Riello 40 FS5 Quick start guide

2903337 (1) - 11/2008
Installation, use and maintenance instructions
Forced draught gas burner
One stage operation
CODE MODEL TYPE
3756615 FS5 564M

3337 1
TECHNICAL DATA
BURNER DESCRIPTION
NOTES
– The grommet (3) 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 (4) fig. 1 supplied as equipment.
TYPE 564M
Thermal output 23 – 58 kW – 20,000 – 50,000 kcal/h
Gas
(Family 2) Net heat value 8 – 12 kWh/m3– 7,000 – 10,340 kcal/m3
Pressure min. 10 mbar – max. 40 mbar
Electrical supply single phase, 230V ±10% ~50Hz
Motor 230V / 0.65A
Capacitor 2 µF
Ignition transformer primary 230V – secondary 15 kV
Absorbed electrical power 0.15 kW
1 –Airdamper
2 – Screws for fixing the air damper
3 – Grommet
4 – Screw for fixing the cover
5 – Air pressure switch
6 – 6 Pole socket
7 – Lock-out lamp and reset button
8 – Control box
9 –Flange
10 – Motor
11 – 7 Pole socket
1
32
4
5
10
7
D7572
Fig. 1
8
9
611

3337 2
OVERALL DIMENSIONS
BURNER EQUIPMENT
BOILER FIXING
Flange Burner
* Length available using an extended head kit.
272 100 295 ø 170
130 28 48
45°
45°
ø 91
233
10
140
Rp 1/2
180
138
*125
D5066
Quantity Description
4
1
3
1
1
Screws with nuts
Insulating gasket
Screws for fixing the cover
Grommet
Hinge
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 equipped insulating gasket (3).
132
AB
D5067
HINGE ASSEMBLY
S7392

3337 3
FIRING RATE
TEST BOILER
The firing rate has been defined according to EN 676 standard.
COMMERCIAL BOILERS
The burner-boiler matching is assured if the boiler is according to EN 303 and the combustion
chamber dimensions are similar to those shown in the diagram EN 676.
For applications where the boiler is not according to EN 303, or where the combustion chamber
dimensions differ from those shown in EN 676, please consult the manufacturers.
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, a gas head pressure of 4.6 mbar is measured with the combustion
chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/m3 (8,570 kcal/m3).
0.8
0
0.2
0.4
0.6
Pressure in the combustion
chamber – mbar
20,000 30,000 40,000 50,000 kcal/h
20 4030 50 60 kW
Burner output D5053
1.0
Gas pressure
mbar
4
1
2
3
5
6
20,000 30,000 40,000 50,000 kcal/h
20 4030 50 60 kW
Burner output D5054

3337 4
LINE OF GAS-SUPPLY
The gas train is supplied separately, for its adjustment see the enclosed instructions.
POSITIONING ELECTRODE-PROBE
GAS TRAIN ACCORDING TO EN 676
MULTIBLOC CODE CONNECTION EMPLOY
GAS TRAIN BURNER
MBC 65 DLE 3970569 Rp 1/2 Rp 1/2 Natural gas and LPG
MBDLE 405 B01 3970530 Rp 1/2 Rp 1/2 Natural gas and LPG
1– Gas supply pipe
2– Manual cock (charged to the installer)
3– Gas pressure gauge (charged to the installer)
4– Filter
5– Gas pressure switch
6– Safety valve
7– Pressure governor
8– Adjusting valve
M1 – Gas-supply pressure test point
M2 – Pressure coupling test point
1
D5069
M2
2 3 M1 4 5 6 7 8
D7279
678
MBC 65 DLE
D5033
Ignition electrodeDiffuser
WARNING 2.5 – 3.5 mm
probe
Probe Electrode
Put the ceramic
near the diffuser disc
2
IMPORTANT
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.
Ionization

3337 5
ELECTRICAL CONNECTIONS
NOTES
The electrical wirings must be carried out in conformity with the regulations in force in the countries of
destination, and by qualified personnel.
Riello S.p.A. cannot accept any responsibility for modifications or connections other than those shown in
these diagrams.
Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth
connection.
The cross section of the wires must be at least 1 mm2. (Unless requested otherwise by local standards and
legislation).
KEY TO ELECTRICAL LAYOUT
A– Electrical control box
B4 – Working signal
+BB – Components on burners
+BC – Components on boiler
C– Motor capacitor
E– Ignition electrode
F1 – Filter
h1 – Hour counter
IN – Manual burner stop switch
MV – Fan motor
Q1 – Single phase knife switch
PA – Air pressure switch
PG – Minimum gas pressure switch
S3 – Remote lock-out signal
ION – Ionisation probe
TA – Ignition transformer
TB – Burner earth
TL – Limit thermostat
TS – Safety thermostat
VR – Adjustment valve
VS – Safety valve
Y–Gasvalve
YVPS – Gas valve leak detection control device
WF.. – Filter connector
WM – Motor connector
WPA – Air pressure switch connector
WS – Ionisation probe connector
X6 – 6-pole socket
X7 – 7-pole socket
XP6 –6-pinplug
XP7 – 6-pin plug/socket
1
2
Indication of references
Electrical wiring is the responsibility of the installation engineer
4
INDEX
3Functional layout
2Indication of references
Sheet no. /1.A1
Co-ordinates

3337 6

3337 7

3337 8
COMBUSTION HEAD ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC
the application of the burner on the boiler, adjust-
ment and testing must be carried out observing
the instruction manual of the boiler, including ver-
ification of the CO and CO2concentration in the
flue gases, their temperatures and the average
temperature of the water in the boiler.
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 position 0).
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 required by the
control box is 5 µA.
The burner would normally have a
higher current value than this, but if a
check is required, open the connector
fitted in the red probe lead and insert a
microammeter as shown.
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
S7015
C
A
B
02134
70
50
40
30
20
10
60
50,000
40,000
30,000
20,000
10,000
kcal/h kW
Set point
D5068
5
60,000
44
Ionization probe
Connector
2
Control box
terminal block D5006

3337 9
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
function at the required power, turn the knob slowly in a clockwise
direction until burner lockout. Then turn the knob anticlockwise to
an extent that is around 20% of the adjusted value and then check
that the burner starts up properly. If the burner locks out again turn
the knob slightly in an anticlockwise direction.
Attention:
In conformity with the standard, the air pressure switch must pre-
vent the air pressure falling below 80% of the adjusted value and
the CO in the flue gases exceeding 1% (10,000 ppm). To check
this, insert a combustion analyser in the flue, slowly reduce the
burner air setting (for example with a piece of cardboard) and verify
that the burner locks out before the CO value in the flue gases ex-
ceeds 1%.
BURNER START-UP CYCLE
When flame-failure occurs during working, shut down takes place within one second.
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
D7404
3s40s40smax. 2s max. 2s
D4172
Lock-out, due to ignition failureNormal
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out

3337 10
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 >3s 3sPulses Pulses
RED LED on
wait at least 10s Interval
Lock-out

3337 11
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are
listed in the table below.
MAINTENANCE
Before cleaning or performing checks, switch off the burner’s power supply with the system’s master
switch and close the gas shutoff valve.
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Periodic maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel
and consequent pollution.
THE BASIC OPERATIONS ARE:
Checking that there are no obstructions or kinks in the supply or return oil pipes, in the air intake regions
and the combustion product discharge tubes.
Checking that the burner and gas train electrical connections are correct.
Checking that the gas train is suitable for the burner's power, the type of gas used and the mains gas
pressure.
Checking the proper positioning of the combustion head and its fixing to the boiler.
Checking the proper positioning of the air damper.
Checking the proper positioning of the ionisation probe and electrode.
Checking the adjustment of the air pressure switch and the gas pressure switch.
Let the burner work at full speed for approximately ten minutes, correctly adjusting all the elements indicated
in this manual. Then carry out the analysis of the scale combustion by checking:
Percentage of CO2(%); CO Content (ppm); NOx content (ppm);
Ionisation current (µA); Flue gases temperature at the flue.
SIGNAL PROBABLE CAUSE
2 pulses

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 pulses

Minimum air pressure switch does not close:
– make sure VPS trips to produce lockout;
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– fan motor does not run;
– maximum air pressure switch operating.
4 pulses

Min. air pressure switch does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
7 pulses

Loss of flame during operations:
– poor burner regulation (insufficient gas);
– faulty or soiled gas valves;
– short circuit between ionisation probe and earth.
10 pulses


– Wiring error or internal fault.

3337 12
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 (9, 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.
BURNER STARTING DIFFICULTIES
Signal Problem Possible cause Recommended remedy
2 blinks Once the pre-purging
phase and safety time
have passed, the
burner goes into lock-
out without the appear-
ance of the flame
1 - The operation solenoid lets little gas . . . .
through Increase
2 - One of the two solenoid valves does . . .
not open. Replace
3 - Gas pressure too low. . . . . . . . . . . . . . . . Increase pressure at governor
4 - Ignition electrode incorrectly adjusted . . . Adjust, see page 4
5 - Electrode grounded due to broken . . . . .
insulation Replace
6 - High voltage cable defective . . . . . . . . . . Replace
7 - High voltage cable deformed by high . . .
temperature Replace and protect
8 - Ignition transformer defective . . . . . . . . . Replace
9 - Incorrect valve or transformer . . . . . . . . .
electrical wiring Check
10 - Defective control box. . . . . . . . . . . . . . . . Replace
11 - A closed valve upline the gas train . . . . . Open
12 - Air in pipework. . . . . . . . . . . . . . . . . . . . . Bleed air
13 - Gas valves unconnected or with . . . . . . .
interrupted coil Check connections or replace coil
3 blinks The burner does not
switch on, and the
lockout appears
14 - Air pressure switch in operating position . Adjust or replace
The burner switches
on, but then stops in
lockout
- Air pressure switch inoperative due to
insufficient air pressure:
15 - Air pressure switch incorrectly adjusted. . Adjust or replace
16 - Pressure switch pressure test point . . . .
pipe blocked Clean
17 - Poorly adjusted head. . . . . . . . . . . . . . . . Adjust
18 - High pressure in the furnace . . . . . . . . . . Connect air pressure switch to fan
suction line
Lockout during pre-
purging phase 19 - Defective motor control contactor . . . . . . (only three-phase version) Replace
20 - Defective electrical motor . . . . . . . . . . . . Replace
21 - Motor lockout (defective electrical motor) Replace
4 pulses The burner switches
on, but then stops in
lockout
22 - Flame simulation . . . . . . . . . . . . . . . . . . . Replace the control box
Lockout when burner
stops 23 - Permanent flame in the combustion . . . . head or flame simulation Eliminate persistence of flame or replace control box
7 blinks The burner goes into
lockout immediately
following the appear-
ance of the flame
24 - The operation solenoid lets little gas . . . .
through Increase
25 - Ionisation probe incorrectly adjusted . . . . Adjust, see page 4
26 - Insufficient ionisation (less than 5 A) . . . . Check probe position
27 - Earth probe . . . . . . . . . . . . . . . . . . . . . . . Withdraw or replace cable
28 - Burner poorly grounded. . . . . . . . . . . . . . Check grounding
29 - Phase and neutral connections inverted . Invert them
30 - Defective flame detection circuit . . . . . . . Replace the control box
Burner goes into lock-
out during operation 31 - Probe or ionisation cable grounded. . . . . Replace worn parts

3337 13
N.B.: If problems still occur after all of the above checks have been made, check the electrical connec-
tions on the plug and sockets, the damper and burner motor, gas control wiring ignition transformer
and external interlocks, if the burner still fails to function, replace the control box.
10 blinks The burner does not
switch on, and the
lockout appears
32 - Incorrect electrical wiring. . . . . . . . . . . . . Check
The burner goes into
lockout 33 - Defective control box. . . . . . . . . . . . . . . . Replace
34 - Presence of electromagnetic . . . . . . . . .
disturbances in the thermostat lines Filter or eliminate
No blink The burner does not
start 35 - No electrical power supply. . . . . . . . . . . . Close all switches - Check connec- tions
36 - A limiter or safety control device is open. Adjust or replace
37 - Line fuse blocked. . . . . . . . . . . . . . . . . . . Replace
38 - Defective control box. . . . . . . . . . . . . . . . Replace
39 - No gas supply . . . . . . . . . . . . . . . . . . . . . Open the manual valves between
contactor and train
40 - Mains gas pressure insufficient . . . . . . . . Contact your GAS COMPANY
41 - Minimum gas pressure switch fails to . . .
close Adjust or replace
The burner continues
to repeat the start-up
cycle, without lockout
42 - The gas pressure in the gas mains lies
very close to the value to which the mini-
mum gas pressure switch has been set.
The sudden drop in pressure after valve
opening causes temporary opening of the
pressure switch itself, the valve immedi-
ately closes and the burner comes to a
halt. Pressure increases again, the pres-
sure switch closes again and the ignition
cycle is repeated. And so on
Reduce the minimum gas pressure
switch intervention pressure.
Replace the gas filter cartridge.
Ignition with pulsations 43 - Poorly adjusted head. . . . . . . . . . . . . . . . Adjust. See page 8
44 - Ignition electrode incorrectly adjusted . . . Adjust, see page 4
45 - Incorrectly adjusted fan air damper: too
much air Adjust
46 - Output during ignition phase is too high . Reduce
Signal Problem Possible cause Recommended remedy

3337 14
NORMAL OPERATION / FLAME DETECTION TIME
The control box has a further function to guarantee the correct burner operation (signal: GREEN LED perma-
nently on).
To use this function, wait at least ten seconds from the burner ignition and then press the control box button for
a minimum of 3 seconds.
After releasing the button, the GREEN LED starts flashing as shown in the figure below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will measure the probe DETECTION TIME since the opening of gas valves, according to
the following table:
KIT INTERFACE ADAPTER RMG TO PC Code 3002719
SIGNAL FLAME DETECTION TIME This is updated in every burner start-up.
Once read, the burner repeats the start-up cycle by
briefly pressing the control box button.
WARNING
If the result is > 2s, ignition will be retarded.
Check the adjustment of the hydraulic brake of the
gas valve, the air damper and the combustion head
adjustment.
1 blink 0.4s
2 blinks 0.8s
6 blinks 2.8s
GREEN LED on
wait at least 10s Press button for > 3s signal signal
Interval
3s

3337 15
WARNINGS AND SAFETY
The dimension of the boiler’s combustion chamber must respond to specific values, in order to guarantee a
combustion with the lowest polluting emissions rate.
You are therefore advised to consult the Technical Assistance Department before choosing this type of burn-
er for the combination with a boiler. Qualified personnel are those with the professional and technical re-
quirements indicated by law no. 46 dated March 5, 1990.
The commercial organisation has a widespread network of agencies and technical offices whose personnel
participates periodically in instructional and refresher courses at the Company Training centre.
This burner must only be used for the purposes it has specifically been designed for.
All contractual and other liability on the part of the manufacturer is excluded for injury caused to people, an-
imals or damage caused to property due to faulty installation, adjustment, maintenance or improper use.
BURNER IDENTIFICATION
The Identification Plate on the product gives the serial number, model and main technical and performance
data. Tampering with, removal or absence of the Identification Plate will mean it is not possible to identify
the product with certainty and therefore make any installation or maintenance difficult and/or dangerous.
BASIC SAFETY MEASURES
The control box may not be used by children or inexpert people.
Under no circumstances may intake grilles or heat dissipation grilles or the ventilation openings in rooms
where the control box is installed be plugged with rags, paper or anything else.
No attempt must be made to repair the control box by non-authorised personnel.
It is dangerous to twist or pull the electrical cables.
Under no circumstances must any attempt be made to carry out any cleaning operations before unplug-
ging the control box from the electrical supply.
Do not clean the control box or any of its parts with substances that can easily catch fire (e.g. petrol, al-
cohol, etc.). The cover must be cleaned with soapy water.
Do not rest anything on the burner.
Do not plug or reduce the size of the ventilation openings in the room where the generator is installed.
Do not leave containers and inflammable substances in the room where the control box is installed.
WARNINGS TO AVOID BURNOUT OR BAD COMBUSTION OF THE BURNER
1 – When the burner is stopped, the flue must stay open and effect a natural draught in the combustion
chamber. If the smoke pipe is closed, the burner must be drawn back till the extraction of blast
pipe from the furnace. Before operating in this way take the voltage off.
2 – The premises the burner operates in must have same openings to allow the air necessary for
combustion to pass through. To be sure about this, you have to control CO2and CO in the exhaust
gases with all the windows and doors closed.
3 – If there are air intakes in the premises the burner works in make sure there are intakes big enough
to ensure the change required; in any case, check that when the burner stops the extractors do
not draw hot fumes from pipes through the burner.

RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.riello.it
http:// www.rielloburners.com