Riello GS10 Quick start guide

Manuel d’entretien

Installation, use and maintenance instructions

Instrucciones para la instalación, uso y mantenimiento

Montage und Bedienungsanleitung

2902721 (0)

Gas-Gebläsebrenner

Brûleur gaz à air soufﬂé

Forced draught gas burner

Quemador de gas de aire soplado

CODE - CÓDIGO MODELL - MODELE - MODEL - MODELO TYP - TYPE - TIPO

3755426 GS10 554T1

Einstuﬁger Betrieb

Fonctionnement à 1 allure

One stage operation

Funcionamiento de una llama

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1GB

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

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 Operating fault diagnostics . . . . . . . . . . . 9

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 9

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 10

1– Air damper actuator

2– Air dampers

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

■The burner meets protection level of IP 40, EN 60529.

■CE marking according to Gas Appliance directive 90/396/EEC; PIN 0063AP6680.

According to directives: EMC 89/336/EEC, Low Voltage 73/23/EEC, Machines 98/37/EEC and

Efﬁciency 92/42/EEC.

■Gas train according to EN 676.

NOTE

The cable grommet (5) and the screw for ﬁxing the cover (6) supplied with the

burner, must be ﬁtted to the same side of the gas train.

Fig. 1

D4181

65 3

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2GB

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 / 0.7 A

Capacitor 2

µF

Ignition transformer Primary 230V / 1.8 A - 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 FR DK - AT - GR - SE - IT LU DE GB - IE - ES - PT NL

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

■Combustion head extension, supplied separately.

FlangeBurner

305 110 346 185

33 61

45°

ø105

262

160

Rp 3/4

204

142

■170

D4201 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

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3GB

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).

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

1 3 2

A B

D6323

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 ■Separate the combustion-head assembly

from the burner body by removing nut (1) and

removing group (A).

■Fix the head assembly group (B) to the boiler

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

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4GB

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 2–3mm

Ionization probe

Probe

Electrode

2.2

~40 mm

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

D5050

2 3 M1 4 5 6 7 8

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5GB

3.4 ELECTRICAL WIRING

NOTES:

–

Do not exchange the neutral with the phase and connect exactly the

above wiring.

– Wires of min. 1 mm2section.

(Unless requested otherwise by local stand-

ards and legislation).

– Carry out a safe earth connection.

– Verify that the burner stops by operating the boiler control thermostats and

that the burner locks out by separating the red ionisation probe lead con-

nector.

– The electric wiring carried out by the installer must be in compliance with

regulations in force in the Country.

Ionization probe

Electrode

Motor

Capacitor

Burner earth

230V ~50Hz

CARRIED-OUT

Air pressure switch

Blue

White

Black

BY THE INSTALLER

Control box

RMG 88.620A2

Suppressor

D4198

Connector

Ignition transformer

3.4.1 STANDARD ELECTRICAL WIRING

LEGEND

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

Air damper actuator

Blue

Black

Brown

In the case of phase-phase

feed, a bridge must be fit-

ted on the control box ter-

minal board between

terminal 6 and the earth

terminal.

ATTENTION

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6GB

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 applica-

tion 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 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 set-

ting

(set point toward position 0).

CARRIED-OUT

BY THE INSTALLER

LEGEND

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

S7015

0 1 32

120

100

80,000

70,000

60,000

50,000

40,000

kcal/h kW

D5258

4 5

110

90,000

100,000

Set point

2721

7GB

4.3 AIR DAMPER SETTING

The air damper (1) is operated by the actuator (2) and assures that

the air damper is fully open before the burner start cycle begins .

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

damper (3), after loosing the screws (4).

When the optimal regulation is reached, screw tight the screws

(4) to assure a free movement of the mobile air damper (1).

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 meas-

ure 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 low-

est 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 verify 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

D5036

Probe

Connector

Terminal board

of control-box

D5006

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8GB

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 ● ❍ ● ❍ ● ❍ ● ❍ ● ❍ ●

Operation, ﬂame ok ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑

Operating with weak ﬂame signal. ❑ ❍ ❑ ❍ ❑ ❍ ❑ ❍ ❑ ❍

Electrical supply lower than ~170V ● ▲ ● ▲ ● ▲ ● ▲ ● ▲ ●

Lock-out ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

Extraneous light ▲ ❑ ▲ ❑ ▲ ❑ ▲ ❑ ▲ ❑ ▲

Index: ❍Off ●Yellow ❑Green ▲Red

3s40s40smax. 2s max. 2s

D4172

Lock-out, due to ignition failureNormal

Thermostat

Motor

Ignition transformer

Valves

Flame

Lock-out

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9GB

4.8 OPERATING FAULT DIAGNOSTICS

The control box has a self-diagnostic system, which easily allows identifying the operating faults (RED LED

signal).

To use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a

minimum of 3 seconds.

After releasing the button, the RED LED starts ﬂashing as shown in the diagram below.

The LED gives of a blink code every 3 seconds.

The blink codes give the information about the possible faults, as follows:

5. MAINTENANCE

The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity

with legislation and local standards.

Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and

consequent pollution.

Before carrying out any cleaning or control always ﬁrst switch off the electrical supply to the

burner acting on the main switch of the system.

THE BASIC CHECKS ARE:

Leave the burner working without interruption for 10 min., checking the right settings of all the components

stated in this manual. Then carry out a combustion check verifying:

●CO2( %) content ●Smoke temperature at the chimney ●CO content (ppm).

SIGNAL PROBABLE CAUSE

2 flashes

The flame does not stabilise at the end of the safety time:

– faulty ionisation probe;

– faulty or soiled gas valves;

– neutral/phase exchange;

– faulty ignition transformer

– poor burner regulation (insufficient gas).

3 flashes

===

Min. air pressure switch does not close:

– air pressure switch faulty;

– air pressure switch incorrectly regulated;

– max. air pressure switch triggered (if installed).

4 flashes

====

Min. air pressure switch does not open or light in the chamber before firing:

– air pressure switch faulty;

– air pressure switch incorrectly regulated.

7 flashes

=======

Loss of flame during operations:

– poor burner regulation (insufficient gas);

– faulty or soiled gas valves;

– short circuit between ionisation probe and earth.

10 flashes

=====

– Wiring error or internal fault.

= = = = = = = = = =

Press reset

for >3s intervalBlink code Blink code

RED LED on

wait at least 10s

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