Riello 40 FS5D Quick start guide

2903312 (2) - 04/2012

Instrucciones de instalación, uso y mantenimiento

Installation, use and maintenance instructions

Forced draught gas burner

Quemador de gas de aire soplado

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3758704 FS5D 587M

3758705 FS5D 587M

Two stage operation

Funcionamiento de dos llamas

3312 1GB

ENGLISH

TECHNICAL DATA

For gas family 3 (LPG) ask for separate kit.

OThe burner meets protection level of IP X0D (IP 40) as EN 60529.

OThe burner is approved for intermittent operation as per Directive EN 676.

OCE marking in accordance with Gas Appliance Directive 90/396/EEC; PIN 0063AP6680.

OBurner with CE marking in conformity with EC Directives: EMC 2004/108/EEC, Low Voltage

2006/95/EC and Machines 2006/42/EC.

OGas train according to EN 676.

NOTES

– The grommet (6) supplied with the burner, must be fitted to the same side of the gas train.

– After having installed the burner verify the access to the fixing screws of the cover.

If necessary replace them with the fixing screws (7, fig. 1) supplied as equipment.

TYPE 587M

Thermal power 12/23 58 kW – 10.000/20.000 50.000 kcal/h

Natural gas

(Family 2) Pci 8 12 kWh/m3– 7.000 10.340 kcal/m3

Pressure min. 10 mbar – max. 40 mbar

Electrical supply Single phase, 230V ± 10% ~ 50Hz

Motor Run current 0.75 A - 2800 rpm - 294 rad/s

Capacitor 2 F

Ignition transformer primary 230V / 0.2A – secondary 8 kV

Absorbed electrical power 0.15 kW

COUNTRY IT - AT - GR - DK - SE GB - IE FR DE LU - PL

GAS CATEGORY II2H3B/P II2H3P II2Er3P II2ELL3B/P II2E3B/P

1 – Air damper opening motor

2 –Airdampers

3 – Capacitor

4 –Motor

5 – Air pressure switch

6 –Grommet

7 – Hood fixing screw

8 – 6 pole socket for gas train

9 – 4 pole socket for 2nd stage

10 – Control box

11 – Lockout lamp with reset button

10 11

D7389

5 4 3

Fig. 1

3312 2GB

DIMENSIONS

BURNER EQUIPMENT

ACCESSORIES

SOFTWARE DIAGNOSTIC KIT

A special kit is available that, by an optical link to a PC, shows the burner life together with oper-

ating hours, type and number of lockout, serial number, etc...

Do the following to display the diagnostic:

Connect the kit supplied separately to the appropriate socket on the control box.

The information is read after the software program in the kit is booted.

RESET KIT

The use of a connection available as an accessory is provided for remote resetting of the control

box.

FlangeBurner

272 100 295 170

28 48

45°

233

140

Rp 1/2

180

138

D6336 130

45°

170

OCombustion head extension, supplied separately.

O125

ø 91

Quantity Description

Screws with nuts

Insulating gasket

Hood fixing screws

Grommet

Hinge

7 pin plug

4 pin plug

3312 3GB

BOILER FIXING

FIRING RATE

TEST BOILER

The firing rate has been defined according to EN 676 standard.

COMMERCIAL BOILERS

The burner-boiler matching is assured if the boiler conforms to EN 303 and the combustion chamber

dimensions are similar to those shown in the diagram EN 676.

For applications where the boiler does not conform to EN 303, or where the combustion chamber

is much smaller than the dimensions given in EN 676, please consult the manufacturers.

INSTALLATION

S7392

HINGE

OSeparate the combustion-head assembly

from the burner body by removing nut (1)

and removing group (A).

OFix the head assembly group (B) to the

boiler plate (2) insert the supplied insulat-

ing gasket (3).

Boiler door must have a max. thickness of 80 mm,

refractory lining included.

If thickness is greater (max. 105 mm), a combus-

tion head extension must be fitted, which is sup-

plied separately.

ATTENTION

132

D5064

0.8

0.2

0.4

0.6

Pressure in combustion

chamber – mbar

10,000 20,000 30,000 40,000 50,000 kcal/h

10 3020 40 50 kW

Output D5057

1.0

3312 4GB

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To get maximum output 4.6 mbar measured on the pipe coupling is necessary with combustion

chamber at 0 mbar and gas G20 - Pci = 10 kWh/m3(8,570 kcal/m3).

GAS FEEDING LINE

The gas train is supplied separately, for its adjustment see the enclosed instructions.

Gas pressure

mbar

10,000 20,000 30,000 40,000 50,000 kcal/h

10 3020 40 50 kW

Output D5058

GAS TRAIN ACCORDING TO EN 676

MULTIBLOC CONNECTIONS USE

TRAIN BURNER

MBZRDLE 405 B01 Rp 1/2 Rp 1/2 Natural gas and LPG

1– Gas arrival pipe

2– Manual gate

(supplied by the installer)

3– Gas pressure gauge (supplied by the installer)

4– Filter

5– Gas pressure switch

6– Safety valve

7– Pressure governor

8– 1st and 2nd stage adjustment valve

M1 – Gas-supply pressure test point

M2 – Pressure coupling test point

D5072

2 3 M1 4 5 6 7 8

3312 5GB

ELECTRICAL WIRING

TB TB

PG VS V1

321NPh

CN1

B4S3T2T1NL1

T6A

21 34 21123412321 1

RNNNL2

S1 S2 BA

MGA

XP6

XP7

B5 T6 T7 T8

XP4

~ 50Hz 230V

MG557-3

Main switch

IMPORTANT

The burners have been approved for intermittent

operation. This means that they must stop once

every twenty four hours to permit the electrical

control box to check its efficiency at start up. Nor-

mally the boiler's limit thermostat (TL) ensures

the stopping of the burner.

If this is not the case, it is necessary to apply in

series with the (TL) a timer switch that turns off

the burner at least once every twenty-four hours.

TESTING

Check the burner has stopped by opening the

thermostats.

Check that the burner has locked out during

operation by opening the connector (CN1) in-

serted in the probe's red wire, located outside

the control box.

CONTROL BOX, (see fig. 2)

To extract the control box from the burner it is

necessary:

to disconnect all the connectors connected to

it, the 7 pin plug, and the earth wire (TB);

undo the screw (A) and pull out the control box

in the direction of the arrow.

For the installation of the control box it is neces-

sary:

to tighten up the screw (A) with a tightening

torque of 1 - 1.2 Nm;

connect all the connectors that were previously

connected.

WARNING:

Do not swap neutral and phase over, follow the diagram shown carefully

and carry out a good earth connection.

The section of the conductors must be at least 1mm².

(Unless requested otherwise by local standards and legislation).

The electrical wiring carried out by the installer must be in compliance with the

rules in force in the country.

CONTROL BOX

D7363

KEY TO LAY-OUT

AD – Air damper opening motor

C– Motor capacitor

CN1 – Ionising probe connector

E– Ignition electrode

h1 –1

st stage hour counter (230V - 0.1A max.)

h1 – 2

nd stage hour counter (230V - 0.1A max.)

MV – Fan motor

PA – Air pressure switch

PG – Minimum gas pressure switch

RS – Remote reset connection

SB – Remote lock-out signal

(230V - 0.5 A max.)

SM – Air damper servomotor

SO – Ionisation probe

TB – Burner earth

TL – Limit thermostat

TS – Safety thermostat

TR –2

nd stage thermostat

T6A –Fuse

V1 –1

st stage valve

V2 –2

nd stage valve

VS – Safety valve

XP – 4 pin plug/socket

XP – 6 pin plug/socket

XP7 – 7 pin plug/socket

E9324

Fig. 2

3312 6GB

ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE

(DUNGS VPS 504)

COMBUSTION HEAD ADJUSTMENT

Loosen the screw (A), move the elbow (B) so that

the rear plate of the coupling (C) coincides with

the set point.

Tighten the screw (A).

Example:

The burner is installed in a 40 kW boiler.

Considering efficiency of 90% the burner must

supply around 44 kW.

The diagram shows that for this

output the adjustment must be

made on notch 3.

The diagram is to be used only

for initial settings, to improve air

pressure switch operation or

improve combustion, it may be

necessary to reduce this setting

(set point toward position 0).

230V

50Hz

KEY TO LAY-OUT

B5 –2

nd stage lock-out signal

h1 –1

st stage Hour counter

h2 –2

nd stage Hour counter

PG – Min. gas pressure switch

S3 – Remote lock-out signal

(230V - 0.5 A max.)

T6A –Fuse

TL – Limit thermostat

TR –2

st stage thermostat

TS – Safety thermostat

V10 – Safety valve

V11 –1

st stage valve

V12 –2

st stage valve

X4 – 4 pin plug

X6 – 6 pin plug

X7 – 7 pin plug

D4371

S7015

02134

50,000

40,000

30,000

20,000

10,000

kcal/h kW

Set point

D5068

60,000

3312 7GB

PROBE - ELECTRODE POSITIONING

IMPORTANT

Do not turn the starting electrode but leave it as shown in the drawing; if the starting electrode is put

near the ionization probe, the amplifier of the control box might be damaged.

AIR DAMPERS ADJUSTMENT

Take the burner to the 2nd stage. The mobile air damper

(1) activated by the motor (2), ensures the suction inlet

opens completely.

Adjust 2nd stage air delivery on the fixed damper (3)

after loosening the screws (4).

Once the ideal setting has been reached, securely

tighten the screws (4).

The damper leaves the factory set at pos. 6.

Take the burner to 1st stage working. The mobile air

damper (1) returns to the standby position.

Adjust 1st stage air delivery by turning the screw (6)

after loosening the nut (5) turning it in a clockwise direc-

tion. Once the ideal setting has been reached, block the

nut (5) turning it in an anticlockwise direction.

D5033

Ignition electrode

Diffuser

WARNING 2.5 3.5 mm

Probe

Probe Electrode

Put the ceramic near

the diffuser disc

D5074

3312 8GB

COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive 92/42/EEC, the application of the burner on the boiler,

adjustment and testing must be carried out by observing the instruction manual of the boiler,

including verification of the CO and CO2concentration in the flue gases, their temperatures and

the average temperature of the water in the boiler. It is advisable to set the burner according to

the type of gas used and following the indications of the table:

IONISATION CURRENT

The minimum current necessary for the

control box operation is 5 µA.

The burner normally supplies a higher cur-

rent value, so that no check is needed.

Should you want to measure the ionisation

current anyway, you must open the con-

nector (CN1), (see wiring diagram page 5) inserted in the red wire and insert a microammeter.

AIR PRESSURE SWITCH

The air pressure switch is set after all other adjustments have

been made. Begin with the switch at the lowest setting. With the

burner function at the required power, turn the knob slowly in a

clockwise direction until burner lockout.

Then turn the knob anticlockwise to an extent that is around 20%

of the adjusted value and then check that the burner starts up

properly. If the burner locks out again turn the knob slightly in an

anticlockwise direction.

Attention:

In conformity with the standard, the air pressure switch must pre-

vent the air pressure falling below 80% of the adjusted value and

the CO in the flue gases exceeding 1% (10,000 ppm). To check

this, insert a combustion analyser in the flue, slowly reduce the

burner air setting (for example with a piece of cardboard) and verify that the burner locks out before

the CO value in the flue gases exceeds 1%.

EN 676 AIR EXCESS: max. output 1,2 – min. output 1,3

GAS Theoretical max. CO2

0 % O2

Setting CO2% CO

mg/kWh NOx

mg/kWh

= 1.2 = 1.3

G 20 11.7 9.7 9.0 100 170

G 25 11.5 9.5 8.8 100 170

G 30 14.0 11.6 10.7 100 230

G 31 13.7 11.4 10.5 100 230

D4625 +_

Probe

Connector

Socket

of control-box

D7404

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