Riello 40 GS10 Quick start guide

2903159 (2) - 07/2022

Installation, use and maintenance instructions

Forced draught gas burner

One - stage operation

CODE MODEL TYPE

3755489 RIELLO 40 GS10 554T85

3159

INDEX

1. BURNER DESCRIPTION . . . . . . . . . . . 1

1.1 Burner equipment . . . . . . . . . . . . . . . . . 1

2. TECHNICAL DATA. . . . . . . . . . . . . . . . 2

2.1 Technical data. . . . . . . . . . . . . . . . . . . . 2

2.2 Overall dimensions . . . . . . . . . . . . . . . . 2

2.3 Firing rate . . . . . . . . . . . . . . . . . . . . . . . 2

3. INSTALLATION . . . . . . . . . . . . . . . . . . 3

3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Probe-electrode positioning. . . . . . . . . . 4

3.3 Gas feeding line . . . . . . . . . . . . . . . . . . 4

3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . 5

3.5 Fixing the electrical wiring . . . . . . . . . . . 6

4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Combustion adjustment. . . . . . . . . . . . . . 6

4.2 Combustion head setting. . . . . . . . . . . . . 6

4.3 Air damper setting. . . . . . . . . . . . . . . . . . 7

4.4 Combustion check. . . . . . . . . . . . . . . . . . 7

4.5 Burner start-up cycle . . . . . . . . . . . . . . . . 7

4.6 Start-up cycle diagnostics . . . . . . . . . . . . 8

4.7 Resetting the control box and using 

diagnostics . . . . . . . . . . . . . . . . . . . . . . . 10

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 14

1. BURNER DESCRIPTION

Gas burner with one stage working.

1– Air-damper

2– Screws for fixing the air-damper

3– Cable clamps

4– Cable grommet

5– Screw for fixing the cover

6– Air pressure switch

7–Terminalstrip

8– Control box

9– Reset button with lock-out lamp

The burner is approved for intermittent operation as per EN 676.

The burner meets protection level of IP X0D (IP 40), EN 60529.

Gas train according to EN 676.

NOTES:

– Gas train can be installed on the right or on the left of the burner.

– The cable grommet (4) and the screw for fixing the cover (5) supplied with the burner, must be fitted to

the same side of the gas train.

Fig. 1

D4177

5 4 3

1.1 BURNER EQUIPMENT

Insulating gasket . . . . . . . . . . . . . No. 1 Screws and nuts for flange to be fixed to boiler . . No. 4

Cable grommet . . . . . . . . . . . . . . No. 1 Screw for fixing the cover . . . . . . . . . . . . . . . . . . . No. 1

Hinge . . . . . . . . . . . . . . . . . . . . . . No. 1

3159

2. TECHNICAL DATA

2.1 TECHNICAL DATA

TYPE 554T85

Thermal power (1) 42 –116 kW - 36,000 –100,000 kcal/h

Natural gas (Family 2)

Net heat val3ue: 8 – 12 kWh/Nm3 -7,000 – 10,340 kcal/Nm3

Pressure: min. 16 mbar - max. 100 mbar

Electrical supply Single phase, 100V ±10% ~50/60 Hz

Motor 100V / 2.2A

Capacitor 5 F

Ignition transformer Primary 100V / 2.3/1.9A - Secondary 8 kV / 30 mA

Absorbed electrical power 0.13 kW

(1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.

2.2 OVERALL DIMENSIONS

OCombustion head extension, supplied separately.

FlangeBurner

305 110 346 185

33 61

45°

ø 105

262

160

Rp 3/4

204

142

O170

D4251 130

45°

2.3 FIRING RATE, (as EN 676)

Thermal power

D5256

0.8

0.2

0.4

0.6

40,000 50,000 60,000 70,000 kcal/h

1206050 70 80 kW

1.0

110

80,000

1.2

90 100

90,000

1.4

1.6

100,000

Pressure in the combustion

chamber – mbar

3159

TEST BOILER

The working field 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 dimen-

sions 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 con-

sult the manufacturers.

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 5.8 mbar is measured (M2, see chapter 3.3, page 4) with

the combustion chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/Nm3(8,570 kcal/Nm3).

Gas pressure in the

combustion head – mbar

40,000 50,000 60,000 70,000 kcal/h

1206050 70 80 kW

Thermal power

D5257

110

80,000

90 100

90,000

100,000

3. INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

3.1 BOILER FIXING

S7392

13 2

D5108

HINGE

ASSEMBLY

Boiler door must have a max. thickness of 90 mm,

refractory lining included.

If thickness is greater (max. 150 mm), a combustion

head extension must be fitted, which is supplied

separately.

IMPORTANT

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

(2) insert the supplied insulating gasket (3).

3159

3.2 PROBE - ELECTRODE POSITIONING

D5104

Ignition electrode

WARNING

–



Ionization probe

Probe

Electrode

2.2

Diffuser

3.3 GAS FEEDING LINE

1– Gas supply pipe

2– Manual cock

3– Filter

4– Pressure governor

5– Pressure test point

6– Gas pressure switch

7– Safety valve

8– Adjustment valve

9– Pressure coupling test point

D5949

6432578

3159

3.4 ELECTRICAL WIRING

Control box

RMG 88....

TO BE DONE BY

THE INSTALLER

CARRIED-OUT

IN THE FACTORY

D7191

ATTENTION:

Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth con-

nection.

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.

Verify that the burner stops by operating the boiler control thermostats and that the burner locks out by sepa-

rating the red ionisation probe lead connector.

NOTES

The burners have been type-approved for intermittent operation. This means they must stop at least once every 24

hours in order to allow the electrical control box to check its efficiency on start-up. The boiler limit thermostat (TL)

normally ensures the burner halts. If this does not happen a time switch halting the burner at least once every 24

hours must be applied in series to limit thermostat (TL).

KEY TO LAY-OUT

C– Capacitor

CN1 – Connector SO

E–Electrode

M– Terminal strip

MV –Motor

PA – Min. air pressure

switch

PG – Min. gas pressure

svitch

SO – Ionisation probe

S3 – Lock-out signal

T6A –Fuse

TA Ignition transformer

TB – Burner-earth

TL – Limit thermostat

TS – Safety thermostat

Connection

with pilot valve

Connection

without pilot valve

3159

3.5 FIXING THE ELECTRICAL WIRING

All the electrical wires, which are to be connected to the terminal strip (7, fig. 1, page 1) should pass through the

cable grommet (4, fig. 1). All the electrical wires, which are to be connected into the terminal strip must be

gripped in the cable clamps (3, fig. 1). This is molded on both sides to allow the use of various diameter cables.

Cable clamps

ACB ACB

A = ø 8B=ø 11 C = ø 16

D5052

4. WORKING

4.1 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 observing the instruction manual of the boiler, including verification of the CO and CO2con-

centration in the flue gases, their temperatures and the average temperature of the water in the boiler.

To suit the required appliance output, choose the proper setting of the combustion head, and the air damper

opening.

4.2 COMBUSTION HEAD SETTING

S7015

01 32

120

100

80,000

70,000

60,000

50,000

40,000

kcal/h kW

D5258

110

90,000

100,000

Set point

Loose 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 on a 81 kW

boiler with an efficiency of 90%, the burner input

is about 90 kW using the diagram, the combus-

tion set point is 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).

3159

4.3 AIR DAMPER SETTING

D5231

The regulation of the air-rate is made by adjusting the air damper

(1), after loosing the screws (2).

When the optimal regulation is reached, screw tight the screws (2).

4.4 COMBUSTION CHECK

CO2

It is advisable to not exceed 10% of CO2(natural gas), in order to avoid the risk that small changes of the

adjustments due, for instance, at draught variation, may cause combustion with insufficient air and consequently

formation of CO.

CO - Not exceeding 100 mg/kWh (93 ppm).



IONIZATION CURRENT

The minimum current necessary for the control box operation is 3 µA. 

The burner normally supplies a higher current value, so that no check is needed. However, if you want to meas-

ure the ionization current, you must open the connector fitted to the red wire and insert a microammeter.

CN1

Terminal strip

of control-box

D5006

4.5 BURNER START-UP CYCLE

3s40s40smax. 2s max. 2s

D4172

Lock-out, due to ignition failureNormal

Thermostat

Motor

Ignition transformer

Valves

Flame

Lock-out

When flame-failure occurs during working, shut down takes place within one second.



3159

4.6 START-UP CYCLE DIAGNOSTICS

During start-up, indication is according to the following table:

COLOUR CODE TABLE

Sequences Colour code

Pre-purging

Firing phase

Operation, flame ok

Operating with weak flame signal

Electrical supply lower than ~ 170V

Lockout

Extraneous light

Key to layout: Off Yellow Green Red

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