Riello 40 FS5D Quick start guide

2903312 (2) - 04/2012
Instrucciones de instalación, uso y mantenimiento
Installation, use and maintenance instructions
Forced draught gas burner
Quemador de gas de aire soplado
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3758704 FS5D 587M
3758705 FS5D 587M
GB
E
Two stage operation
Funcionamiento de dos llamas

3312 1GB
ENGLISH
TECHNICAL DATA
For gas family 3 (LPG) ask for separate kit.
OThe burner meets protection level of IP X0D (IP 40) as EN 60529.
OThe burner is approved for intermittent operation as per Directive EN 676.
OCE marking in accordance with Gas Appliance Directive 90/396/EEC; PIN 0063AP6680.
OBurner with CE marking in conformity with EC Directives: EMC 2004/108/EEC, Low Voltage
2006/95/EC and Machines 2006/42/EC.
OGas train according to EN 676.
NOTES
– The grommet (6) 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 (7, fig. 1) supplied as equipment.
TYPE 587M
Thermal power 12/23 58 kW – 10.000/20.000 50.000 kcal/h
Natural gas
(Family 2) Pci 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 Run current 0.75 A - 2800 rpm - 294 rad/s
Capacitor 2 F
Ignition transformer primary 230V / 0.2A – secondary 8 kV
Absorbed electrical power 0.15 kW
COUNTRY IT - AT - GR - DK - SE GB - IE FR DE LU - PL
GAS CATEGORY II2H3B/P II2H3P II2Er3P II2ELL3B/P II2E3B/P
1 – Air damper opening motor
2 –Airdampers
3 – Capacitor
4 –Motor
5 – Air pressure switch
6 –Grommet
7 – Hood fixing screw
8 – 6 pole socket for gas train
9 – 4 pole socket for 2nd stage
10 – Control box
11 – Lockout lamp with reset button
1
6
2
7
9
10 11
D7389
5 4 3
Fig. 1
8

3312 2GB
DIMENSIONS
BURNER EQUIPMENT
ACCESSORIES
SOFTWARE DIAGNOSTIC KIT
A special kit is available that, by an optical link to a PC, shows the burner life together with oper-
ating hours, type and number of lockout, serial number, etc...
Do the following to display the diagnostic:
Connect the kit supplied separately to the appropriate socket on the control box.
The information is read after the software program in the kit is booted.
RESET KIT
The use of a connection available as an accessory is provided for remote resetting of the control
box.
FlangeBurner
272 100 295 170
28 48
45°
233
140
Rp 1/2
180
138
D6336 130
10
45°
170
OCombustion head extension, supplied separately.
O125
ø 91
Quantity Description
4
1
3
1
1
1
1
Screws with nuts
Insulating gasket
Hood fixing screws
Grommet
Hinge
7 pin plug
4 pin plug

3312 3GB
BOILER FIXING
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 conforms to EN 303 and the combustion chamber
dimensions 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 consult the manufacturers.
INSTALLATION
S7392
HINGE
A
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 plate (2) insert the supplied insulat-
ing gasket (3).
Boiler door must have a max. thickness of 80 mm,
refractory lining included.
If thickness is greater (max. 105 mm), a combus-
tion head extension must be fitted, which is sup-
plied separately.
ATTENTION
132
AB
D5064
0.8
0
0.2
0.4
0.6
Pressure in combustion
chamber – mbar
10,000 20,000 30,000 40,000 50,000 kcal/h
10 3020 40 50 kW
Output D5057
60
1.0

3312 4GB
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To get maximum output 4.6 mbar measured on the pipe coupling is necessary with combustion
chamber at 0 mbar and gas G20 - Pci = 10 kWh/m3(8,570 kcal/m3).
GAS FEEDING LINE
The gas train is supplied separately, for its adjustment see the enclosed instructions.
Gas pressure
mbar
4
1
2
3
5
6
10,000 20,000 30,000 40,000 50,000 kcal/h
10 3020 40 50 kW
Output D5058
60
0
GAS TRAIN ACCORDING TO EN 676
MULTIBLOC CONNECTIONS USE
TRAIN BURNER
MBZRDLE 405 B01 Rp 1/2 Rp 1/2 Natural gas and LPG
1– Gas arrival pipe
2– Manual gate
(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– 1st and 2nd stage adjustment valve
M1 – Gas-supply pressure test point
M2 – Pressure coupling test point
1
D5072
M2
2 3 M1 4 5 6 7 8

3312 5GB
ELECTRICAL WIRING
RS
E
TB TB
1
P
2
P
PG VS V1
321NPh
MV
C
M
SO
TL
PE
CN1
B4S3T2T1NL1
h1
TS
LN
SB
T6A
21 34 21123412321 1
2
3
1
2
RNNNL2
S1 S2 BA
C
MGA
XP6
XP7
SM
M
h2
TR
B5 T6 T7 T8
XP4
P
12
PA
P
V2
AD
~ 50Hz 230V
MG557-3
Main switch
IMPORTANT
The burners have been approved for intermittent
operation. This means that they must stop once
every twenty four hours to permit the electrical
control box to check its efficiency at start up. Nor-
mally the boiler's limit thermostat (TL) ensures
the stopping of the burner.
If this is not the case, it is necessary to apply in
series with the (TL) a timer switch that turns off
the burner at least once every twenty-four hours.
TESTING
Check the burner has stopped by opening the
thermostats.
Check that the burner has locked out during
operation by opening the connector (CN1) in-
serted in the probe's red wire, located outside
the control box.
CONTROL BOX, (see fig. 2)
To extract the control box from the burner it is
necessary:
to disconnect all the connectors connected to
it, the 7 pin plug, and the earth wire (TB);
undo the screw (A) and pull out the control box
in the direction of the arrow.
For the installation of the control box it is neces-
sary:
to tighten up the screw (A) with a tightening
torque of 1 - 1.2 Nm;
connect all the connectors that were previously
connected.
WARNING:
Do not swap neutral and phase over, follow the diagram shown carefully
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.
CONTROL BOX
D7363
KEY TO LAY-OUT
AD – Air damper opening motor
C– Motor capacitor
CN1 – Ionising probe connector
E– Ignition electrode
h1 –1
st stage hour counter (230V - 0.1A max.)
h1 – 2
nd stage hour counter (230V - 0.1A max.)
MV – Fan motor
PA – Air pressure switch
PG – Minimum gas pressure switch
RS – Remote reset connection
SB – Remote lock-out signal
(230V - 0.5 A max.)
SM – Air damper servomotor
SO – Ionisation probe
TB – Burner earth
TL – Limit thermostat
TS – Safety thermostat
TR –2
nd stage thermostat
T6A –Fuse
V1 –1
st stage valve
V2 –2
nd stage valve
VS – Safety valve
XP – 4 pin plug/socket
XP – 6 pin plug/socket
XP7 – 7 pin plug/socket
E9324
Fig. 2
A

3312 6GB
ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE
(DUNGS VPS 504)
COMBUSTION HEAD ADJUSTMENT
Loosen 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 in a 40 kW boiler.
Considering efficiency of 90% the burner must
supply around 44 kW.
The diagram shows that for this
output the adjustment must be
made on notch 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).
230V ~ 50Hz
KEY TO LAY-OUT
B5 –2
nd stage lock-out signal
h1 –1
st stage Hour counter
h2 –2
nd stage Hour counter
PG – Min. gas pressure switch
S3 – Remote lock-out signal
(230V - 0.5 A max.)
T6A –Fuse
TL – Limit thermostat
TR –2
st stage thermostat
TS – Safety thermostat
V10 – Safety valve
V11 –1
st stage valve
V12 –2
st stage valve
X4 – 4 pin plug
X6 – 6 pin plug
X7 – 7 pin plug
D4371
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

3312 7GB
PROBE - ELECTRODE POSITIONING
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.
AIR DAMPERS ADJUSTMENT
Take the burner to the 2nd stage. The mobile air damper
(1) activated by the motor (2), ensures the suction inlet
opens completely.
Adjust 2nd stage air delivery on the fixed damper (3)
after loosening the screws (4).
Once the ideal setting has been reached, securely
tighten the screws (4).
The damper leaves the factory set at pos. 6.
Take the burner to 1st stage working. The mobile air
damper (1) returns to the standby position.
Adjust 1st stage air delivery by turning the screw (6)
after loosening the nut (5) turning it in a clockwise direc-
tion. Once the ideal setting has been reached, block the
nut (5) turning it in an anticlockwise direction.
D5033
Ignition electrode
Diffuser
WARNING 2.5 3.5 mm
Probe
Probe Electrode
Put the ceramic near
the diffuser disc
2
4
1
4
6
2
D5074
5
3

3312 8GB
COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC, the application of the burner on the boiler,
adjustment and testing must be carried out by 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. It is advisable to set the burner according to
the type of gas used and following the indications of the table:
IONISATION CURRENT
The minimum current necessary for the
control box operation is 5 µA.
The burner normally supplies a higher cur-
rent value, so that no check is needed.
Should you want to measure the ionisation
current anyway, you must open the con-
nector (CN1), (see wiring diagram page 5) inserted in the red wire and insert a microammeter.
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 exceeds 1%.
EN 676 AIR EXCESS: max. output 1,2 – min. output 1,3
GAS Theoretical max. CO2
0 % O2
Setting CO2% CO
mg/kWh NOx
mg/kWh
= 1.2 = 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
D4625 +_
Probe
Connector
Socket
of control-box
D7404