Riello GS20 Quick start guide

Installation, use and maintenance instructions

Instrucciones de instalación, montaje y funcionamiento

2902754 (4) - 09/2014

Forced draught gas burner

Quemador de gas de aire soplado

One stage operation

Funcionamiento de una llama

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3755683 GS20 556T80

2754

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 Pipe fitting for gas train . . . . . . . . . . . . . . . . . . . . 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

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 . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

D4178

5 4 3

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

❱

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

2754

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD

Thermal power (1) 81 – 220 kW - 70,000 – 189,000 kcal/h

Natural gas (Family 2) Net heat value: 8 – 12 kWh/Nm

-7,000 – 10,340 kcal/Nm

Pressure: min. 20 mbar - max. 100 mbar

Electrical supply Single phase, 220V ±10% ~

60Hz

Motor 220V / 2.2A

Capacitor 4 µF

Ignition transformer

Primary

220V / 1.25A - Secondary 8 kV / 25 mA

Absorbed electrical power 0.43 kW

(1) Reference conditions:

Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.

FlangeBurner

350 120 389 170

155

33 67

45°

125

298

170

Rp 3/4

230

152

■

280

D4257

200

■

Combustion head extension, supplied separately.

D5212

Thermal power

0.8

1.6

2.4

3.2

4.0

4.8

70,000 90,000 110,000 130,000 kcal/h

80 120100 140 160 kW180

170,000

200 220

150,000 190,000

Pressure in the combustion

chamber – mbar

2754

2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 6.9 mbar is measured with the combustion chamber at

0 mbar using gas G20 with a net heat value of 10 kWh/Nm

(8,570 kcal/Nm

3. INSTALLATION

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

3.1 BOILER FIXING

D5213

Thermal power

70,000 90,000 110,000 130,000 kcal/h

80 120100 140 160 kW180

170,000

200 220

150,000 190,000

Gas pressure in the

combustion head – mbar

Boiler door must have a max. thickness of 100 mm,

refractory lining included.

If thickness is greater (max. 260 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).

HINGE

S7393

ASSEMBLY

1 3 2

A B

D5097

2754

3.2 PROBE - ELECTRODE POSITIONING

3.3 GAS FEEDING LINE

D5104

Ignition electrode

WARNING

–

Ionization probe

Probe

Electrode

3.7

Diffuser

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

D5959

6432

5 7 8

2754

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 between terminal 6 and

the earth terminal.

ATTENTION

switch

ATTENTION:

❱

Do not swap neutral and phase over, follow the diagram shown care-

fully 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.

❱

Verify 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 series to limit thermostat (TL).

TO BE DONE BY

THE INSTALLER

CARRIED-OUT

IN THE FACTORY

2754

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.

4. WORKING

4.1 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 155 kW boiler with an efficiency of

90%, the burner input is about 172 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 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).

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

Cable clamps

ACB A CB

A =

8 B =

11 C =

D5052

S7015

D5231

Fig. 2

kcal/h kW

Set point

0 21 3 4

240

140

120

100

160

200,000

140,000

120,000

100,000

70,000

D5109

180

200

220

80,000

160,000

180,000

172

2754

4.3 COMBUSTION CHECK

It is advisable to not exceed 10% of CO

(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.

- 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.

4.4 BURNER START-UP CYCLE

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 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

Probe

Connector

Terminal board

of control-box

D5006

3s40s40smax. 2s max. 2s

D4172

Lock-out, due to ignition failureNormal

Thermostat

Motor

Ignition transformer

Valves

Flame

Lock-out

2754

4.6 RESETTING THE CONTROL BOX AND USING DIAGNOSTICS

The control box features a diagnostics function through which any causes of malfunctioning are easily iden-

tified (indicator: RED LED).

To use this function, you must wait at least 10 seconds once it has entered the safety condition (lock-out),

and then press the reset button.

The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second

intervals.

Once you have seen how many times the light pulses and identified the possible cause, the system must

be reset by holding the button down for between 1 and 3 seconds.

The methods that can be used to reset the control box and use diagnostics are given below.

RESETTING THE CONTROL BOX

To reset the control box, proceed as follows:

➣

Hold the button down for between 1 and 3 seconds.

The burner restarts after a 2-second pause once the button is released.

If the burner does not restart, you must make sure the limit thermostat is closed.

VISUAL DIAGNOSTICS

Indicates the type of burner malfunction causing lock-out.

To view diagnostics, proceed as follows:

➣

Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.

A yellow light pulses to tell you the operation is done.

Release the button once the light pulses. The number of times it pulses tells you the cause of the mal-

function, indicated in the table below.

SOFTWARE DIAGNOSTICS

Reports the life of the burner by means of an optical link with the PC, indicating hours of operation, number

and type of lock-outs, serial number of control box etc ...

To view diagnostics, proceed as follows:

➣

Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.

A yellow light pulses to tell you the operation is done.

Release the button for 1 second and then press again for over 3 seconds until the yellow light pulses

again.

Once the button is released, the red LED will flash intermittently with a higher frequency: only now can

the optical link be activated.

Once the operations are done, the control box’s initial state must be restored using the resetting procedure

described above.

BUTTON PRESSED FOR CONTROL BOX STATUS

Between 1 and 3 seconds Control box reset without viewing visual diagnostics.

More than 3 seconds Visual diagnostics of lock-out condition:

(LED pulses at 1-second intervals).

More than 3 seconds starting from

the visual diagnostics condition Software diagnostics by means of optical interface and PC (hours

of operation, malfunctions etc. can be viewed)

   

Press reset

for

3sPulses Pulses

RED LED on

wait at least

10s

Interval

Lock-out

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