Riello 554T80 Quick start guide

GB
2902753 (5) - 07/2022
Installation, use and maintenance instructions
Instrucciones para la instalación, uso y mantenimiento
Forced draught gas burner
E
Quemador de gas de aire soplado
One stage operation
Funcionamiento de una llama
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3755483 RIELLO 40 GS10 554T80

2753 1GB
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 Working field . . . . . . . . . . . . . . . . . . . . . 2
2.4 Correlation between gas pressure and
burner output . . . . . . . . . . . . . . . . . . . . 3
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 head setting . . . . . . . . . . . . 6
4.2 Air damper setting . . . . . . . . . . . . . . . . . 6
4.3 Combustion check . . . . . . . . . . . . . . . . . 7
4.4 Burner start-up cycle . . . . . . . . . . . . . . . 7
4.5 Start-up cycle diagnostics. . . . . . . . . . . . 7
4.6 Resetting the control box and using 
diagnostics . . . . . . . . . . . . . . . . . . . . . . . 9
5. MAINTENANCE. . . . . . . . . . . . . . . . . . . 10
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 11
1. BURNER DESCRIPTION
Gas burner with one stage working.
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.
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– Terminal board
8– Control box
9– Reset button with lock-out lamp
Fig. 1
2
1
2
D4177
5 4 3
9
8
7
6
The burner is approved for intermittent operation as per Directive EN 676.
The burner meets protection level of IP X0D (IP 40), EN 60529.
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

2753 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
Thermal power (1) 42 –116 kW - 36,000 –100,000 kcal/h
Natural gas (Family 2) Net heat value: 8 – 12 kWh/Nm3 -7,000 – 10,340 kcal/Nm3
Pressure: min. 16 mbar - max. 100 mbar
Electrical supply Single phase, 220V ±10% ~60Hz
Motor 220V / 1.1A
Capacitor 2.5 F
Ignition transformer Primary 220V / 1.25A - Secondary 8 kV / 25 mA
Absorbed electrical power 0.2 kW
(1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.
2.2 OVERALL DIMENSIONS
O
Combustion head extension, supplied separately.
FlangeBurner
305 110 346 185
33 61
45°
ø
105
262
160
Rp 3/4
204
142
O
170
D4251
130
11
45°
2.3 WORKING FIELD
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

2753 3GB
2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, a gas head pressure of 5.8 mbar is measured 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
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).
13 2
AB
D5108

2753 4GB
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
6432
9
578

2753 5GB
3.4 ELECTRICAL WIRING
KEY TO LAY-OUT
PG – Minimum gas pressure switch
S3 – Remote lock-out signal 
(220V - 0.5 A max.)
T6A – Fuse
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
Ionization probe
Ignition transformer
Electrode
Motor
Capacitor Burner
220V ~ 60Hz
Terminal board
Air pressure
White
Blue
Brown
VERSION
FOR GAS LEAK CONTROL DEVICE
(DUNGS VPS 504)
Control box
RMG 88.620A2
D4352
Connector
earth
Black
In the case of phase-phase feed,
a bridge must be fitted on the
control box terminal board be-
tween terminal 6 and the earth
terminal.
IMPORTANT
switch
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN THE FACTORY
ATTENTION:
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 compli-
ance with the rules in force in the country.
Verify that the burner stops by operating the boiler control thermo-
stats and that the burner locks out by separating 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 ther-
mostat (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).

2753 6GB
3.5 FIXING THE ELECTRICAL WIRING
All the electrical wires, which are to be connected to the terminal board (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 board 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 HEAD SETTING
S7015
C
A
B
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
combustion set point is 3.
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
1
D5231
2
2
Fig. 2
The diagram is to be used only for initial settings, to improve air pressure switch operation or improve combus-
tion, it may be necessary to reduce this setting (set point toward position 0)

4.2 AIR DAMPER SETTING (See Fig. 2)
The regulation of the air-rate is made by adjusting the air damper (1), after loosing the screws (2).

2753 7GB
When the optimal regulation is reached, screw tight the screws (2).
4.3 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.
Probe
Connector
Terminal board
of control-box
D5006
10
4.4 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.
4.5 START-UP CYCLE DIAGNOSTICS
During start-up, indication is according to the following table:
COLOUR CODE TABLE
Sequences Colour code
Pre-purging 
Ignition phase 11111
Operation, flame ok vvvvvvvvvvvv
Operating with weak flame signal. v1v1v1v1v1
Electrical supply lower than ~170V 
Lock-out 
Extraneous light vvvvv
Index: 1Off Yellow vGreen Red

2753 8GB
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