Riello GS5 Quick start guide

2902773 (2) - 09/2014

Installation, use and maintenance instructions

Instrucciones para la instalación, uso y mantenimiento

Forced draught gas burner

Quemador de gas de aire soplado

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3755281 GS5 552 T80

One stage operation

Funcionamiento de una llama

2773 1GB

INDEX

1. BURNER DESCRIPTION

Gas burner with one stage working.

OThe burner meets protection level of 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. 3

Hinge . . . . . . . . . . . . . . . . . . . . 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 of the electrical wiring . . . . . . . . . 6

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

4.1 Air damper setting . . . . . . . . . . . . . . . . . 6

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

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

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

5. MAINTENANCE. . . . . . . . . . . . . . . . . . . 7

6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 7

1- Reset button with lock-out lamp

2- Control box

3- Air pressure switch

4- Screw fixing burner cover

5- Cable grommet

6- Terminal board

7- Cable clamp

8- Screw for fixing the air damper

9- Air damper

NOTES:

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

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

the same side of the gas train.

D4290

Fig. 1

6 7

2773 2GB

2. TECHNICAL DATA

2.1 TECHNICAL DATA

2.2 OVERALL DIMENSIONS

2.3 WORKING FIELD

Thermal power (1) 23 – 65 kW – 20,000 – 56,000 kcal/h

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

Pressure: min. 15 mbar - max. 100 mbar

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

Motor 220V / 1A

Capacitor 2.5 F

Ignition transformer Primary 220V / 0.2A - Secondary 8 kV / 30 mA

Absorbed electrical power 1A

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

Flange Burner

272 100 295ø 170

130 28 48

ø 91

233

140

Rp 1/2

180

138

*125

D4293

*Lenght available using an extended head kit

45°

Pressure in the combustion

chamber – mbar

0.8

0.2

0.4

0.6

1.0

D4291

Thermal power

20,000 30,000 40,000 50,000 kcal/h

20 4030 50 60 kW

2773 3GB

2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 5.2 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).

3. INSTALLATION

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

3.1 BOILER FIXING

D4292

Thermal power

Gas pressure in the

combustion head – mbar

20.000 30.000 40.000 50.000 kcal/h

20 4030 50 60 kW

Boiler door must have a max. thickness of 80 mm,

refractory lining included.

If thickness is greater (max. 105 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).

HINGE

S7392

ASSEMBLY

132

D4294

2773 4GB

3.2 PROBE - ELECTRODE POSITIONING

3.3 GAS FEEDING LINE

D5033

Ignition electrodeDiffuser

WARNING 2.5 – 3.5 mm

probe

Probe Electrode

Put the ceramic

near the diffuser disc

Do not turn the starting electrode but leave it as shown in the drawing; if the starting electrode is put near

the ionization probe, the amplifier of the control box might be damaged.

IMPORTANT

Ionization

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

2773 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 standards 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 connector.

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

Country.

LEGEND

BO - Ionization probe

C- Capacitor

E- Elecrode

F- Fuse T6A

H3 - Remote lock-out signal

(220V - 0.5A max.)

MV - Motor

SG - Gas pressure switch

SL - Limit thermostat

SPA - Air pressure switch

ST - Safety thermostat

XB - Burner terminal board

XT - Burner earth

X1 - Probe connector

X2 - Connector

YS - Safety valve

Y1 - Adjustment valve

D4287

CONTROL BOX

525SE/5

CARRIED-OUT

BY THE INSTALLER

220V

60Hz

2773 6GB

3.5 FIXING OF THE ELECTRICAL WIRING

All the electrical wires, which are to be connected into the terminal board (6, fig. 1, page 1) should pass

through the cable grommet (5, fig. 1).

All the electrical wires, which are to be connected into the terminal board must be gripped in the cable

clamps (7, fig. 1). This is molded on both sides to allow the use of various diameter cables.

4. WORKING

4.1 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).

4.2 COMBUSTION HEAD SETTING

(See fig. 3)

Loose the screw (A), move the elbow (B) so that the rear

plan of the coupling (C) coincides with the set point.

Tight the screw (A).

Example:

The burner is installed on a 40 kW boiler with an efficiency

of 90%, the burner input is about 44 kW using the diagram

below, 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 posi-

tion 0).

BACB

A = ø8B=ø11 C = ø16

D5052

Cable clamps

D5231

Fig. 2

S7015

Fig. 3

02134

40,000

50,000

30,000

20,000

10,000

kcal/h kW

N° set point

D5137

60,000

2773 7GB

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 conse-

quently formation of CO.

Not exceeding 100 mg/kWh (93 ppm).

IONIZATION CURRENT

The minimum current necessary for the control box operation is 5 µA.

The burner would normally have a higher current value than this, but if a check is required, open the con-

nector fitted in the red probe lead and insert a microammeter as shown.

4.4 BURNER START-UP CYCLE

When flame-failure occurs during working, shut down takes place within one second; and the cycle starts

again; a lock-out follows if the flame do not start.

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).

6. FAULTS / SOLUTIONS

Here below you can find some causes and the possible solutions for some problems that could cause a fail-

ure to start or a bad working of the burner. A fault usually makes the lock-out lamp light which is situated

inside the reset button of the control box (1, fig. 1, page 1).

When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the

burner functions correctly, the lock-out can be attributed to a temporary fault.

If however the lock out continues the cause must be determined and the solution found.

Ionization probe

Connector

Control box

terminal board D5006

Normal Lock-out, due to light-failure

Thermostat

Motor

Ignition transformer

Valves

Flame

Lock-out

35s min. 5s max. 35s min. 5s max.

D5048

2773 8GB

BURNER STARTING DIFFICULTIES

OPERATING FAULTS

Re-cycle and lock-out may occur, because of : – Flame failure

– Ionization probe earthed

The burner goes to lock-out because of . . . . .: – Opening of the air pressure switch

Burner stop because of . . . . . . . . . . . . . . . . . .: – Gas pressure switch opening

DIFFICULTIES CAUSES

The burner goes through the

pre-purge period normally,

the flame ignites, but the

burner goes to lock-out with-

in 5 seconds after the igni-

tion.

The ionization probe is earthed or not in contact with the flame, or its

wiring to the control box is broken, or there is a fault on its insulation to

earth.

The connection of the phase and neutral leads has been inverted: you

need to exchange it.

The wiring to the earth is lacking or ineffective.

The burner goes to lock-out,

after the pre-purge period,

because the flame does not

ignite.

The valves are passing too little gas (low pressure in the gas pipe-

work).

The valves are defective.

It is irregular or the ignition arc is not present; in this case remove the

control box and insert it again, taking care that the electrode push-rod

is in the proper seat.

The pipe has not been purged from the air.

The burner does not pass

through the pre-purge period

and the control box goes to

lock-out.

The air pressure switch does not change over: it has failed or the air

pressure is too low (combustion head bad set).

Flame simulation exists (or the flame really lights).

The burner does not start at

the limit thermostat closing.

Gas is not supplied.

The gas pressure switch does not close its contact due to incorrect set-

ting or a faulty switch.

The air pressure switch is changed over to the operational position.

Before to replace the control box, check that short-circuits are not pres-

ent on the power-line: of the motor, of the gas electrovalve/s and on the

external signaling devices.

The burner continues to re-

peat the starting cycle with-

out going on lock-out.

This concerns a very particular irregularity, caused by the fact that the

gas pressure in the gas-mains lies very close to the value to which the

gas pressure switch has been set.

As a result of this, the sudden falling-off of pressure at the opening of

the valves causes the opening of the pressure switch.

However this only temporarily, because the valves immediately close

again, so then does the pressure switch, because the pressure builds-

up again the cycle to be repeated over and over.

This can be remedied by lowering the setting of the pressure switch.

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