Riello 40 GS10 Quick start guide

GB
2903159 (2) - 07/2022
Installation, use and maintenance instructions
Forced draught gas burner
One - stage operation
CODE MODEL TYPE
3755489 RIELLO 40 GS10 554T85

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1
INDEX
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 Firing rate . . . . . . . . . . . . . . . . . . . . . . . 2
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 adjustment. . . . . . . . . . . . . . 6
4.2 Combustion head setting. . . . . . . . . . . . . 6
4.3 Air damper setting. . . . . . . . . . . . . . . . . . 7
4.4 Combustion check. . . . . . . . . . . . . . . . . . 7
4.5 Burner start-up cycle . . . . . . . . . . . . . . . . 7
4.6 Start-up cycle diagnostics . . . . . . . . . . . . 8
4.7 Resetting the control box and using 
diagnostics . . . . . . . . . . . . . . . . . . . . . . . 10
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 14
1. BURNER DESCRIPTION
Gas burner with one stage working.
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–Terminalstrip
8– Control box
9– Reset button with lock-out lamp
The burner is approved for intermittent operation as per EN 676.
The burner meets protection level of IP X0D (IP 40), EN 60529.
Gas train according to EN 676.
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.
Fig. 1
2
1
2
D4177
5 4 3
9
8
7
6
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

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2. TECHNICAL DATA
2.1 TECHNICAL DATA
TYPE 554T85
Thermal power (1) 42 –116 kW - 36,000 –100,000 kcal/h
Natural gas (Family 2)
Net heat val3ue: 8 – 12 kWh/Nm3 -7,000 – 10,340 kcal/Nm3
Pressure: min. 16 mbar - max. 100 mbar
Electrical supply Single phase, 100V ±10% ~50/60 Hz
Motor 100V / 2.2A
Capacitor 5 F
Ignition transformer Primary 100V / 2.3/1.9A - Secondary 8 kV / 30 mA
Absorbed electrical power 0.13 kW
(1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.
2.2 OVERALL DIMENSIONS
OCombustion head extension, supplied separately.
FlangeBurner
305 110 346 185
33 61
45°
ø 105
262
160
Rp 3/4
204
142
O170
D4251 130
11
45°
2.3 FIRING RATE, (as EN 676)
Thermal power
D5256
0.8
0
0.2
0.4
0.6
40,000 50,000 60,000 70,000 kcal/h
1206050 70 80 kW
1.0
110
80,000
1.2
90 100
90,000
1.4
40
1.6
100,000
Pressure in the combustion
chamber – mbar

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TEST BOILER
The working field 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 dimen-
sions 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 con-
sult the manufacturers.
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, a gas head pressure of 5.8 mbar is measured (M2, see chapter 3.3, page 4) with
the combustion chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/Nm3(8,570 kcal/Nm3).
4
1
2
3
5
6
7
Gas pressure in the
combustion head – mbar
40,000 50,000 60,000 70,000 kcal/h
1206050 70 80 kW
Thermal power
D5257
110
80,000
90 100
90,000
40
100,000
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
S7392
13 2
AB
D5108
HINGE
ASSEMBLY
Boiler door must have a max. thickness of 90 mm,
refractory lining included.
If thickness is greater (max. 150 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).

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3.2 PROBE - ELECTRODE POSITIONING
D5104
Ignition electrode
WARNING
2 –  3 mm
Ionization probe
Probe
Electrode
2.2
~
40 mm
Diffuser
=
=
3.3 GAS FEEDING LINE
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
1
D5949
6432578
9

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3.4 ELECTRICAL WIRING
Control box
RMG 88....
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN THE FACTORY
D7191
ATTENTION:
Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth con-
nection.
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 sepa-
rating 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).
KEY TO LAY-OUT
C– Capacitor
CN1 – Connector SO
E–Electrode
M– Terminal strip
MV –Motor
PA – Min. air pressure
switch
PG – Min. gas pressure
svitch
SO – Ionisation probe
S3 – Lock-out signal
T6A –Fuse
TA Ignition transformer
TB – Burner-earth
TL – Limit thermostat
TS – Safety thermostat
Connection
with pilot valve
Connection
without pilot valve

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3.5 FIXING THE ELECTRICAL WIRING
All the electrical wires, which are to be connected to the terminal strip (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 strip must be
gripped in the cable clamps (3, fig. 1). This is molded on both sides to allow the use of various diameter cables.
Cable clamps
ACB ACB
A = ø 8B=ø 11 C = ø 16
D5052
4. WORKING
4.1 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 observing the instruction manual of the boiler, including verification of the CO and CO2con-
centration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper setting of the combustion head, and the air damper
opening.
4.2 COMBUSTION HEAD SETTING
S7015
C
A
B
01 32
120
90
80
70
60
50
100
80,000
70,000
60,000
50,000
40,000
kcal/h kW
D5258
45
40
110
90,000
100,000
Set point
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 81 kW
boiler with an efficiency of 90%, the burner input
is about 90 kW using the diagram, the combus-
tion 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).

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4.3 AIR DAMPER SETTING
1
D5231
2
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).
4.4 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 consequently
formation of CO.
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.
SO
CN1
Terminal strip
of control-box
D5006
4.5 BURNER START-UP CYCLE
3s40s40smax. 2s max. 2s
D4172
Lock-out, due to ignition failureNormal
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out
When flame-failure occurs during working, shut down takes place within one second.


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4.6 START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the following table:
COLOUR CODE TABLE
Sequences Colour code
Pre-purging
Firing phase
Operation, flame ok
Operating with weak flame signal
Electrical supply lower than ~ 170V
Lockout
Extraneous light
Key to layout: Off Yellow Green Red