V1

Adjustment valve V2

Pilot valve VP

Limit lockout

90°
Nominal load
Pos. of post-purging
Ignition load
Low flame
fuel

Pos. without load

SERVOMOTORS

0°

90°
Nominal load
Pos. of post-purging
Ignition load
air

Low flame
Pos. without load
0°

D7727
Fig. 34
List of the phases
Ph00 Lockout phase Ph44 t44 = interval time 1
Ph01 Safety phase Ph60 Operation
Ph10 t10 = closure in pause Ph62 t62 = max. time to reach the low flame (the burner
Ph12 Standby moves to the switch-off position)
Ph22 t22 = Uphill train of the fan motor (fan motor = ON, Ph70 t13 = post-combustion time
safety valve = ON) Ph72 The burner moves to the post-purging position
Ph24 The burner moves to the pre-purging position Ph74 t8 = post-purging time
Ph30 t1 = pre-purging time Ph80 t80 = emptying time (valve leak detection)
Ph36 The burner moves to the ignition position Ph81 t81 = atmospheric test time (valve leak detection)
Ph38 t3 = pre-ignition time Ph82 t82 = filling time (valve leak detection)
Ph40 TSA1 = safety time 1 (ignition transformer ON) Ph83 t83 = pressure test time (valve leak detection)
Ph42 TSA1 = safety time 1 (ignition transformer OFF), t42 = Ph90 Standby time due to lack of gas
pre-ignition time OFF Ph = Phase

6367
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5 Start-up, calibration and operation of the burner

5.8 Start-up procedure

P Check that the display of the Operator Panel shows request for heat and “OFF Upr”: this
means it is necessary to set the modulation curve of the burner.

D7734
m³ m³/h l l/h %

P Access the Parameters Level referring to “Access procedure with password”.

The display visualises the parameters group 400; confirm with the key “i/reset”.
D7736

m³ m³/h l l/h %

The display visualises “run”.

Confirm with the key “i/reset”: the burner starts up.
P
The display visualises in sequence all the various phases and relative times.
D7742

The phases are those defined on page 29.

m³ m³/h l l/h %
Phase 22:
Start of the fan motor.
As the burner is not fitted with a device to check the sequence of the phases, the motor rotation
may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor
and check it is rotating anticlockwise. See Fig. 28.
If this is not the case:
 place the switch of Fig. 28 in position “0” and wait for the control box to carry out the
switch-off phase;
 disconnect the electrical supply from the burner;
 invert the phases on the three-phase power supply.
This operation must be carried out
with the electrical supply discon-
nected.
DANGER

Phase 24:
The burner goes to the pre-purging position, the air servomotor opens the damper at 90°.
Phases 80, 81, 82, 83:
These phases relate to the valve seal test (for the burner RS68/E this function is not inserted
in the factory, as it is optional).
Phase 30:
The count of the pre-purging time pre-set in the factory begins.

Phase 36:
The burner goes to the ignition position, point “P0”, defined in the table on page 31: the
P display visualises the indication “P0” flashing. If the value proposed is suitable, confirm.
Otherwise, modify the ignition point (see “Procedure for inserting and adjusting points on the
D7747

modulation curve”).
m³ m³/h l l/h % Warning: the values shown in the figure alongside are purely for indication
purposes.

DANGER
Confirm with the key “+”.

Phase 38:
The ignition phase begins and the spark goes off.
Phase 40:
P The gas valves open (the count of the safety time begins).
Check the presence of the flame from the special inspection window, and the correctness of
D7712

the combustion parameters; if necessary, vary the degrees of opening/closing of the air and
fuel servomotors.
m³ m³/h l l/h %
If the control box goes into lockout, press the keys “+” and “-” (esc) simultaneously: the
display visualises alternately the lockout code for flame absence (c: 4) and the relative
diagnostic (d: 3).
P Resolve the problem, referring to Ch. 5.12.
D7713

Reset (see “Reset procedure”): the display visualises “OFF Upr”.

m³ m³/h l l/h % Repeat the start-up procedure.
Warning: the values inserted previously remain stored.

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5 Start-up, calibration and operation of the burner

After ignition (point “P0”), proceed with the calibration of the modulation curve,
starting from the minimum point “P1”.
Press the key “+”: the display visualises the indication “P1” flashing and proposes
the same settings as for point “P0”. It is possible to modify this value and obtain a
modulation minimum different from the ignition point.

After adjusting point “P1”, press the key “+”: the display shows “CALC” for a few
seconds. The control box will automatically calculate the points from “P2” to “P8”,
distributing them in a straight line, assuming for point “P9” the factory setting (see the
table below). These are theoretical and must be checked.
P Press the key “+” to check if the settings of point “P2” are suitable. If not, modify the
point. Proceed in sequence until point “P9”.
D7763

Important: before moving on from one point to the next, wait for the
m³ m³/h l l/h %
servomotors to reach the position visualised on the display.

WARNING

During the adjustment of each point, work on the air and gas servomotors, without
modifying the position of the gas valve stabiliser.
Halfway through the procedure (i.e. around point P4 or P5), you are advised to
measure gas delivery and check that the output is about 50% of the maximum output.
If this is not the case, work also on the gas valve stabiliser: in this case however, it is
necessary to revise the calibrations of all the points previously set.
Once you have arrived at point “P9”, if the maximum output is not as you wish, work
on the gas valve stabiliser: in this case however, it is necessary to revise the
calibrations of all the points previously set.
P At this point, confirm by pressing simultaneously the keys “+” and “-” (esc): the
parameter “546” will appear.
D7765

If you want to make the burner work on the entire modulation curve, press
m³ m³/h l l/h % simultaneously the keys “+” and “-” (esc): in this way, the parameter “546” will
automatically be assigned the value of 100% and the parameter “545” will have a
value of 20%.
If you want to make the burner work on a part of the modulation curve, modify the
parameters “546” and “545” according to “Parameter modification procedure”.
Press simultaneously the keys “+” and “-” (esc) twice: the display will visualise the
current load position.

Factory settings

Point of Burner
the curve RS 70/E RS 100/E RS 130/E RS 190/E RS 250/E MZ
air 20° 20° 20° 20° 20°
P0
gas 24° 24° 24° 24° 24°
air 90° 90° 90° 90° 90°
P9
gas 90° 90° 90° 90° 90°

6367
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5 Start-up, calibration and operation of the burner

5.9 CALC function

100 D7908 100 D7909

90 90

80 80
e l l
70 original Fu 70 Fu
e
curve
Angle (degrees)

Angle (degrees)
60 60

50 CALC+ 50

40 40

30 30

20 CALC- 20

10 10
Recalculation
0 0
P0 P1 P2 P3 P4 P5 P6 P7 P8 P9 P0 P1 P2 P3 P4 P5 P6 P7 P8 P9

Point of the curve Fig. 35 Point of the curve Fig. 36

The diagram of Fig. 35 shows how the fuel modulation curve is The diagram of Fig. 36 shows the fuel modulation curve
modified if the values of point “P5” are changed. when, after the modification of point “P5”, the recalculation
By keeping the key “+” pressed for more than 3 s, the points of all the other points is not carried out.
from “P6” to “P8” are recalculated.
By keeping the key “-” pressed for more than 3 s, the points from
“P4” to “P2” are recalculated.

5.10 Burner adjustment

Output upon ignition Example for gas G 20 (9.45 kWh/Sm3):

ignition output 150 kW
According to the regulation EN 676. corresponding to 15.87 Sm3/h.
Burners with MAX output up to 120 kW After 10 ignitions with lockout, the delivery indicated on the
Ignition can be performed at the maximum operation output meter must be equal to, or less than:
level. Example:
 max. operation output: 120 kW 15.87 x 10 x 3
Vg = = 0.132 Sm3
 max. output upon ignition: 120 kW 3600
Burners with MAX output above 120 kW
Ignition must be performed at a lower output than the max. oper- Maximum output
ation output.
If ignition output does not exceed 120 kW, no calculations are The MAX output must be set within the firing rate of Fig. 3.
required. If ignition output exceeds 120 kW, the regulations pre-
scribe that the value be defined according to the control box Gas adjustment
safety time "ts": Measure the gas delivery on the meter.
for ts = 3s, ignition output must be equal to, or lower than, 1/3 of As a general rule, this value can be found on the table on page
max. operation output. 52: just read the gas pressure on the pressure gauge (Fig. 38)
Example and follow the indications given on page 52.
MAX operation output of 450 kW.  If it is necessary to reduce it, lower the output gas pressure
The ignition output must be equal to, or less than, 150 kW with via the pressure adjuster located beneath the gas valve.
ts = 3 s  If it needs to be increased, increase the output gas pressure
via the adjuster.
In order to measure the ignition output:
 disconnect the plug-socket 7)(Fig. 5) on the ionisation probe Note
cable (the burner will fire and then go into lockout after the Check that the combustion is satisfactory and without pulsations.
safety time has elapsed);
 perform 10 ignitions with consecutive lockouts; Air adjustment
 on the meter, read the quantity of gas burned: If necessary vary the degrees of the air servomotor.
this quantity must be equal to, or lower than, the quantity
given by the formula, for ts = 3s: Minimum output
Qa (max. burner delivery) x n x ts The MIN output must be set within the firing rate of Fig. 3.
Vg =
3600

Vg: volume supplied in ignitions carried out (Sm3)

Qa: ignition delivery (Sm3/h)
n: number of ignitions (10)
ts: safety time (sec)

6367
32 GB
5 Start-up, calibration and operation of the burner

5.11 Steady state operation 5.15 Measuring the ionisation current

Burner without modulating operation kit The burner is fitted with an ionisation system to check that a
Once the start-up cycle is completed, the servomotor command flame is present.
moves on to the thermostat/pressure switch TR that controls the The minimum current for control box operation is 4 µA. The
pressure or the temperature in the boiler. Operator Panel visualises “30%” (see Parameters List, parame-
ter no. 954).
 If the temperature or the pressure is low (so the thermostat/
The burner provides a much higher current, so controls are not
pressure switch TR is closed), the burner progressively normally required. However, if it is necessary to measure the
increases the output as far as the MAX value (point “P9”). ionisation current, disconnect the plug-socket Ap.37 on the ioni-
 If the temperature or the pressure increases as far as the sation probe cable and insert a direct current microammeter with
opening of the thermostat/pressure switch TR, the burner a base scale of 100 µA - see Fig. 37.
progressively reduces the output as far as the MIN value Carefully check the polarities!
(point “P1”). And so on.
 The burner switches off when the request for heat is lower
than the heat supplied by the burner at MIN output. The ther-
mostat/pressure switch TL opens and the control box carries
out the switching off phase (see Ch. 5.7). The damper closes
completely to reduce thermal dispersions to a minimum.

Burner with modulating operation kit

See the manual supplied with the regulator.

5.12 Ignition failure

If the burner does not switch on, there is a lockout within 3 s of

the electrical supply reaching the gas valve.
It may be that the gas does not arrive at the combustion head
within the safety time of 3 s.
Fig. 37
In this case, increase gas delivery upon ignition. D7977
The arrival of the gas at the pipe coupling is shown on the
pressure gauge of Fig. 38. 5.16 Checking the air and gas pressure on the
combustion head
5.13 Burner flame goes out during operation

If the flame accidentally goes out during operation, the control

Checking
box carries out a recycle (i.e. it repeats the start-up phase once, gas pressure
and makes a further ignition attempt).
If the flame is still absent, the control box goes into lockout.

5.14 Stopping of the burner

The burner can be stopped by:

 intervening on the disconnecting switch of the electrical sup-
ply line, located on the boiler panel;
 removing the hood and working on the switch 0-1 of Fig. 28;
 removing the transparent protection that covers the Operator
Panel, after loosening the relative screw, and using the
Panel itself according to “Manual lockout procedure”.
Checking
air pressure
D7978 Fig. 38

5.17 Final checks (with the burner working)

 Open the thermostat/pressure switch TL:

 Open the thermostat/pressure switch TS:
the burner must stop
 Rotate the maximum gas pressure switch knob to the mini-
mum end-of-scale position.
 Rotate the air pressure switch knob to the maximum end-of-
scale position.
the burner must stop in lockout
 Switch off the burner and disconnect the voltage.
 Disconnect the minimum gas pressure switch connector.
the burner must not start
 Disconnect the ionisation probe wire.
the burner must stop in lockout due to firing failure
 Make sure that the mechanical locking systems on the differ-
ent adjustment devices are fully tightened.

6367
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5 Start-up, calibration and operation of the burner

5.18 List of parameters

Parameter Unit of Values interval

Number of Modifica- Degree of Predefined Access
No. measure-
Description elements tion Min. Max. precision setting mode
par. ment

100 General parameters

Reading
102 Control box identification date 1 - 0 255 1 Info Mode
only

Reading
103 Control box identification number 1 - 0 65535 1 Info Mode
only

Reading
104 Identification number of the group of parameters set 1 - 0 255 1 Info Mode
only

Reading
105 Version of the group of parameters set 1 - 0 0xFFFF 1 Info Mode
only

Reading
107 Software version 1 - 0 0xFFFF 1 Info Mode
only

Modifica-
113 Burner identification 1 - 0 99999999 1 Not defined Info Mode
tion

Modifica-
Manual setting of output Service
121 1 - tion / 0% 100 % 0.1 % Not defined
Not defined = automatic operation Mode
zero setting

Frequency of main power supply

Modifica- Parameters
125 0 = 50 Hz 1 - 0 1 1 0
tion Mode
1 = 60 Hz

Modifica- Parameters
126 Brightness of display 1 - 0% 100 % 1% 75 %
tion Mode

Fuel meter: Led pulse valence Modifica- Parameters

128 1 - 0 400 0.01 0
(led pulses / volumetric flow units) tion Mode

Eliminate visualisation error chronology

To eliminate the visualisation, set the parameter to 1,
Modifica- Parameters
130 then to 2 1 - -5 2 1 0
tion Mode
Answer 0: Process successful
Answer -1: Time-out of 1_2 - Sequence

Remote management of control box

0 = off Modifica- Parameters
141 - 0 2 1 0
1 = Modbus tion Mode
2 = reserved

Standby time before a new attempt in event of fault Modifica- Parameters

142 s 0s 7200 s 1s 600 s
in communication tion Mode

Modifica-
143 Reserved - 1 8 1 1 Info Mode
tion

Modifica- Parameters
144 Reserved - 10 s 60 s 1s 30 s
tion Mode

Modifica- Parameters
145 Peripheral address for Modbus - 1 247 1 1
tion Mode

Baud Rate for Modbus

Modifica- Parameters
146 0 = 9600 - 0 1 1 0
tion Mode
1 = 19200

Parity for Modbus

0 = none Modifica- Parameters
147 1 - 0 2 1 0
1 = odd tion Mode
2 = even

Selection of the burner operation during the interrup-

tion of the switch-over with the system of remote man-
agement.
0 = burner switched off

With modulating operation the settings of the values

are the following:
0...19.9 = burner switched off
Modifica-
20...100 = 20...100% burner modulation field (20% = Parameters
148 1 tion / 0% 100 % 0.1 % Not defined
low flame) Mode
zero setting
These settings adapt to parameters 545 (modulation
minimum) and 546 (modulation maximum)

With stage operation: 0 = burner switched off, 1st,

2nd, 3rd stage according to the values assigned to P1,
P2, P3
No setting = no function in the event of communication
interruption

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5 Start-up, calibration and operation of the burner

Parameter Unit of Values interval

Number of Modifica- Degree of Predefined Access
No. measure-
Description elements tion Min. Max. precision setting mode
par. ment

Reading Service
161 Total number of errors 1 - 0 65535 1 0
only Mode

162 Hours of operation (that can be reset) 1 h Reset 0h 999999h 1h 0h Info Mode

Reading
163 Total hours of power supply to control box 1 h 0h 999999h 1h 0h Info Mode
only

164 Total number of start-ups (that can be reset) 1 - Reset 0 999999 1 0 Info Mode

Reading
166 Total number of start-ups 1 - 0 999999 1 0 Info Mode
only

Volumetric delivery of fuel in the selected unit of

167 measurement 1 - Reset 0 99999999 1 0 Info Mode
(that can be reset)

200 Checks on the burner

Burner operation mode (fuel supply line, modulating/
stage, servomotors, etc.)
-- = not defined (eliminate curves)
1 = Gmod
2 = Gp1 mod
Modifica-
3 = Gp2 mod Parameters
201 1 - tion / 1 9 1 Not defined
4 = Lo mod Mode
zero setting
5 = Lo 2 stages
6 = Lo 3 stages
7 = Gmod pneu
8 = Gp1 mod pneu
9 = Gp2 mod pneu

Stopping of the program

0 = deactivated
1 = Pre-purging (Ph24) Modifica- Parameters
208 1 - 0 4 1 0
2 = Ignition (Ph36) tion Mode
3 = Interval 1 (Ph44)
4 = Interval 2 (Ph52)

Modifica- Parameters
210 Alarm/lockout at start 1 - 0 1 1 0
tion Mode

Modifica- Parameters
211 Uphill train fan motor 1 s 2s 60 s 0.2 s 2s
tion Mode

Modifica- Parameters
212 Maximum time to reach low flame 1 s 0.2 s 10 min 0.2 s 45 s
tion Mode

Modifica- Parameters
215 Maximum repeats of safety circuit 1 - 1 16 1 16
tion Mode

Gas: Selection of flame sensor

Modifica- Parameters
221 0 = QRB.../ QRC 1 - 0 1 1 1
tion Mode
1 = ION / QRA

222 Gas: Selection of the pre-purging function 1 - Modifica- 0 1 1 1 Parameters

0 = deactivated tion Mode
1 = activated

223 Maximum repeats of minimum gas pressure switch 1 - Modifica- 1 16 1 16 Parameters

intervention tion Mode

225 Gas: Pre-purging time 1 s Modifica- 20 s 60 min 0.2 s 20 s Parameters

tion Mode

226 Gas: Pre-ignition time 1 s Modifica- 0.2 s 60 min 0.2 s 2s Parameters

tion Mode

230 Gas: Interval 1 1 s Modifica- 0.2 s 60 s 0.2 s 2s Parameters

tion Mode

232 Gas: Interval 2 1 s Modifica- 0.2 s 60 s 0.2 s 2s Parameters

tion Mode

233 Gas: Post-combustion time 1 s Modifica- 0.2 s 60 s 0.2 s 8s Parameters

tion Mode

234 Gas: Post-purging time 1 s Modifica- 0.2 s 108 min 0.2 s 0.2 s Parameters
tion Mode

242 Gas: Emptying time (valve leak detection) 1 s Modifica- 0.2 s 3s 0.2 s 3s Parameters
tion Mode

243 Gas: Atmospheric test time (valve leak detection) 1 s Modifica- 0.2 s 60 s 0.2 s 10 s Parameters
tion Mode

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5 Start-up, calibration and operation of the burner

Parameter Unit of Values interval

Number of Modifica- Degree of Predefined Access
No. measure-
Description elements tion Min. Max. precision setting mode
par. ment

244 Gas: Filling time (valve leak detection) 1 s Modifica- 0.2 s 3s 0.2 s 3s Parameters
tion Mode

245 Gas: Pressure test time (valve leak detection) 1 s Modifica- 0.2 s 60 s 0.2 s 10 s Parameters
tion Mode

261 Oil: Selection of flame sensor 1 - Modifica- 0 1 1 0 Parameters

0 = QRB.../ QRC... tion Mode
1 = ION / QRA

265 Oil: Pre-purging time 1 s Modifica- 15 s 60 min 0.2 s 15 s Parameters

tion Mode

266 Oil: Pre-ignition time 1 s Modifica- 0.2 s 60 min 0.2 s 2s Parameters

tion Mode

270 Oil: Interval 1 1 s Modifica- 0.2 s 60 min 0.2 s 2s Parameters

tion Mode

272 Oil: Interval 2 1 s Modifica- 0.2 s 60 min 0.2 s 2s Parameters

tion Mode

273 Oil: Post-combustion time 1 s Modifica- 0.2 s 60 s 0.2 s 8s Parameters

tion Mode

274 Oil: Post-purging time 1 s Modifica- 0.2 s 108 min 0.2 s 0.2 s Parameters
tion Mode

281 Oil: Selection transformer ignition phase TA 1 - Modifica- 0 1 1 0 Parameters

0 = brief pre-ignition (Ph38) tion Mode
1 = long pre-ignition (with fan) (Ph22)

400 Air / fuel modulation curve

401 Checking fuel servomotor 13 (°) Modifica- 0° 90° 0.1° 0°; 0°; 15°; Parameters
tion not Mode
defined

402 Checking air servomotor 13 (°) Modifica- 0° 90° 0.1° 0°; 90°; Parameters
tion 45°; not Mode
defined

500 Positioning of servomotors

501 Position of the fuel servomotor in absence of flame 3 (°) Modifica- 0° 90° 0.1° 0°; 0°; 15° Parameters
Index 0 = standby position tion Mode
Index 1 = pre-purging position
Index 2 = post-purging position

502 Position of the air servomotor in absence of flame 3 (°) Modifica- 0° 90° 0.1° 0°; 90°; 45° Parameters
Index 0 = standby position tion Mode
Index 1 = pre-purging position
Index 2 = post-purging position

545 Minimum modulation limit 1 - Modifica- 20 % 100 % 0.1 % Not defined Parameters
tion / Mode
zero setting

546 Maximum modulation limit 1 - Modifica- 20 % 100 % 0.1 % Not defined Parameters
tion / Mode
zero setting

600 Servomotors
645 Analogical exit configuration 1 - Modifica- 0 2 1 0 Parameters
0 = CC 0...10 V tion Mode
1 = CC 2...10 V
2 = CC 0 / 2...10 V

700 Log of the errors

701 Error chronology: 701-725.01.Code 25 - Reading 0 255 1 0 Service
only Mode

• Error chronology: 701-725.02.Diagnostic code 25 - Reading 0 255 1 0 Service

only Mode

• Error chronology: 701-725.03.Error class 25 - Reading 0 6 1 0 Service

only Mode

• Error chronology: 701-725.04.Phase 25 - Reading 0 255 1 0 Service

only Mode

• Error chronology: 701-725.05.Start-up meter 25 - Reading 0 99999999 1 0 Service

only Mode

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5 Start-up, calibration and operation of the burner

Parameter Unit of Values interval

Number of Modifica- Degree of Predefined Access
No. measure-
Description elements tion Min. Max. precision setting mode
par. ment

725 Error chronology: 701-725.06.Load 25 - Reading 0% 100 % 0.1 % 0% Service

only Mode

900 Process information

903 Current output 2 - Reading 0% 100 % 0.1 % 0% Parameters
Index 0 = fuel only Mode
Index 1 = air

910 Servomotors active 3 - Reading 0 1 1 0 Parameters

only Mode

922 Position of the servomotors 2 (°) Reading -50° 150° 150° 0° Service
Index 0 = fuel only Mode
Index 1 = air

942 Heat source active 1 - Reading 0 255 1 0 Parameters

only Mode

947 Result of the sampling of the contact (codified in bits) 2 - Reading 0 255 1 0 Parameters
only Mode

950 Relay request status (coded in bits) 1 - Reading 0 255 1 0 Parameters

only Mode

954 Flame intensity 1 - Reading 0% 100 % 1% 0% Service

only Mode

961 Status of external modules and visualisation 1 - Reading 0 255 1 0 Parameters

only Mode

992 Error indicators 10 - Reset 0 0xFFFFFF 1 0 Parameters

FF Mode

6367
37 GB
 6 Faults - Possible causes - Solutions

If faults arise in ignition or operations, the burner performs a "safety stop", which is signalled by the red burner lockout LED. The display
visualises alternately the lockout code and the relative diagnostic.
To reset the start-up conditions, refer to “Reset procedure”. When the burner starts up again, the red LED goes out.

6.1 List of error codes

Error Diagnostic
Meaning of the system REC27.100A2 Recommended measures
code code
2 4 No flame at the end of TSA1
3 # Air pressure error
0 Air pressure switch off
1 Air pressure switch on
4 Air pressure on – Lockout alarm at start
4 # Extraneous light
0 Extraneous light during start-up
1 Extraneous light during switch-off
2 Extraneous light during start-up – Lockout alarm at start
7 3 Loss of flame
12 # Valve leak detection / CPI
Leak test
Check if the valve on the side of the burner has any leaks.
Check if the pressure switch for the leak test (PGVP) is closed when gas pressure is not
0 V2 leaks / CPI open present.
CPI
Check the wiring.
Check if the CPI contact is closed.
Leak test
Check if the valve on the side of the gas has any
leaks.
1 V1 leaks / CPI closed
CPI
Check the wiring.
Check if the CPI contact opens when the valve is powered.
Pmin
20 0
Min. gas / oil pressure absent
Pmax
21 0
Max. gas / oil pressure exceeded
22 0 Safety circuit open
50 - 58 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
60 0 Internal error: No valid load checking device Carry out a reset; if the error arises repeatedly, replace the control box
65 - 67 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
Fuel / air checking error: Calculation position in
#
70 modulation
21 Invalid load No valid load
26 Curve points not defined Adjust the curve points of all the actuators
71 # Special position not defined
0 Standby position Set the standby position of all the servomotors used
1 Post-purging position Set the post-purging position of all the servomotors used
2 Pre-purging position Set the pre-purging position of all the servomotors used
3 Ignition position Set the ignition position of all the servomotors used
72 # Fuel / air internal checking error Carry out a reset; if the error arises repeatedly, replace the control box
73 # Fuel / air internal checking error
21 Position calculation, invalid stage load No valid load
26 Position calculation, stage curve points not defined Adjust the curve points of all the servomotors
75 # Fuel / air ratio internal checking error
1 Check synchronisation data, different current load
2 Check synchronisation data, different target load
4 Check synchronisation data, different target positions
16 Check synchronisation data, different positions reached
76 # Fuel / air internal checking error Carry out a reset; if the error arises repeatedly, replace the control box
84 # Servomotors curve slope
Bit 1 The slope of the curve can correspond to a maximum position variation of 31°
Fuel servomotor: Curve too steep in terms of train ratio
Valence 2..3 between 2 points of the modulation curve
Bit 2 The slope of the curve can correspond to a maximum position variation of 31°
Air servomotor: Curve too steep in terms of train ratio
Valence 4..7 between 2 points of the modulation curve

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6 Faults - Possible causes - Solutions

Error Diagnostic
Meaning of the system REC27.100A2 Recommended measures
code code
85 # Reference error of a servomotor
The reference of the fuel servomotor was not successful.
Bit 0 It was not possible to reach the reference point.
Reference error of the fuel servomotor
Valence 1 1. Check if the servomotors have been inverted.
2. Check if the servomotor is blocked or overloaded.
The reference of the air servomotor was not successful.
Bit 1 Reference error of the air servomotor It was not possible to reach the reference point.
Valence 2…3 1. Check if the servomotors have been inverted.
2. Check if the servomotor is blocked or overloaded.
Bit 7 The parameterization of an actuator (e.g. the reference position) has been
Reference error owing to parameter modification
Valence  128 modified. This error will be visualised to start up a new reference.

86 # Fuel servomotor error

It was not possible to reach the target position within the requested tolerance range.
0 Position error
1. Check if the servomotor is blocked or overloaded.
Bit 0 Circuit open shown on the servomotor connection.
Circuit open
Valence 1 1. Check the wiring.
Bit 3 The slope of the curve can correspond to a maximum position modification of 31°
Curve too steep in terms of train ratio
Valence  8 between 2 points of the modulation curve.

Bit 4 Overloading of the servomotor or servomotor subjected to mechanical torsion.

Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its range of action.
Valence  16 2. Check if the torque is sufficient for the application.
87 # Air servomotor error
It was not possible to reach the target position within the requested tolerance range.
0 Position error
1. Check if the servomotor is blocked or overloaded.
Bit 0 Circuit open shown on the servomotor connection.
Circuit open
Valence 1 1. Check the wiring.
Bit 3 The slope of the curve can correspond to a maximum position modification of 31°
Curve too steep in terms of train ratio
Valence  8 between 2 points of the modulation curve.

Bit 4 Overloading of the servomotor or servomotor subjected to mechanical torsion.

Deviation of section compared with the last reference 1. Check if the servomotor is blocked in any point along its range of action.
Valence  16 2. Check if the torque is sufficient for the application.
90 - 91 # Burner internal checking error
93 # Flame signal acquisition error
Short circuit in the QRB sensor...
Short circuit of the sensor 1. Check the wiring.
3 2. Flame detector probably faulty.
95 # Relay supervision error
3 Ignition
transformer
4 Fuel valve 1 External power supply - Contact active
5 Fuel valve 2 Check the wiring.
6 Fuel valve 3
96 # Relay supervision error

Check the contacts:

1. Control box connected to the power supply: the fan output must be without voltage.
3 Ignition
2. Disconnect the power supply. Disconnect the fan. The resistive connection
transformer
between the fan output and the neutral wire is not allowed.
4 Fuel valve 1
The relay contacts have joined together If one of the 2 tests fails, replace the control box because the contacts are definitively
5 Fuel valve 2
joined together and it is no longer possible to guarantee safety.
6 Fuel valve 3
97 # Relay supervision error
Check the contacts:
1. Control box connected to the power supply: the fan output must be without voltage.
2. Disconnect the power supply. Disconnect the fan. The resistive connection
The safety relay contacts have joined together or the
between the fan output and the neutral wire is not allowed.
safety relay has been powered by an external power
0 If one of the 2 tests fails, replace the control box because the contacts are definitively
supply joined together and it is no longer possible to guarantee safety.

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6 Faults - Possible causes - Solutions

Error Diagnostic
Meaning of the system REC27.100A2 Recommended measures
code code
98 # Relay supervision error
2 Safety valve
3 Ignition
transformer
The relay does not start up Carry out a reset; if the error arises repeatedly, replace the unit
4 Fuel valve 1
5 Fuel valve 2
6 Fuel valve 3
99 - 100 # Relay internal checking error Carry out a reset; if the error arises repeatedly, replace the control box
105 # Contact sampling internal error
0 Min. pressure
switch
1 Max.
pressure
switch
2 Valve
operation test
pressure
switch
3 Air pressure
4 Load
controller open
5 Load Can be caused by capacitive loads or presence of DC voltage on the main power
controller on/ Blocked upon irregularity supply of the control box. The diagnostic code indicates the input in which the problem
off arose
6 Load
controller
closed
7 Safety loop /
Burner flange
8 Safety valve
9 Ignition
transformer
10 Fuel valve 1
11 Fuel valve 2
12 Fuel valve 3
13 Reset
106 - 108 # Contact request internal error Carry out a reset; if the error arises repeatedly, replace the control box
110 # Voltage monitoring test internal error Carry out a reset; if the error arises repeatedly, replace the control box
111 0 Low level of power supply Insufficient mains voltage
Error code for the carrying out of a reset in the event of power supply restoration
112 0 Reset power supply voltage
(absence of error)
113 # Mains voltage supervision internal error Carry out a reset; if the error arises repeatedly, replace the control box
115 # Control box meter internal error
116 0 Life cycle of the control box in the critical interval The envisaged life cycle of the control box has been exceeded. Replace it.
117 0 Life cycle of the control box exceeded The switch-off threshold has been reached.
Too many disturbance impulses on the input of the fuel meter.
120 0 Interruption of fuel limiting meter input
Improve the electromagnetic compatibility.
Carry out a reset, repeat and check the last setting of the parameters. Restore the
121 - 124 # EEPROM access internal error group of parameters. If the error arises repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the parameters. If the error
125 # EEPROM reading access internal error
arises repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the parameters. If the error
126 # EEPROM writing access internal error
arises repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the parameters. Restore the
127 # EEPROM access internal error
group of parameters. If the error arises repeatedly, replace the control box.
EEPROM access internal error - synchronisation
128 0 Carry out a reset; If the error arises repeatedly, replace the control box.
during the initialisation
EEPROM access internal error – Carry out a reset, repeat and check the last setting of the parameters. If the error
129 #
command synchronisation arises repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the parameters. If the error
130 # EEPROM access internal error - time-out
arises repeatedly, replace the control box.
Carry out a reset, repeat and check the last setting of the parameters. If the error
131 # EEPROM access internal error - page interrupted
arises repeatedly, replace the control box.
132 # EEPROM register initialisation internal error Carry out a reset; If the error arises repeatedly, replace the control box.
EEPROM access internal error – request Carry out a reset, repeat and check the last setting of the parameters. If the error
133 - 135 #
synchronisation arises repeatedly, replace the control box.
136 1 Restoration started The restoration of a backup has been started (no error)

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6 Faults - Possible causes - Solutions

Error Diagnostic
Meaning of the system REC27.100A2 Recommended measures
code code
137 # Internal error – backup / restoration
Restoration – OK, but backup < compared with set data of Restoration successful, but the backup data installed are fewer than those currently present in
157
current system the system.
242 Backup – the backup carried out is contradictory The backup is irregular and cannot be transferred again
Backup – the data comparison between the internal
243 Repeat the reset and backup
microprocessors is irregular
The backup data are incompatible with the current version of the software; the
244 The backup data are incompatible
restoration is not possible
245 Error in access to the parameter Restore_Complete Repeat the reset and backup
246 Restoration – time-out during logging in EEPROM Repeat the reset and backup
247 The data received are contradictory The series of backup data is not valid; restoration is not possible
248 The restoration cannot currently be carried out Repeat the reset and backup
Restoration – interruption caused by inadequate The backup has an inadequate identification of the burner and must not be transferred
249
identification of the burner to the control box
250 Backup – The CRC of a page is not correct The series of backup data is not valid; restoration is not possible
251 Backup – the identification of the burner is not defined Define the identification of the burner and repeat the backup
252 After restoration, the pages are still in INTERRUPTION Repeat the reset and backup
253 The restoration cannot currently be carried out Repeat the reset and backup
254 Interruption owing to transmission error Repeat the reset and backup
255 Interruption owing to time-out during the restoration Carry out a reset, check the connections and repeat the backup
146 # Time-out of the system automation interface Refer to the Modbus User Documentation (A7541)
1 Modbus time-out
2 Reserved
165 # Internal error
166 0 Watchdog reset internal error
167 # Manual lockout The control box has been manually blocked (no error)
1 Manual lockout from remote reset command
2 Manual lockout from Operator Panel
3 Manual lockout from PC interface
168 - 171 # Internal error management Carry out a reset; if the error arises repeatedly, replace the control box
200 # System free of errors No error
201 # Lockout or error at start Lockout or error due to lack of parameter settings
1 No operation mode selected
2..3 No fuel train defined
4..7 No curve defined
8..15 Standardisation speed not defined
16..31 Backup / restoration impossible
202 # Selection of internal operation mode Redefine the operation mode (parameter 201)
Redefine the operation mode (parameter 201)
203 # Internal error
Carry out a reset; if the error arises repeatedly, replace the control box
Phase
204 Program stop The program stop is active (no error)
number
205 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
Combination of control box and Operator Panel not
206 0
allowed
207 # Compatibility of control box with Operator Panel
0 Obsolete version of control box
1 Obsolete version of Operator Panel
208-209 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
240 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
245 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box
250 # Internal error Carry out a reset; if the error arises repeatedly, replace the control box

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 7 Maintenance

7.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper-
safety, yield and duration of the burner. ations:
It allows you to reduce consumption and polluting emissions and
to keep the product in a reliable state over time. disconnect the electricity supply from the burner by
means of the main switch of the system;
The maintenance interventions and the calibration of
DANGER
the burner must only be carried out by qualified, au-
thorised personnel, in accordance with the contents of close the fuel interception tap;
DANGER this manual and in compliance with the standards and
regulations of current laws.
DANGER

7.2 Maintenance programme

Maintenance frequency Combustion head

Open the burner and make sure that all the components of the
The gas combustion system should be checked at least once a
combustion head are:
year by a representative of the manufacturer or another
- undamaged;
specialised technician.
- not deformed due to high temperature;
Checking and cleaning - free of ambient dirt or dust;
- free of rusted materials;
Combustion - adequately positioned.
The optimum calibration of the burner requires an analysis of the Make sure that the gas outlet holes for the start-up, on the com-
flue gases. Significant differences with respect to the previous bustion head distributor, are free of dirt or rust deposits.
measurements indicate the points where more care should be In case of doubt, disassemble the elbow 5)(Fig. 39).
exercised during maintenance. Combustion
Gas leaks Adjust the burner if the combustion values found at the begin-
Make sure there are no gas leaks on the conduit between the ning of the operation do not comply with the Regulations in force
gas meter and the burner. or, at any rate, do not produce good combustion.
Gas filter Use the appropriate card to record the new combustion values;
Replace the gas filter when it is dirty. they will be useful for subsequent controls.
Flame inspection window
Clean the glass of the flame inspection window.

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7 Maintenance

7.3 Opening the burner 7.4 Closing the burner

 Disconnect the electrical supply from the burner.  Push the burner up to approximately 100 mm from the pipe
 Loosen the 4 screws 1) and remove the hood 2). coupling.
 Assemble the two extensions supplied on the guides 4) (ver-  Reinsert the cables and slide the burner as far as the stop.
sions TL).  Connect the plug of the servomotor 7) and tighten the grom-
 Disconnect the plug 7) and loosen the cable grommet 8); met 8).
 Disconnect the socket from the maximum gas pressure  Connect the socket of the maximum gas pressure switch.
switch;  Replace the screws 3) and carefully pull the probe and elec-
 Remove the screws 3) and pull back the burner on the trode cables outwards until they are slightly taut.
guides 4) by about 100 mm. Disconnect the cables of the  Disassemble the two extensions from the guides 4).
probe and electrode, then pull the burner back completely.
At this point it is possible to extract the inner part 5) after having
removed the screw 6).

6
4

5
1
3
8

7
D8272
1
Fig. 39

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 A Appendix - Electrical panel layout

1 Index of layouts

2 Indication of references

3 Functional layout REC27...

4 Functional layout REC27...

5 Functional layout REC27...

6 Electrical wiring that the installer is responsible for

7 Functional layout RWF40...

2 Indication of references

/1.A1
Sheet no.

Co-ordinates

Wiring layout key

A1 - Control box for the air/fuel ratio IN - Manual burner arrest switch
A2 - Operator Panel K1 - Clean contacts output relay burner switched on
+BB - Burner components K2 - Clean contacts output relay burner lockout
+BC - Boiler components KM - Fan motor contact maker
B - Filter to protect against radio disturbance MV - Fan motor
B1 - Output regulator RWF40 PA - Air pressure switch
B2 - Fuel meter PE - Burner earth
BA - Input in current DC 4...20 mA PGM - Maximum gas pressure switch
BA1 - Input in current DC 4...20 mA to modify remote PGMin - Minimum gas pressure switch
setpoint PGVP - Gas pressure switch for valve leak detection con-
BP - Pressure probe trol device
BP1 - Pressure probe Q1 - Three-phase disconnecting switch
BR - Remote setpoint potentiometer Q2 - Single phase disconnecting switch
BT1 - Thermocouple probe RS - Remote burner reset button
BT2 - Probe Pt100, 2 wires S1 - On/off selector
BT3 - Probe Pt100, 3 wires SM1 - Air servomotor
BT4 - Probe Pt100, 3 wires SM2 - Gas servomotor
BTEXT - External probe for climatic compensation of the TA - Ignition transformer
setpoint TL - Limit thermostat/pressure switch
BV - Input in voltage DC 0...10V TR - Adjustment thermostat/pressure switch
BV1 - Input in voltage DC 0...10V to modify remote set- TS - Safety thermostat/pressure switch
point X1 - Burner terminal strip
CN1 - Ionisation probe connector XP1 - Connector for output power regulator kit RWF40
F1 - Fan motor thermal relay XPD - Operator Panel connector
G1 - Load indicator XPGM - Maximum gas pressure switch connector
G2 - Communication interface for Modbus system XPGVP - Gas pressure switch connector for valve leak
H - Remote lockout signal detection control device
ION - Ionisation probe XRWF - Terminal board for output power regulator RWF40
Y - Gas adjustment valve + gas safety valve

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 A

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Appendix - Electrical panel layout

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A Appendix - Electrical panel layout

6367
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A Appendix - Electrical panel layout

6367
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A Appendix - Electrical panel layout

6367
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A Appendix - Electrical panel layout

6367
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 B Appendix - Accessories (on request)

Output power regulator kit for modulating operation

With the modulating operation, the burner continually adapts the power to the request for heat, ensuring great stability for the parameter
controlled: temperature or pressure.
Two components should be ordered:
• the output regulator to install on the burner;
• the probe to install on the heat generator.

Parameter to be checked Probe Output Regulator

Adjustment field Type Code Type Code
Temperature - 100...+ 500°C PT 100 3010110
0...2.5 bar Output probe 3010213 RWF40 3010414
Pressure
0...16 bar 4...20 mA 3010214

Software interface Kit (ACS410 + OCI410.30) - Service Level

Code 3010436

Modbus interface Kit (OCI412)

Code 3010437

Gas trains in compliance with standard EN 676 (complete with valves, pressure adjuster and filter)
Gas train - burner adapters

Gas train coupling Gas train - burner

Gas train
on burner adapter
Code Model Ø RS 70/E RS 100/E RS 130/E RS 190/E RS 250/E Code
3970256 Multibloc MB DLE 412 S52 1”1/4   3010126
3970250 Multibloc MB DLE 415 S52 1”1/2      3000843
3970257 Multibloc MB DLE 420 S52 2”      -
3970221 MBC-1200-SE -50 2”      -
3970222 MBC-1900-SE-65 FC DN 65      3000825
3970223 MBC-3100-SE-80 FC DN 80    3000826

PVP Kit (Pressure Valve Proving)

Code 3010344 for RS 70-100/E

Note: for RS 130/E, RS 190/E and RS 250/E MZ, the Kit is supplied as standard equipment with the burner.

Continuous purging kit

Burner Kit code

RS 70-100/M
RS 130/M MZ
3010094
RS 190/E
RS 250/M MZ

Soundproofing chamber

Reduction of
Burner Kit code Type
noise average
RS 70-100/M
RS 130/M MZ
3010404 C4/5 10 [dB(A)]
RS 190/E
RS 250/M MZ

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 B Appendix - Accessories (on request)

Pipes Kit (for flame inversion boilers)

Combustion
Burner Kit code
head
TC
RS 70/E 3010201
TL
TC
RS 100/E 3010202
TL
TC 3010373
RS 130/E
TL 3010374
RS 190/E TC 3010375
TC
RS 250/E MZ -
TL

Kit for LPG operation

Combustion Obtainable output with

Burner Kit code
head the kit
TC 20008175
RS 70/E 200/470 - 930 kW
TL 20008176
TC 20008177
RS 100/E 300/700 - 1340 kW
TL 20008178
TC 20008179
RS 130/E 300/920 - 1600 kW
TL 20008180
RS 190/E TC 3010166 465 - 2290 kW
TC
RS 250/E MZ 3010411 600 - 2700 kW
TL

Kit for TOWN GAS operation - not CE type-approved

Combustion
Burner Kit code
head
TC
RS 70/E 3010286
TL
TC
RS 100/E 3010287
TL
TC
RS 130/E 3010288
TL
RS 190/E TC 3010297
TC
RS 250/E MZ -
TL

Long head kit

Head length obtained

Burner Kit code Standard head length
with the kit
RS 70/E 3010117 250 mm 385 mm
RS 100/E 3010118 250 mm 385 mm
RS 130/E 3010119 280 mm 415 mm
RS 190/E 3010443 372 mm 530 mm
RS 250/E MZ 3010412 370 mm 520 mm

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 C Appendix - Gas supply pressure

The table show minimum load losses along the gas supply line depending on the maximum burner output operation.

1 2 3
p (mbar) p (mbar) p (mbar)
Model

kW MB-DLE 412 MB-DLE 415 MB-DLE 420 MBC-1200-SE MBC-1900-SE MBC-3100-SE

(Rp 1” 1/4) (Rp 1” 1/2) (Rp 2") (Rp 2") (DN 65) (DN 80)
G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25
470 4.2 5.7 0.4 0.5 18.1 24.9 9.3 12.4 6.5 8.8 4.0 4.5 3.5 3.8 - -
500 4.6 6.3 0.5 0.5 19.9 27.5 10.1 13.5 7.0 9.8 4.2 4.7 3.6 3.9 - -
550 5.3 7.2 0.6 0.7 23.2 31.9 11.6 15.4 8.2 11.3 4.4 5.0 3.8 4.2 - -
600 6.0 8.2 0.7 0.8 26.7 36.4 13.2 17.4 9.5 12.9 4.6 5.3 3.9 4.3 - -
650 6.7 9.1 0.8 0.9 30.3 41.0 14.7 19.6 10.8 14.6 4.9 5.7 4.0 4.6 - -
RS 70/E

700 7.4 10.1 0.9 1.1 34.0 45.7 16.4 22.0 12.1 16.4 5.1 6.2 4.2 4.9 - -
750 8.5 11.8 1.0 1.2 37.7 50.3 18.0 24.4 13.4 18.2 5.4 6.7 4.5 5.2 - -
800 9.6 13.4 1.2 1.4 41.5 - 19.9 26.8 14.8 19.9 5.8 7.2 4.6 5.5 - -
850 10.8 15.1 1.3 1.6 45.3 - 21.8 29.3 16.3 21.8 6.2 7.8 4.9 5.8 - -
900 12.1 16.9 1.5 1.8 49.1 - 23.8 31.8 17.7 23.8 6.6 8.4 5.1 6.1 - -
930 12.9 17.9 1.6 1.9 51.4 - 25.0 33.4 18.6 25.1 6.9 8.8 5.2 6.3 - -

700 3.1 4.6 0.7 1.0 - - 16.4 22.0 12.1 16.4 5.1 6.2 4.2 4.9 - -
750 3.7 5.5 0.8 1.1 - - 18.0 24.4 13.4 18.2 5.4 6.7 4.5 5.2 - -
800 4.3 6.4 0.9 1.2 - - 19.9 26.8 14.8 19.9 5.8 7.2 4.6 5.5 - -
850 4.9 7.3 1.0 1.4 - - 21.8 29.3 16.3 21.8 6.2 7.8 4.9 5.8 - -
900 5.5 8.2 1.1 1.6 - - 23.8 31.8 17.7 23.8 6.6 8.4 5.1 6.1 - -
950 6.2 9.0 1.2 1.8 - - 25.8 34.4 19.2 25.9 7.0 9.0 5.3 6.4 - -
RS 100/E

1000 6.8 9.9 1.3 1.9 - - 27.7 37.0 20.6 28.0 7.4 9.6 5.5 6.8 - -
1050 7.3 10.7 1.5 2.1 - - 29.8 39.6 22.2 30.1 7.9 10.3 5.8 7.1 - -
1100 7.9 11.6 1.6 2.4 - - 31.9 42.9 23.9 32.8 8.4 11.2 6.1 7.6 - -
1150 8.4 12.4 1.8 2.6 - - 34.0 46.1 25.6 35.4 8.9 12.2 6.4 8.2 - -
1200 9.1 13.5 1.9 2.8 - - 36.1 49.4 27.2 38.1 9.4 13.1 6.6 8.7 - -
1250 9.9 14.8 2.1 3.0 - - 38.2 52.6 28.9 40.7 9.9 14.0 6.9 9.1 - -
1300 10.8 16.1 2.3 3.3 - - 40.5 55.9 30.9 43.4 10.6 15.0 7.2 9.7 - -
1340 11.4 17.1 2.4 3.5 - - 42.7 58.5 32.6 45.5 11.2 15.7 7.6 10.1 - -

920 4.5 7.0 1.3 2.0 - - 21.5 28.9 14.7 20.2 6.8 8.6 5.2 6.2 3.9 4.4
950 4.7 7.4 1.4 2.1 - - 22.6 30.2 15.5 21.2 7.0 9.0 5.3 6.4 3.9 4.5
1000 5.1 7.9 1.5 2.3 - - 24.4 32.5 16.8 23.0 7.4 9.6 5.5 6.8 4.1 4.6
1050 5.5 8.5 1.7 2.5 - - 26.2 34.9 18.1 24.9 7.9 10.3 5.8 7.1 4.2 4.8
1100 5.9 9.1 1.8 2.8 - - 28.0 37.5 19.5 26.9 8.4 11.1 6.1 7.6 4.3 5.0
1150 6.2 9.6 2.0 3.1 - - 29.9 40.2 20.9 29.1 8.9 12.0 6.4 8.1 4.5 5.2
1200 6.6 10.2 2.2 3.3 - - 31.7 42.9 22.4 31.3 9.4 12.8 6.6 8.6 4.6 5.4
RS 130/E

1250 7.0 10.8 2.4 3.6 - - 33.6 45.7 23.9 33.5 9.9 13.7 6.9 9.1 4.8 5.6
1300 7.4 11.3 2.6 3.9 - - 35.7 48.6 25.5 35.8 10.5 14.7 7.2 9.7 4.9 5.8
1350 7.8 11.9 2.8 4.2 - - 37.8 51.5 27.2 38.2 11.2 15.6 7.6 10.1 5.1 6.0
1400 8.2 12.8 3.0 4.5 - - 40.0 54.5 28.9 40.7 11.9 16.6 8.0 10.7 5.2 6.2
1450 8.6 13.8 3.2 4.9 - - 42.2 57.5 30.7 43.2 12.6 17.6 8.5 11.2 5.3 6.4
1500 9.0 14.7 3.4 5.2 - - 44.5 60.6 32.5 45.8 13.3 18.6 8.9 11.8 5.5 6.6
1550 10.2 15.6 3.6 5.6 - - 46.8 63.8 34.4 48.4 14.1 19.6 9.3 12.4 5.7 6.9
1600 11.4 16.6 3.9 5.9 - - 49.2 67.0 36.3 51.1 14.8 20.7 9.7 13.0 5.8 7.0
1605 11.5 16.7 3.9 6.0 - - 49.4 67.3 36.5 51.4 14.9 20.8 9.8 13.1 5.8 7.0

6367
52 GB
 C Appendix - Gas supply pressure

1 2 3
p (mbar) p (mbar) p (mbar)
Model

kW MB-DLE 412 MB-DLE 415 MB-DLE 420 MBC-1200-SE MBC-1900-SE MBC-3100-SE

(Rp 1” 1/4) (Rp 1” 1/2) (Rp 2") (Rp 2") (DN 65) (DN 80)
G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25 G 20 G 25
1280 9.6 14.3 1.3 2.0 - - 39.5 54.6 30.0 42.3 10.3 14.6 7.1 9.5 4.8 5.7
1300 9.6 14.3 1.4 2.1 - - 40.5 55.9 30.9 43.4 10.6 15.0 7.2 9.7 4.9 5.8
1400 9.7 14.4 1.6 2.4 - - 45.9 62.4 35.2 48.7 12.1 16.9 8.2 10.8 5.2 6.2
1500 9.7 14.5 1.8 2.8 - - 51.2 68.9 39.6 54.1 13.6 18.7 9.0 11.8 5.5 6.6
1600 9.8 14.6 2.1 3.1 - - 56.5 75.4 43.9 59.8 15.2 20.7 9.8 13.0 5.8 7.0
RS 190/E

1700 9.8 14.7 2.4 3.5 - - 61.8 - 48.3 66.3 16.7 23.0 10.7 14.3 6.1 7.6
1800 9.9 14.7 2.7 4.0 - - 67.2 - 52.7 72.9 18.2 25.3 11.5 15.8 6.4 8.2
1900 10.3 15.5 3.0 4.4 - - 72.5 - 57.0 79.5 19.8 27.6 12.4 17.2 6.9 8.8
2000 11.5 17.1 3.3 4.9 - - - - 62.2 - 21.6 29.9 13.5 18.7 7.3 9.3
2100 12.6 18.8 3.6 5.4 - - - - 67.6 - 23.5 32.3 14.6 20.1 7.7 10.0
2200 13.7 20.5 4.0 5.9 - - - - 73.0 - 25.4 35.8 15.8 21.7 8.2 10.7
2290 14.9 22.2 4.3 6.4 - - - - 77.8 - 27.1 38.9 16.8 23.0 8.6 11.4

1250 5.2 7.8 3.0 4.0 - - 38.2 52.6 28.9 40.7 9.9 14.0 6.9 9.1 4.7 5.5
1300 5.6 8.4 3.3 4.3 - - 40.5 55.9 30.9 43.4 10.6 15.0 7.2 9.7 4.9 5.8
1400 6.4 9.6 3.8 5.0 - - 45.9 62.4 35.2 48.7 12.1 16.9 8.2 10.8 5.2 6.2
1500 7.2 10.8 4.4 5.7 - - 51.2 68.9 39.6 54.1 13.6 18.7 9.0 11.8 5.5 6.6
1600 8.0 12.0 5.0 6.5 - - 56.5 75.4 43.9 59.8 15.2 20.7 9.8 13.0 5.8 7.0
1700 8.8 13.2 5.6 7.3 - - 61.8 - 48.3 66.3 16.7 23.0 10.7 14.3 6.1 7.6
1800 9.7 14.5 6.3 8.2 - - 67.2 - 52.7 72.9 18.2 25.3 11.5 15.8 6.4 8.2
RS 250/E MZ

1900 10.5 15.7 7.0 9.2 - - 72.5 - 57.0 79.5 19.8 27.6 12.4 17.2 6.9 8.8
2000 11.3 16.9 7.7 10.1 - - - - 62.2 - 21.6 29.9 13.5 18.7 7.3 9.3
2100 12.4 18.6 8.5 11.2 - - - - 67.6 - 23.5 32.3 14.6 20.1 7.7 10.0
2200 13.6 20.3 9.4 12.3 - - - - 73.0 - 25.4 35.8 15.8 21.7 8.2 10.7
2300 14.7 22.0 10.2 13.4 - - - - 78.3 - 27.3 39.2 17.0 23.2 8.7 11.4
2400 15.8 23.6 11.2 14.6 - - - - 83.7 - 29.1 42.7 18.1 24.8 9.2 12.1
2500 17.0 25.3 12.1 15.8 - - - - - - 31.0 46.1 19.4 26.3 9.6 12.9
2600 18.6 27.7 13.1 17.1 - - - - - - 33.3 49.6 20.6 28.0 10.2 13.5
2650 19.4 28.9 13.6 17.8 - - - - - - 34.8 51.7 21.2 28.8 10.5 13.9

The values shown in the tables refer to: Column 2

• Natural gas G 20 PCI 9.45 kWh/Sm3 (8.2 Mcal/Sm3) Load loss at gas butterfly valve 2)(Fig. 40) with maximum opening:
• Natural gas G 25 PCI 8.13 kWh/Sm3 (7.0 Mcal/Sm3) 90°.
Column 1 Column 3
Load loss at combustion head. Load loss at train 3)(Fig. 40) including:
Gas pressure measured at the test point 1)(Fig. 40), with: • adjustment valve (VR)
• Combustion chamber at 0 mbar; • safety valve (VS) (both fully open)
• Burner working at maximum output; • pressure adjuster (R)
• Combustion head adjusted according to the diagram of Fig. 17. • filter (F)

6367
53 GB
 C Appendix - Gas supply pressure

NOTE NOTE
To know the approximate output at which the burner is operating To know the required gas pressure at test point 1)(Fig. 40), set
at its maximum: the MAX output required from the burner operation:
- Subtract the combustion chamber pressure from the gas pres- - Find the nearest output value in the table for the burner in
sure measured at test point 1)(Fig. 40). question.
- Find, in the table relating to the burner concerned, column 1, - Read, on the right, column 1, the socket pressure 1)(Fig. 40).
the pressure value closest to the result you want. - Add this value to the estimated pressure in the combustion
- Read off the corresponding output on the left. chamber.
Example with natural gas G 20 - RS 100/E Example with natural gas G 20 - RS 100/E
• Maximum output operation • Required burner maximum output operation: 900 kW
• Ring nut 5)(Fig. 15) adjusted as in the diagram of (Fig. 17) • Ring nut 5)(Fig. 15) adjusted as in the diagram of (Fig. 17)
• Gas pressure at test point 1)(Fig. 39) = 8 mbar • Gas pressure at output of 900 kW = 5.5 mbar
• Pressure in combustion chamber = 2.5 mbar • Pressure in combustion chamber = 2.5 mbar
8 - 2.5 = 5.5 mbar 5.5 + 2.5 = 8 mbar
A pressure of 5.5 mbar, column 1, corresponds in the table to pressure required at test point 1)(Fig. 40).
an output of 900 kW.
This value serves as a rough guide; the effective output must
be measured at the gas meter.

D3734 Fig. 40

6367
54 GB
 D Appendix - Firing rate on basis of air density

The firing rate of the burner shown in the manual is valid for a If H3 is greater than H1, as in Fig. 41, the burner can produce the
room temperature of 20 °C and an altitude of 0 m above sea level delivery requested.
(barometric pressure around 1013 mbar). If H3 is less than H1, it is necessary to reduce the output of the
burner. The reduction in output is accompanied by a reduction in
It may be that a burner has to operate with combustive air at a
the combustion chamber pressure:
higher temperature and/or higher altitudes.
Qr = reduced output
The heating of the air and the increase in altitude produce the H1r = reduced pressure
same effect: the expansion of the air volume (i.e. the reduction of
its density).
The delivery of the burner fan remains essentially the same, but
H1r = H1 x ( QrQ )
2

the oxygen per m3 of air, and the thrust (discharge head) of the
Example, 5% reduction in output:
fan are reduced.
Qr = Q x 0.95
It is therefore important to know if the maximum output requested
from the burner at a determinate combustion chamber pressure H1r = H1 x (0.95)2
remains within the firing rate of the burner even with the changed With the new values - Qr and H1r - repeat steps 2 - 5.
temperature and altitude conditions.
To check it, proceed as follows: Warning:
the combustion head should be adjusted in relation to the equiv-
1 -Find the corrective factor F (relating to the air temperature and
alent output Qe.
altitude of the system) in the table alongside.
2 -Divide the output Q required from the burner by F to obtain the
equivalent output Qe:
mbar
mbar
Qe = Q : F (kW)

3 -In the firing rate of the burner, mark the work point identified H2
H3
by:
H1 A
Qe = equivalent output
H1 = pressure in combustion chamber
point A that must remain within the firing rate (Fig. 41). D388
4 -Trace a vertical line from point A, Fig. 41, and find the maxi- Qe
Qe kW
kg/h
mum pressure H2 of the firing rate.
5 -Multiply H2 by F to obtain the maximum lowered pressure H3 Fig. 41
of the firing rate

H3 = H2 x F (mbar)

Average F
Altitude barometric
pressure Air temperature °C

m. above sea
mbar 0 5 10 15 20 25 30 40
level

0 1013 1.087 1.068 1.049 1.031 1.013 0.996 0.980 0.948

100 1000 1.073 1.054 1.035 1.017 1.000 0.983 0.967 0.936
200 989 1.061 1.042 1.024 1.006 0.989 0.972 0.956 0.926
300 978 1.050 1.031 1.013 0.995 0.978 0.962 0.946 0.916
400 966 1.037 1.018 1.000 0.983 0.966 0.950 0.934 0.904
500 955 1.025 1.007 0.989 0.972 0.955 0.939 0.923 0.894
600 944 1.013 0.995 0.977 0.960 0.944 0.928 0.913 0.884
700 932 1.000 0.982 0.965 0.948 0.932 0.916 0.901 0.872
800 921 0.988 0.971 0.954 0.937 0.921 0.906 0.891 0.862
900 910 0.977 0.959 0.942 0.926 0.910 0.895 0.880 0.852
1000 898 0.964 0.946 0.930 0.914 0.898 0.883 0.868 0.841
1200 878 0.942 0.925 0.909 0.893 0.878 0.863 0.849 0.822
1400 856 0.919 0.902 0.886 0.871 0.856 0.842 0.828 0.801
1600 836 0.897 0.881 0.866 0.851 0.836 0.822 0.808 0.783
1800 815 0.875 0.859 0.844 0.829 0.815 0.801 0.788 0.763
2000 794 0.852 0.837 0.822 0.808 0.794 0.781 0.768 0.743
2400 755 0.810 0.796 0.782 0.768 0.755 0.742 0.730 0.707
2800 714 0.766 0.753 0.739 0.726 0.714 0.702 0.690 0.668
3200 675 0.724 0.711 0.699 0.687 0.675 0.664 0.653 0.632
3600 635 0.682 0.669 0.657 0.646 0.635 0.624 0.614 0.594
4000 616 0.661 0.649 0.638 0.627 0.616 0.606 0.596 0.577

6367
55 GB
 RIELLO S.p.A.
I - 37045 Legnago (VR)
Tel.: +39.0442.630111
http:// www.riello.it
http:// www.rielloburners.com

Subject to modifications