Riello 554T80 Quick start guide

2902753 (5) - 07/2022

Installation, use and maintenance instructions

Instrucciones para la instalación, uso y mantenimiento

Forced draught gas burner

Quemador de gas de aire soplado

One stage operation

Funcionamiento de una llama

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3755483 RIELLO 40 GS10 554T80

2753 1GB

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 Working field . . . . . . . . . . . . . . . . . . . . . 2

2.4 Correlation between gas pressure and

burner output . . . . . . . . . . . . . . . . . . . . 3

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 head setting . . . . . . . . . . . . 6

4.2 Air damper setting . . . . . . . . . . . . . . . . . 6

4.3 Combustion check . . . . . . . . . . . . . . . . . 7

4.4 Burner start-up cycle . . . . . . . . . . . . . . . 7

4.5 Start-up cycle diagnostics. . . . . . . . . . . . 7

4.6 Resetting the control box and using 

diagnostics . . . . . . . . . . . . . . . . . . . . . . . 9

5. MAINTENANCE. . . . . . . . . . . . . . . . . . . 10

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 11

1. BURNER DESCRIPTION

Gas burner with one stage working.

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.

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– Terminal board

8– Control box

9– Reset button with lock-out lamp

Fig. 1

D4177

5 4 3

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

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

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

2753 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

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

Natural gas (Family 2) Net heat value: 8 – 12 kWh/Nm3 -7,000 – 10,340 kcal/Nm3

Pressure: min. 16 mbar - max. 100 mbar

Electrical supply Single phase, 220V ±10% ~60Hz

Motor 220V / 1.1A

Capacitor 2.5 F

Ignition transformer Primary 220V / 1.25A - Secondary 8 kV / 25 mA

Absorbed electrical power 0.2 kW

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

2.2 OVERALL DIMENSIONS

Combustion head extension, supplied separately.

FlangeBurner

305 110 346 185

33 61

45°

105

262

160

Rp 3/4

204

142

170

D4251

130

45°

2.3 WORKING FIELD

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

2753 3GB

2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 5.8 mbar is measured 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

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).

13 2

D5108

2753 4GB

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

6432

578

2753 5GB

3.4 ELECTRICAL WIRING

KEY TO LAY-OUT

PG – Minimum gas pressure switch

S3 – Remote lock-out signal 

(220V - 0.5 A max.)

T6A – Fuse

TL – Limit thermostat

TS – Safety thermostat

V10 – Safety valve

V11 – Adjustment valve

Ionization probe

Ignition transformer

Electrode

Motor

Capacitor Burner

220V

60Hz

Terminal board

Air pressure

White

Blue

Brown

VERSION

FOR GAS LEAK CONTROL DEVICE

(DUNGS VPS 504)

Control box

RMG 88.620A2

D4352

Connector

earth

Black

In the case of phase-phase feed,

a bridge must be fitted on the

control box terminal board be-

tween terminal 6 and the earth

terminal.

IMPORTANT

switch

TO BE DONE BY

THE INSTALLER

CARRIED-OUT

IN THE FACTORY

ATTENTION:

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 compli-

ance with the rules in force in the country.

Verify that the burner stops by operating the boiler control thermo-

stats and that the burner locks out by separating 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 ther-

mostat (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).

2753 6GB

3.5 FIXING THE ELECTRICAL WIRING

All the electrical wires, which are to be connected to the terminal board (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 board 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 HEAD SETTING

S7015

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

combustion set point is 3.

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

D5231

Fig. 2

The diagram is to be used only for initial settings, to improve air pressure switch operation or improve combus-

tion, it may be necessary to reduce this setting (set point toward position 0)



4.2 AIR DAMPER SETTING (See Fig. 2)

The regulation of the air-rate is made by adjusting the air damper (1), after loosing the screws (2).

2753 7GB

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

4.3 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.

Probe

Connector

Terminal board

of control-box

D5006

4.4 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.

4.5 START-UP CYCLE DIAGNOSTICS

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

COLOUR CODE TABLE

Sequences Colour code

Pre-purging 

Ignition phase 11111

Operation, flame ok vvvvvvvvvvvv

Operating with weak flame signal. v1v1v1v1v1

Electrical supply lower than ~170V 

Lock-out 

Extraneous light vvvvv

Index: 1Off Yellow vGreen Red

2753 8GB

SAFETY TEST - WITH GAS BALL VALVE CLOSED

It is fundamental to ensure the correct execution of theelectrical connections between the gas solenoid valves

and the burner to perform safely the commissioning.

For this purpose, after checking that the connections have been carried out in accordance with the burner's elec-

trical diagrams, an ignition cycle with closed gas ball valve -dry test- must be performed.

1 The manual ball gas valve must be closed

2The electrical contacts of the burner limit switch need to be closed

3 Ensures closed the contact of the low gas pressure switch

4 Make a trial for burner ignition

The start-up cycle must be as follows:

– starting the fan for pre-ventilation

–Performing the gas valve seal control, if provided

– Completion of pre-ventilation

– Arrival of the ignition point

– Power supply of the ignition transformer

– Electrical Supply of solenoid gas valves

Since the manual gas ball valve is closed, the burner will not light up and its control box will go to a safety lockout

condition.

The actual electrical supply of the solenoid gas valves can be verified by inserting a tester, Some valves are

equipped with light signals (or close/open position indicator) that turn on at the same time as their power supply.

IF THE ELECTRICAL SUPPLY OF THE GAS VALVES OCCURS AT UNEXPECTED TIMES. DO NOT

OPEN MANUAL GAS BALL VALVE, SWITCH OFF POWER LINE; CHECK THE WIRES; CORRECT

THE ERRORS AND REPEAT THE COMPLETE TEST.

SAFETY COMPONENTS

The safety components must be replaced at the end of their life cycle indicated in Tab. The specified life cycles

do not refer to the warranty terms indicated in the delivery or payment conditions.

Safety component Life cycle

Flame control 10 years or 250,000

operation cycles

Flame sensor 10 years or 250,000

operation cycles

Gas valves (solenoid) 10 years or 250,000

operation cycles

Pressure switches 10 years or 250,000

operation cycles

Pressure adjuster 15 years

Servomotor (electronic cam) (if present) 10 years or 250,000

operation cycles

Oil valve (solenoid)

(if present)

10 years or 250,000

operation cycles

Oil regulator (if present) 10 years or 250,000

operation cycles

Oil pipes / couplings (metallic) (if present) 10 years

Fan impeller 10 years or 500,000 start-ups

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