Riello Burners 40 Series Quick start guide

G750 Rev.2 -06/10/2002
1
RIELLO 40 SERIES POWER GAS BURNER MODEL G750 NATURAL & PROPANE GAS
INSTALLATION INSTRUCTIONS AND OWNER’S HANDBOOK
CAUTION: All Riello power gas burners MUST be installed by certified or licensed gas technician.
WARNING: Installation of this burner must conform with local codes requirements or, in the absence of local codes,
with the Standard: National Fuel Gas code ANSI Z223.1-1984, and CAN/CGA B149.1 & 2 AND UL 795. If an external
electrical source is utilized, the conversion burner, when installed, must be electrically grounded in accordance with
local codes or, in the absence of local codes, with the national Electrical Code, ANSI/NFPA No. 70-1990 and CSA
Electrical Code C22.2 No.0 M1982 & C22.2 No 3. 1988.
Authorities having jurisdiction should be consulted before installations are made. The owner is required to retain this
manual for future reference.
This burner must be fired ONLY with the fuel listed on the burner nameplate.
TECHNICAL SPECIFICATIONS
FIRING RATES: 250 to 750 KBTU/Hr
NATURAL PROPANE
MANIFOLD PRESSURES 1.4” w.c. 2.1” w.c. 1.0” w.c. 3.0” w.c.
GAS SUPPLY PRESSURES 7 –14” w.c. 8 –14” w.c.
POWER 120 VOLTS 60 Hz. single phase
MOTOR 233T 4.3 AMPS 3250 RPM 325 RAD/sec
TRANSFORMER Primary: 120Vac 1.4A. Secondary: 6000Vac 20mA
SAFETY CONTROL 120 VOLT 60 Hz.
WARNING: If the information in these instructions is not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
Do not store or use gasoline or any other flammable vapours or liquid in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS:
1) Do not try to light any appliance.
2) Do not touch electrical switches; Do not use any phone in your building.
3) Immediately call your gas supplier from a neighbour's phone. Follow the gas
supplier's instructions.
4) If you cannot reach your gas supplier, call the fire department.

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TABLE OF CONTENT
SERIAL NUMBER IDENTIFICATION..........................................................................................3
PRINCIPAL BURNER COMPONENTS.........................................................................................4
DIMENSIONS.................................................................................................................................4
UNIVERSAL MOUNTING FLANGE DIMENSIONS...................................................................5
ELECTRODE AND FLAME PROBE ADJUSTMENTS.................................................................5
TYPICAL GAS TRAIN LAYOUT..................................................................................................6
INSTALLING THE BURNER.....................................................................................................7-9
COMBUSTION HEAD SETTING ..................................................................................................9
FIRING RATE SPECIFICATIONS AND SETTINGS ..................................................................10
WORKING RANGE OF BURNER ...............................................................................................10
COMBUSTION CHAMBER SIZING............................................................................................11
COMBUSTION CHECKS ............................................................................................................11
BURNER START-UP CYCLES ...................................................................................................12
BURNER TECHNICAL DATA ....................................................................................................12
FACTORY WIRING DIAGRAM ..................................................................................................13
OPERATING MODES...................................................................................................................13
FIELD WIRING DIAGRAM .........................................................................................................14
INSTALLATION OF SEDIMENT TRAP & BURNER SUPPLY.................................................15
OPERATING FAULTS..................................................................................................................16
OWNER INFORMATION & ROUTINE MAINTENANCE.........................................................16
PROBLEM SOLVING GUIDE................................................................................................16-17
SPARE PARTS LIST.....................................................................................................................18
SPARE PARTS DIAGRAM ..........................................................................................................19
BURNER START-UP FORM................................................................................................20

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The following pages contain information, descriptions and diagrams for the proper
installation and wiring of the burner. Please read carefully before attempting final
installation.
The responsibility for ensuring that this manual is complete rests with the holder
of these instructions.
SERIAL NUMBER IDENTIFICATION
The Riello 15 character serial number, example, 99 A 8511111 00025, is identified as follows:
99 = last two digits of the year of manufacture; A= BI-week of manufacture; 8511111 = burner product
code; 00025 = increment of 1 for each burner produced –specific to product code –reset to zero each
January 1st.
(99) (A) (8511111) (00025)
Year of
manufacture
BI
-
week of
manufacture
Burner p
roduct
code Increment

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A
E
E1
B
F
D
3/4
pipe
Model 750
Inches
mm
A
11 3/4
298
B
13 3/4
350
D
15 5/16
389
E
4 1/8
105 10 5/8 270
F
4 15/16
125
NOTE: Actual available insertion length must be measured from tip of end cone to face of mounting gasket.
E1
CONTROL BOX
509 SE/A
CAPACITOR MOTOR
AIR GATE
PLATE
AIR
PRESSURE
SWITCH
ELECTRICAL POWER
CONNECTION TERMINAL
IONIZATION
ROD
CONNECTION
IGNITION
TRANSFORMER
CONNECTION
PRINCIPAL BURNER COMPONENTS
BURNER DIMENSIONS
Accessory Package:
1-Insulating
gasket
1-Data tag
1-Instruction
booklet
2-Bilingual
warning labels
(CAN1-B149)

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UNIVERSAL MOUNTING FLANGE DIMENSIONS
ELECTRODE AND FLAME PROBE ADJUSTMENTS
ABCD
inches 1 1/2 1/4 7/16 2 7/8
mm 38 611 73
4
31
/
32
-- 128 mm
6
17
/
32
-- 166 mm
8
1
/
4
-- 210 mm
9
1
/
4
-- 235 mm
7
7
/
8
--
200
mm
2.0
3.7
Orifice
Propane adapter Propane orifice
Warning 2-3 mm
Ionization Probe
Ignition
electrode

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1) GAS SUPPLY & FLOW DIRECTION OF GAS
2) GAS SUPPLY MAIN SHUTOFF MANUAL VALVE (FIELD SUPPLIED)
3) GAS SUPPLY PRESSURE TEST POINT (FIELD SUPPLIED)
4) GAS TRAIN PIPE DIAMETER SIZE(S):
BURNER G750 3/4"
BURNER G900 1" NPT (REDUCED AT COMBUSTION HEAD TO 3/4")
GAS SUPPLY PRESSURE RANGES:
NATURAL GAS PRESSURE:
MIN. = 7.0" WC
MAX. 14.0" WC
L.P. PROPANE GAS PRESSURE:
MIN. = 8.0" WC
MAX. 13.0" WC
9
FIELD SUPPLIED
1 2 35 6
RIELLO SUPPLIED
74
Ø
NOTE: ITEMS 5,6 & 7 COMBINATION GAS VALVE(S) ASSEMBLIES MAY BE UTILIZED WHERE APPROVED.
5) GAS APPLIANCE PRESSURE REGULATOR
6) SAFETY SHUTOFF GAS VALVE (VS) 120V
OPERATED
7) MAIN GAS VALVE 120V OPERATED
BURNER G750 = SINGLE STAGE V1 ONLY
BURNER G900 = TWO STAGE V1 & V2
8) FIRING VALVE MANUAL SHUTOFF
9) GAS BURNER MANIFOLD TEST POINT
GAS TRAIN LEGEND
SEE GAS
SUPPLY
RANGE
8
TYPICAL GAS TRAIN LAYOUT
This gas train scope of supply meets the minimum controls requirements according to CGA and AGA regulations. Any
additional requirements needed to meet local codes are the responsibility of others.

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INSTALLING THE BURNER
1. Burner Chassis
2. Lock-nut
3. Burner Mounting Gasket
4. Insulation on Mounting Plate
5. Combustion Chamber
6. Forced Air Heat Exchanger
7. Burner Hinge Assembly
8. Gas Train Supply
Separate the combustion head of the burner
from the chassis (1) by removing the
lock-nut (2). Install the combustion head
into the appliance.
NOTE: Unless other else noted, it is recommended that the combustion head do not protrude into the
combustion chamber.
Use this checklist prior to installation:
1) Check the input/output requirements of the boiler/furnace.
2) Check the physical size of the combustion chamber against the thermal
Requirements of the application and relate this to the sizing charts.
3) Check that there is sufficient air for proper combustion and adequate ventilation.
Local codes should be followed. Check that you have adequate space for servicing the equipment.
Riello Burner requires a minimum of 13 inches clear space behind the red cover. This is required to
allow easy removal of the cover for servicing and periodic maintenance.
4) Check that the chimney is of sufficient area to handle the exhaust gases. Make
sure that the chimney is clear and there are not obstructions.
5) Barometric draft regulators, when used, should be of the double acting type, and
Must be installed in accordance with the draft regulator Manufacturer’s instructions. Single acting
barometric dampers are not permitted.
6) Affix the supplied operating instructions label to the burner. This label reads
As follows:
TO START THE BURNER: Switch on power, open manual gas cocks, set the thermostat above
ambient temperature. If the burner does not start,
Press the illuminated re-set button on the burner safety control.
TO SHUT DOWN BURNER:Switch off power supply. If burner is switched off for extended
periods, close manual gas cocks.
IMPORTANT:
The installer must identify the main electrical power switch and manual gas shut off valve, for emergency
conditions. The red cover on the burner must be in place and secured before the burner is placed in operation.
GENERAL INFORMATION
Your Riello gas burner comes to you completely assembled and wired, ready for installation. The short head
version has a fixed flange, which bolts directly to the front of the boiler/furnace. The long head version is
equipped with a universal flange, which, when bolted to the boiler/furnace, allows the burner to be adjusted
inwards or outwards for exact positioning in the combustion zone.
8
7
1
23
6
45

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STEP-BY-STEP PROCEDURE
1) Remove the burner from the carton, taking care not to lose any of the supplied accessories, and check for
signs of physical damage.
2) Bolt the burner to furnace/boiler. Be sure to install the supplied mounting gasket. Ensure that the burner
is level and that the combustion head is centered in the boiler/furnace port. A spirit level placed across the
cover will give you a good level. Refer to page 7 for position of combustion head relative to the chamber.
3) Check that the gas train is tight and make your connections to the incoming gas supply.
a) A sediment trap must be provide at the gas connection inlet to the burner gas
train.
b) If not already installed, a manual shutoff valve must be supplied. This valve must be upstream of
the burner/supply connection.
c) A 1/8 NPT plugged tapping must be installed immediately upstream of the
Burner/supply connections and must be accessible for a test gauge.
d) If required by local codes, provide gas vent lines at the gas regulators and
And valve (Riello gas trains are equipped with vent limiting orifices).
NOTE: Details of sediment trap, manual gas valve and test point can be found in installation of sediment trap
and burner supply section.
4) Remove the red protective cover by removing the three screws. Make your adjustment of stop gate, (refer
to firing rate specifications and settings charts for details). Replace and secure the air cover plate.
5) Electrical hookup: 120Volt 60 Hz incoming power lines should be connected to Terminals 1 and 2 on
burner terminal block. A manual disconnect switch must be installed in the incoming power lines.
Incoming power lines must be rigid conduit or flexible approved cable.
CAUTION: The hot wire must be connected to the black lead of the relay: neutral to the white lead. Do
not reverse the polarity. The burner will not operate with the Phase/Neutral reversed, and the control box may
be damaged. Proper earth ground should be connected to the terminal block mounting plate which should be
a solid green wire to Earth Ground.
6) Start and check the burner functions as follows:
a) Make a final check on the gas and electrical connections.
b) Check that all adjustments have been completed
c) Loosen the screw in the manifold gas test point and install a manometer.
d) Switch on power.
e) Set the thermostat at its highest setting and press the burner reset button. Allow the burner to run
through a complete cycle to check control functions.
f) Turn on the manual gas valve and reset the safety. At this stage, the burner will open the air shutter
and once it is open, the burner will prepurge for aprox.30 seconds. Allow about 66 seconds for the
control module to check all the operating circuits.
It may be necessary to repeat the starting cycle several times to free the gas train of entrapped air. If the
burner goes to lockout, reset the safety button.
7) With the burner running and flame established, check the manifold gas pressure. Adjust manifold
pressure to the correct value for the selected firing rate specified in the FIRING RATE
SPECIFICATIONS AND SETTINGS chart. After completing the setting, remove the manometer and
tighten the screws.
NOTE: Do not assume the burner is operating at optimum performance.
A COMBUSTION TEST MUST BE PERFORMED

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8) Make your final combustion efficiency test and fine tune the fan air damper as necessary. Replace the red
protective cover and secure with three screws.
NOTE: Do not assume the burner is operating at optimum performance.
9) If the burner is installed on a central warm air furnace, affix the supplied warning labels to the furnace fan
cover door (inside and outside).
10) Always do a final set up by checking the gas flow rate by clocking the meter. Do a complete combustion
check with proper test equipment to obtain the best and safe CO² , O², and CO results. This test must be
done by a qualified technician. The maximum CO² level for Natural Gas is 10%.
The maximum CO² level for Propane Gas is 12%. The recommended flue gas temperature is from 350
degrees Fahrenheit to 550 degrees Fahrenheit.
Fill out the installation data on the label described below and explain the burner’s essential functions (starting
and stopping) to the owner. Do not forget to give the dealer or service company’s name and address.
NOTE: This label is supplied in the package with the burner and should be filled out and affixed to the
appliance when the conversion burner is installed.
COMBUSTION HEAD SETTING
COMBUSTION HEAD ADJUSTMENTS
To set combustion head, loosen the Allen screw (A) and
move the elbow (B) so that the rear edge of the air tube (C)
coincides with the set point number (D). See firing rate chart
for set points. Retighten the Allen screw (A).

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FIRING RATE SPECIFICATIONS AND SETTINGS
Make sure you are using the correct table for either Natural gas or Propane gas.
Natural gas burner setup chart
BTU Input Air Gate Stop Gate Manifold Pressure Line Pressure
250,000 1.7 0.0 1.4” w.c. 8.0”w.c.
350,000 1.6 0.0 1.6” w.c. 8.0”w.c.
450,000 1.8 1.0 1.5” w.c. 8.0”w.c.
550,000 2.2 2.0 1.4” w.c. 8.0”w.c.
650,000 2.8 3.0 1.8” w.c. 10.0”w.c.
750,000 3.5 4.0 2.1” w.c. 12.0”w.c.
Line pressure measured at gas valve with burner firing.
Propane gas burner setup chart
BTU Input Air Gate Stop Gate Manifold Pressure Line Pressure
250,000 2.0 0.0 1.0” w.c. 11.0”w.c.
350,000 2.1 0.0 1.4” w.c. 11.0”w.c.
450,000 3.0 1.0 1.5” w.c. 11.0”w.c.
550,000 3.2 2.0 2.1” w.c. 11.0”w.c.
650,000 3.7 3.0 2.6” w.c. 11.0”w.c.
750,000 4.1 4.0 3.0” w.c. 11.0”w.c.
Line pressure measured at gas valve with burner firing.
NOTE: The above settings are a starting point for adjustments ONLY; a qualified gas technician using proper
test equipment must do the final adjustments. Proper CO², 0², and CO readings must be taken and be within
regulating code requirements.
All the settings above are based on zero (0) over fire-draft. If positive or negative chamber conditions exist
some settings changes made be required.
NOTE: For any referral to valve setting, please check the attached manufacturer valve specification.
WORKING RANGE OF BURNER
Example (shown above): With the gas burner installed on a boiler with an over-fire pressure of 1” water
column in the combustion zone with the burner firing, the maximum output of the burner will be 615,000
100 120 180160140 240220200 260 2808060
205 410311273 819751685615546472 955888
50
170
KW/H
KBTU/H
0.2
0.4
0.6
0.8
1.0
1.2
1.6
1.4
In/wc
PRESSURE
INPUT