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

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SAFETY TEST - WITH GAS BALL VALVE CLOSED
It is fundamental to ensure the correct execution of theelectrical connections between the gas solenoid valves
and the burner to perform safely the commissioning.
For this purpose, after checking that the connections have been carried out in accordance with the burner's elec-
trical diagrams, an ignition cycle with closed gas ball valve -dry test- must be performed.
1 The manual ball gas valve must be closed
2The electrical contacts of the burner limit switch need to be closed
3 Ensures closed the contact of the low gas pressure switch
4 Make a trial for burner ignition
The start-up cycle must be as follows:
– starting the fan for pre-ventilation
–Performing the gas valve seal control, if provided
– Completion of pre-ventilation
– Arrival of the ignition point
– Power supply of the ignition transformer
– Electrical Supply of solenoid gas valves
Since the manual gas ball valve is closed, the burner will not light up and its control box will go to a safety lockout
condition.
The actual electrical supply of the solenoid gas valves can be verified by inserting a tester, Some valves are
equipped with light signals (or close/open position indicator) that turn on at the same time as their power supply.
IF THE ELECTRICAL SUPPLY OF THE GAS VALVES OCCURS AT UNEXPECTED TIMES. DO NOT
OPEN MANUAL GAS BALL VALVE, SWITCH OFF POWER LINE; CHECK THE WIRES; CORRECT
THE ERRORS AND REPEAT THE COMPLETE TEST.
SAFETY COMPONENTS
The safety components must be replaced at the end of their life cycle indicated in Tab. The specified life cycles
do not refer to the warranty terms indicated in the delivery or payment conditions.
Safety component Life cycle
Flame control 10 years or 250,000
operation cycles
Flame sensor 10 years or 250,000
operation cycles
Gas valves (solenoid) 10 years or 250,000
operation cycles
Pressure switches 10 years or 250,000
operation cycles
Pressure adjuster 15 years
Servomotor (electronic cam) (if present) 10 years or 250,000
operation cycles
Oil valve (solenoid)
(if present)
10 years or 250,000
operation cycles
Oil regulator (if present) 10 years or 250,000
operation cycles
Oil pipes / couplings (metallic) (if present) 10 years
Fan impeller 10 years or 500,000 start-ups

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4.7 RESETTING THE CONTROL BOX AND USING DIAGNOSTICS
The control box features a diagnostics function through which any causes of malfunctioning are easily identified
(indicator: RED LED). To use this function, you must wait at least 10 seconds once it has entered the safety
condition (lockout), and then press the reset button.
The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second inter-
vals. 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.
RED LED on
wait at least 10s Lockout Press reset for > 3s Pulses Interval 3s Pulses
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 lockout.
To view diagnostics, proceed as follows:
- Hold the button down for more than 3 seconds once the red LED (burner lockout) 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 malfunc-
tion, according to the coding system indicated in the table on page 10.
SOFTWARE DIAGNOSTICS
Reports burner life by means of an optical link with thePC, indicating hours of operation, number and type of
lockouts, 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 lockout) remains steadily lit.
A yellow light pulses to tell you the operation is done.
Release the button for 1 second and then press again forover 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 lockout 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)

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The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in
the table below.
Signal Problem Possible cause Recommended remedy
2 blinks Once the pre-purg-
ing phase and safety
time have passed,
the burner goes into
lockout without the
appearance of the
flame
The operation solenoid lets little gas
through
Increase
One of the two solenoid valves does not
open.
Replace
Gas pressure too low Increase pressure at governor
Ignition electrode incorrectly adjusted Adjust
Electrode grounded due to broken insula-
tion
Replace
High voltage cable defective Replace
High voltage cable deformed by high tem-
perature
Replace and protect
Ignition transformer defective Replace
Incorrect valve or transformer electrical wir-
ing
Check
Defective control box Replace
A closed valve upline the gas train Open
Air in pipework Bleed air
Gas valves unconnected or with interrupted
coil
Check connections or replace
coil
3 blinks The burner does not
switch on, and the
lockout appears
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:
Air pressure switch incorrectly adjusted. Adjust or replace
Pressure switch pressure test point pipe
blocked
Clean
Poorly adjusted head Adjust
High pressure in the furnace Connect air pressure switch to
fan suction line
Lockout during pre-
purging phase
Defective motor control contactor
(only three-phase version)
Replace
Defective electrical motor Replace
Motor lockout (defective electrical motor) Replace
4 blinks The burner switches
on, but then stops in
lockout
Flame simulation Replace the control box
Lockout when
burner stops
Permanent flame in the combustion head or

flame simulation
Eliminate persistence of flame
or replace control box
6 blinks The burner switches
on, but then stops in
lockout
Defective or incorrectly adjusted servomo-
tor
Adjust or replace

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7 blinks The burner goes into
lockout immediately
following the appear-
ance of the flame
The operation solenoid lets little gas
through
Increase
Ionisation probe incorrectly adjusted Adjust
Insufficient ionisation (less than 5 A) Check probe position
Earth probe Withdraw or replace cable
Burner poorly grounded Check grounding
Phase and neutral connections inverted Invert them
Defective flame detection circuit Replace the control box
Burner lockout mov-
ing between 1st and
2nd stages, or
between 2nd and 1st
stages
Too much air or too little gas Adjust air and gas
Burner goes into
lockout during oper-
ation
Probe or ionisation cable grounded Replace worn parts
10 blinks The burner does not
switch on, and the
lockout appears
Incorrect electrical wiring Check
The burner goes into
lockout
Defective control box Replace
Presence of electromagnetic disturbances
in 
the thermostat lines
Presence of electromagnetic disturbance
Filter or eliminate
Use the radio disturbance pro-
tection kit
No blink The burner does not
start
No electrical power supply Close all switches - Check con-
nections
A limiter or safety control device is open Adjust or replace
Line fuse blocked Replace
Defective control box Replace
No gas supply Open the manual valves
between contactor and train
Mains gas pressure insufficient Contact your GAS COMPANY
Minimum gas pressure switch fails to close Adjust or replace
Servomotor fails to move to min. ignition
position
Replace
The burner contin-
ues to repeat the
start-up cycle, with-
out lockout
The gas pressure in the gas mains lies very
close to the value to which the minimum
gas pressure switch has been set. 
The sudden drop in pressure after valve
opening causes temporary opening of the
pressure switch itself, the valve immediately
closes and the burner comes to a halt.
Pressure increases again, the pressure
switch closes again and the ignition cycle is
repeated. And so on
Reduce the minimum gas pres-
sure switch intervention pres-
sure. Replace the gas filter
cartridge.
Signal Problem Possible cause Recommended remedy

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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.
GREEN LED on
wait at least 10s
Press reset
for > 3s Pulses Interval 3s Pulses
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:
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
No blink Ignition with pulsa-
tions
Poorly adjusted head Adjust
Ignition electrode incorrectly adjusted Adjust
Incorrectly adjusted fan air damper: too
much air
Adjust
Output during ignition phase is too high Reduce
The burner does not
move into the 2nd
stage
Remote control device TR fails to close Adjust or replace
Defective control box Replace
Defective servomotor Replace
Burner stops with air
damper open
Defective servomotor Replace
Signal Problem Possible cause Recommended remedy

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5. MAINTENANCE
Disconnect the electric supply to the burner by switching off the main power switch and close the gas
shut-off valve before maintaining or checking the system.
The burner requires scheduled maintenance that must be carried out by qualified personnel and in compliance
with local legislation.
Scheduled maintenance is vital for the smooth operation of the burner; it avoids waste of fuel and reduces harm-
ful emissions into the atmosphere.
THE FUNDAMENTAL OPERATIONS TO CARRY OUT ARE AS FOLLOWS:
Check that the burner and gas train electrical connections are correct.
Check that the positioning of the air pressure test point is correct.
Check that the gas train is suited to the burner capacity, the type of gas used and the network gas pressure.
Check that the positioning of the combustion head is correct and that it is properly fixed to the boiler.
Check that the air pressure switch and the gas pressure switch are set correctly.
Check that the ionisation probe and the electrode are positioned correctly.
Let the burner run at full capacity for about ten minutes, setting all the elements correctly as explained in this
manual. Then carry out the analysis of the combustion by checking:
CO2percentage (%); CO content (ppm); NOx content (ppm); Ionisation current (µA).
Flue gases temperature at the stack.

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