Riello FS10 Quick start guide

Installation, use and maintenance instructions
20039281 (2) - 10/2011
Forced draught gas burner
CODE MODEL TYPE
20033121 FS10 564T31
GB
One stage operation

1 20039281
GB
CONTENTS
1. BURNER DESCRIPTION
Gas burner with one stage working.
1.1 BURNER EQUIPMENT
Insulating gasket . . . . . . . . . . . . No. 1 Screws and nuts for flange to be fixed to boiler. . . No. 4
Cable grommet. . . . . . . . . . . . . . No. 1 Screws for fixing the cover . . . . . . . . . . . . . . . . . . No. 3
Hinge . . . . . . . . . . . . . . . . . . . . . No. 1 7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
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
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
3.4.1 Standard electrical wiring . . . . . . . . . . . 5
3.4.2 Electrical wiring with gas leak control
device . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Air pressure switch . . . . . . . . . . . . . . . . . 7
4.6 Burner start-up cycle. . . . . . . . . . . . . . . . 8
4.7 Start-up cycle diagnostics . . . . . . . . . . . . 8
4.8 Resetting the control box and using
diagnostics . . . . . . . . . . . . . . . . . . . . . . . 9
5. WARNINGS
to avoid burnout or bad combustion of the
burner . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. MAINTENANCE . . . . . . . . . . . . . . . . . . . 10
7. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 11
1– Air-damper
2– Screws for fixing the air-damper
3– 7 pole socket for electrical supply
and control
4– 6 pole socket for gas train
5– Cable grommet
6– Screw for fixing the cover
7– Air pressure switch
8– Control box
9– Reset button with lock-out lamp
According to Directives: Electromagnetic Compatibility 2004/108/EC, Low Voltage 2006/95/EC and Machine 2006/
42/EC.
The burner is approved for intermittent operation as per Directive EN 676.
The burner meets protection level of IP X0D (IP 40), EN 60529.
Gas train according to EN 676.
NOTES
– The cable grommet (5) 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 (6, fig. 1) supplied as equipment.
Fig. 1
D11054
6 5 3
2
1
9
8
7
4
2

20039281 2 GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
For gas family 3 (LPG) ask for separate kit.
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD (as EN 676)
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, 230V ±10% ~50Hz
Motor 230V / 0.7A
Capacitor 4 µF
Ignition transformer Primary 230V / 1.8A - 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.
COUNTRY DE AT FR ES - GB-IE LU - PL NL
GAS CATEGORY II2ELL3B/P II2H3B/P II2Er3P II2H3P II2E3B/P II2L3B/P
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°
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

3 20039281
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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 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.
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).
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
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
S7392
HINGE
ASSEMBLY
13 2
AB
D5108
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).

20039281 4 GB
3.2 PROBE - ELECTRODE POSITIONING
3.3 GAS FEEDING LINE
D5104
Ignition electrode
WARNING
2 – 3 mm
Ionization probe
Probe
Electrode
2.2
~
40 mm
Diffuser
=
=
1– Gas supply pipe
2– Manual cock (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– Adjustment valve
M1 – Gas-supply pressure test point
M2 – Pressure coupling test point
1
D5069
2 3 M1 4 5 6 7 8
M2

5 20039281
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3.4 ELECTRICAL WIRING
All the installation, maintenance and disassembly operations must be carried out with the electricity sup-
ply disconnected.
The burner requires periodic maintenance carried out by a qualified and authorised technician in con-
formity with legislation and local standards.
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 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 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 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).
STANDARD ELECTRICAL WIRING (see page 13).
3.4.1 ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504)
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 car-
ried out 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.
To suit the required appliance output, choose the proper set-
ting of the combustion head, and the air damper opening.
WARNING
DANGER
KEY TO LAY-OUT
X6 – 6 pin plug
X7 – 7 pin plug
B4 – Working signal
h1 – Hour counter
PG – Minimum gas pressure
switch
S3 – Remote lock-out signal
(230V - 0.5 A max.)
T6A – Fuse
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
230V ~ 50Hz
D4199
TO BE DONE BY
THE INSTALLER
S7015
C
A
B

20039281 6 GB
4.2 COMBUSTION HEAD SETTING
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.
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).
4.3 AIR DAMPER SETTING
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
It is advisable to set the burner according to the type of gas used and following the indications of the table:
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
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

7 20039281
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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 measure
the ionization current, you must open the connector fitted to the red wire and insert a microammeter.
4.5 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 working at the minimum output, adjust the dial clockwise, increasing its value until
the burner shuts down. Now reduce the value by one set point, turning the dial anti-clockwise.
Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.
Attention:
To comply with the EN 676 standard, the air pressure switch must operate when the CO value exceeds 1%
(10,000 ppm). To check this, insert a combustion analyser in the flue, slowly reduce the burner air setting and ver-
ify that the burner shuts down by the action of the air pressure switch before the CO value exceeds 1%.
Probe
Connector
Terminal board
of control-box
D5006
10

20039281 8 GB
4.6 BURNER START-UP CYCLE
When flame-failure occurs during working, shut down takes place within one second.
4.7 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
S8271
AL - Error message (alarm)
BV - Fuel valve
FS - Flame signal
GP - Gas pressure switch
LP - Air pressure switch
LR - Load controller
M- Fan motor
R- Control thermostat / pressurestat
SB -Safetylimiter
W- Limit thermostat / pressure switch
Z- Ignition transformer
AStart command (switching on by «R»)
B-B´ Interval for establishment of flame
COperating position of burner reached
C-D Burner operation (generation of heat)
DControlled shutdown by «R»
Burner will immediately be shut down
Burner control will immediately be ready
for new startup

9 20039281
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4.8 RESETTING THE CONTROL BOX AND USING DIAGNOSTICS
The control box features a diagnostics function through which any causes of malfunctioning are easily identi-
fied (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 malfunc-
tion, 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 ...
(WITH KIT INTERFACE ADAPTER LME TO PC Code 3002719).
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

20039281 10 GB
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are
listed in the table below.
5. WARNINGS TO AVOID BURNOUT OR BAD COMBUSTION OF THE BURNER
1– When the burner is stopped, the smoke pipe must be opened 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 tube from the furnace. Before operating in this way take the voltage off.
2– The place, where the burner works, must have same openings suitable for the passage of air necessary
for combustion. To be sure about this, you have to control CO2and CO in the exhaust gases with
all the windows and doors closed.
3– If in the place, where the burner works, there are air-breathings, check the existence of air-input
openings with dimensions suitable for the necessary air-exchange. In any case check that, when the
burner is stopped, the air-breathings do not draw warm smokes from pipes through the burner.
6. MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity
with legislation and local standards.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and con-
sequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the burn-
er acting on the main switch of the system.
THE BASIC CHECKS ARE:
Leave the burner working without interruption for 10 min., checking the right settings of all the components
stated in this manual. Then carry out a combustion check verifying:
CO2(%) content Smoke temperature at the chimney CO content (ppm).
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.
5 pulses

Time out “LP”:
– “LP” is welded working position.
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.

11 20039281
GB
7. 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

20039281 12 GB
N.B.: If problems still occur after all of the above checks have been made, check the electrical connections
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 6
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

8. STANDARD ELECTRICAL WIRING
20039281 13
2
Sheet no
/1.A1
Co-ordinates
1
2
INDEX
3
Indication of references
Functional layout
Indication of references

20039281 14
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20039281 15
KEY TO ELECTRICAL LAYOUT
A– Control box
B– Suppresor
B4 – Working signal
C– Capacitor
CN1 – Connector
h1 – Hour counter
IN – Switch
ION – Ionisation probe
Y– Valve assembly
PA – Air pressure switch
PGMin– Minimum gas pressure switch
Q2 – Main disconnecting swich
S3 – Remote lock-out signal (230V - 0.5 A max.)
T6A –Fuse
TA – Ignition transformer
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
XM – Motor connector
XP6 – 6 pole socket
XP7 – 7 pole socket
XTM – Burner ground (earth) connection
XTZ – Burner shelf
In the case of phase-phase feed, a bridge
must be fitted on the control box terminal
board between terminal 6 and the earth ter-
minal.
WARNING

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