Riello FS10 Quick start guide

20013746 (2) - 07/2009

Installation, use and maintenance instructions

安装 , 使用以及维护说明书

Forced draught gas burner

强制通风燃气燃烧器

CODE - 编码 MODEL - 型号 TYPE - 类型

20013626 FS10 564T30

One stage operation

一段火运行

20013746

INFORMATION ABOUT THE INSTRUCTION MANUAL

INTRODUCTION

The instruction manual supplied with the burner:

- is an integral and essential part of the product and must not be sepa-

rated from it; it must therefore be kept carefully for any necessary

consultation and must accompany the burner even if it is transferred

to another owner or user, or to another system. If the manual is lost

or damaged, another copy must be requested from the Technical

Assistance Service of the area;

- is designed for use by qualified personnel;

- offers important indications and instructions relating to the installation

safety, start-up, use and maintenance of the burner.

DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-

UAL

When the system is delivered, it is important that:

- The instruction manual is supplied to the user by the system manu-

facturer, with the recommendation to keep it in the room where the

heat generator is to be installed.

- The instruction manual shows:

- the serial number of the burner;

- the address and telephone number of the nearest Assistance

Centre;

- The system supplier carefully informs the user about:

- the use of the system,

- any further tests that may be necessary before the system is

started up,

- maintenance and the need to have the system checked at least

once a year by the manufacturer or another specialised techni-

cian.

To ensure a periodic check, recommends the drawing up

of a Maintenance Contract.

..................................................................................

1 20013746

INDEX

1. BURNER DESCRIPTION

Gas burner with one stage working.

1.1 BURNER EQUIPMENT

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

Cable grommet . . . . . . . . . . . . . . No. 1 Screws for fixing the cover . . . . . . . . . . . . . . . . . .. No. 3

Hinge . . . . . . . . . . . . . . . . . . . . . No. 1 7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. No. 1

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

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

3.4.1 Standard electrical wiring . . . . . . . . . . . 5

3.4.2 Electrical wiring with gas leak control

device . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Air pressure switch . . . . . . . . . . . . . . . . 7

4.6 Burner start-up cycle . . . . . . . . . . . . . . . 8

4.7 Start-up cycle diagnostics . . . . . . . . . . . 8

4.8 Resetting the control box and using

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

5. WARNINGS

to avoid burnout or bad combustion of the

burner . . . . . . . . . . . . . . . . . . . . . . . . . 10

6. MAINTENANCE . . . . . . . . . . . . . . . . . 10

7. FAULTS / SOLUTIONS . . . . . . . . . . . . 11

1– Air-damper

2– Screws for fixing the air-damper

3– 7 pole socket for electrical supply

and control

4– 6 pole socket for gas train

5– Cable grommet

6– Screw for fixing the cover

7– Air pressure switch

8– Control box

9– Reset button with lock-out lamp

³According to Directives: EMC 89/336/EEC - 2004/108/EC, Low Voltage 73/23/EEC - 2006/95/EC and Effi-

ciency 92/42/EEC.

³The burner is approved for intermittent operation as per Directive EN 676.

³The burner meets protection level of IP X0D (IP 40), EN 60529.

³Gas train according to EN 676.

NOTES

– The cable grommet (5) 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 (6, fig. 1) supplied as equipment.

Fig. 1

D4182

6 5 3

20013746 2

2. TECHNICAL DATA

2.1 TECHNICAL DATA

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

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD (as EN 676)

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, 230 V ±10% ~50Hz

Motor 230V / 0.7A

Capacitor 4 μF

Ignition transformer Primary 230V / 1.8A - 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.

COUNTRY DE AT FR ES - GB - IE LU NL

GAS CATEGORY II2ELL3B/P II2H3B/P II2Er3P II2H3P II2E3B/P II2L3B/P

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°

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

3 20013746

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 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.

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).

3. INSTALLATION

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

3.1 BOILER FIXING

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

S7392

HINGE

ASSEMBLY

13 2

D5108

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).

20013746 4

3.2 PROBE - ELECTRODE POSITIONING

3.3 GAS FEEDING LINE

GAS TRAIN ACCORDING TO EN 676

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

GAS TRAIN CONNECTIONS USE

TYPE CODE INLET OUTLET

MBDLE 405 B01 3970530 Rp 1/2 Rp 3/4 Natural gas ≤80 kW and LPG

MBDLE 407 B01 3970531 Rp 3/4 Rp 3/4 Natural gas and LPG

D5104

Ignition electrode

WARNING

–

Ionization probe

Probe

Electrode

2.2

Diffuser

1– Gas supply pipe

2– Manual cock (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– Adjustment valve

M1 – Gas-supply pressure test point

M2 – Pressure coupling test point

D5069

2 3 M1 4 5 6 7 8

5 20013746

3.4 ELECTRICAL WIRING

ATTENTION:

³Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth connection.

³The section of the conductors must be at least 1mm. (Unless requested otherwise by local standards and legislation).

³The electrical wiring carried out by the installer must be in compliance with the rules in force in the country.

³Verify that the burner stops by operating the boiler control thermostats 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 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 se-

ries to limit thermostat (TL).

Ionization probe

Electrode

Motor

Capacitor

Burner earth

230V

50Hz

Air pressure switch

Blue

White

Black

Control box

RMG 88.620A2

Suppressor

D4275

Connector

Ignition transformer

3.4.1 STANDARD ELECTRICAL WIRING

KEY TO LAY-OUT

XP6 – 6 pole socket

XP7 – 7 pole socket

X6 – 6 pin plug

X7 – 7 pin plug

B4 – Working signal

h1 – Hour counter

PG – Minimum gas pressure

switch

S3 – Remote lock-out signal

(230V - 0.5 A max.)

T6A – Fuse

TL – Limit thermostat

TS – Safety thermostat

V10 – Safety valve

V11 – Adjustment valve

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.

ATTENTION

TO BE DONE BY

THE INSTALLER

CARRIED-OUT

IN THE FACTORY

20013746 6

3.4.2 ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504)

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 car-

ried out 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.

To suit the required appliance output, choose the proper set-

ting of the combustion head, and the air damper opening.

4.2 COMBUSTION HEAD SETTING

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.

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).

KEY TO LAY-OUT

X6 – 6 pin plug

X7 – 7 pin plug

B4 – Working signal

h1 – Hour counter

PG – Minimum gas pressure

switch

S3 – Remote lock-out signal

(230V - 0.5 A max.)

T6A – Fuse

TL – Limit thermostat

TS – Safety thermostat

V10 – Safety valve

V11 – Adjustment valve

230V

50Hz

D4199

TO BE DONE BY

THE INSTALLER

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

7 20013746

4.3 AIR DAMPER SETTING

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

It is advisable to set the burner according to the type of gas used and following the indications of the table:

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 measure

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

4.5 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 working at the minimum output, adjust the dial clockwise, increasing its value until

the burner shuts down. Now reduce the value by one set point, turning the dial anti-clockwise.

Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.

Attention:

To comply with the EN 676 standard, the air pressure switch must operate when the CO value exceeds 1%

(10,000 ppm). To check this, insert a combustion analyser in the flue, slowly reduce the burner air setting and ver-

ify that the burner shuts down by the action of the air pressure switch before the CO value exceeds 1%.

EN 676 AIR EXCESS:

max. output λ≤1.2 – min. output λ≤1.3

GAS Theoretical max. CO2

0 % O2

Setting CO2% CO

mg/kWh

NOx

mg/kWh

λ= 1.2 λ= 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

D5231

Probe

Connector

Terminal board

of control-box

D5006

20013746 8

4.6 BURNER START-UP CYCLE

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

4.7 START-UP CYCLE DIAGNOSTICS

During start-up, indication is according to the followin 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YellowvGreenRed

3s40s40smax. 2s max. 2s

D4172

Lock-out, due to ignition failureNormal

Thermostat

Motor

Ignition transformer

Valves

Flame

Lock-out

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