Riello G200 Installation instructions

Installation & Operating Manual
2903254 (1)
Single stage operation forced draught natural gas/propane burner
CODE MODEL TYPE
3757116 G200 571T
The following pages contain information, descriptions and diagrams for the proper instal-
lation and wiring of the burner. Please read carefully before attempting final installation.
This manual is to remain with the final installation designation. It is the installer’s responsibil-
ity to ensure that the burner installation and operation instructions mentioned in this manual
are followed and operated within local code authority limits.

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TABLE OF CONTENTS
Installation instructions and owner's handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step by step procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Serial number identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner components identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrode & flame probe adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical gas train layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of sediment trap & burner supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Factory wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Field wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting up the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step by step procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air gate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Orifice installation and combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manifold pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure working chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Combustion chamber size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Combustion checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Burner start-up cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Problem solving guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Owner information & routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Propane burner application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Burner start-up form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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INSTALLATION INSTRUCTIONS AND OWNER'S HANDBOOK
CAUTION:
All gas burners MUST be installed by trained and licensed technicians.
WARNING:
Installation of this burner must conform with local codes or, in the absence of local codes, with the
Standard for the Installation of Domestic Gas Conversion Burners, ANSI Z21.8-1984, and Addendum,
Z21.8a-1989, and the National Fuel Gas code, ANSI Z223.1-1984, and CAN/CGA B149.1 &.2. If an ex-
ternal electrical source is utilized, the conversion burner, when installed, must be electrically ground-
ed in accordance with local codes or, in the absence of local codes, with the national Electrical Code,
ANSI/NFPA No. 70-1990 and CSA Electrical Code.
Owner is required to retain this manual for future reference.
WARNING:
If the information in these instructions is not followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
Do not store or use gasoline or any other flammable vapours or liquid in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS:
1) Do not try to light any appliance.
2) Do not touch electrical switches; do not use any phone in your building.
3) Immediately call your gas supplier from a neighbour's phone.
Follow the gas supplier's instructions.
4) If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
TECHNICAL SPECIFICATIONS
FIRING RATE 70,000 TO 200,000 Btu/hr
NATURAL GAS PROPANE
GAS SUPPLY PRESSURES MIN. 5" wc
MAX. 7" wc
MIN. 12" wc
MAX. 14" wc
MANIFOLD PRESSURES MIN. 3" wc
MAX. 5" wc
MIN. 3" wc
MAX. 5" wc
POWER
MOTOR
CONTROL MODULE
120 Volts 60 Hz 1 phase
232T 2.2 Amps 3250 rpm
525 SE/A ELECTRONIC

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GENERAL INFORMATION
Your Riello gas burner comes to you completely assembled and factory wired, ready for installation.
Models equipped with the short combustion head have a fixed flange, which bolts directly to the front of the appli-
ance. When equipped with the long combustion head, the burner comes with a universal flange, which when bolt-
ed to the appliance, allows the burner to be adjusted for exact positioning in the combustion zone.
STEP-BY-STEP PROCEDURE
1) Remove the burner from the carton, taking care not to lose any of the supplied accessories.
Check for signs of physical damage.
2) Bolt the combustion head and burner to the appliance. Be sure to install the supplied mounting gasket.
Ensure that the burner is level (we suggest using a spirit level) and that the combustion head is centred in the
appliance port. Refer to page 7 for positioning of combustion head relative to the chamber.
3) Check that all gas train connections are tight and make your connections to the incoming gas supply.
a) A sediment trap must be provided. See page 8.
b) If not already installed, a manual shutoff valve must be supplied. This valve must be upstream of the burner
gas train supply connection.
c) A 1/8" NPT plugged tapping must be installed immediately upstream of the burner gas train supply connec-
tion and must be accessible for a test gauge.
d) If required by local codes, provide gas vent lines at the gas regulators and valve (Riello gas trains are
equipped with vent limiting orifices).
e) Perform required gas pressure test on incoming gas supply lines.
NOTE: Details of sediment trap, manual gas valve, and pressure test point, and line pressure test point can be
found on page 8.
4) To make electrical connections, refer to field wiring diagram on page 9. A manual disconnect switch must be in-
stalled in the incoming lines. Wiring to the low voltage-switching relay, if used, (Honeywell R8038A) must be
rigid conduit or flexible approved cable.
CAUTION:
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing. (Step 5 e below.)
CAUTION:
The phase (HOT) wire must be connected to the black lead of the 24v relay if used; neutral to the
white lead. Do not reverse the polarity.
The burner will not operate with the Phase/Neutral reversed, and the control box may be damaged.
5) Check the burner functions as follows:
a) Make a final check on both the gas and electrical connections.
b) Loosen the screw in the manifold gas test point and install an appropriate manometer.
c) Set the thermostat at its highest setting.
d) Switch on power.
e) With the manual gas valve turned off, press the burner reset button (9, page 4), and allow the burner to run
through a complete cycle to ensure that the sequence of operations is correct. A full starting cycle should
take approximately 40 seconds from a no power condition until burner lockout; refer to the start-up cycle
chart found on page 14.
f) Once burner is operational (up and running) a final gas leak check must be completed on the gas train.
6) If the burner is installed on a central warm air furnace, affix the mandatory warning labels to the furnace fan
cover door (inside and outside).

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SERIAL NUMBER IDENTIFICATION
Your Riello burner may have been manufactured in more than one location and therefore there are two possible serial
number identification.
The Riello 9 character serial number, example,
06 01 12345, is identified as follows:
06 = Last two digits of the year of manufacture;
01 = Week of manufacture;
12345 = Increment of 1 for each burner produced – specific
to product code – reset to zero each January 1st.
The Riello 15 character serial number, example,
06 A 8511111 00025, is identified as follows:
06 = Last two digits of the year of manu-
facture;
A= BI-week of manufacture;
8511111 = Burner product code;
00025 = Increment of 1 for each burner pro-
duced – specific to product code –
reset to zero each January 1st.
BURNER COMPONENTS IDENTIFICATION
(06) (01) (12345)
Year of
manufacture
BI-week of
manufacture Increment
(06) (A) (8511111) (00025)
Year of
manufacture
BI-week of
manufacture Increment
BI-week of
manufacture
LN
L
N
1 – Control box
2 – Air pressure switch
3 – Screw for fixing the cover
4 – Cable grommet
5 – Wiring terminal block
6 – Screws for fixing the air-damper
7 – Air damper
8 – Capacitor
9 – Reset button with lock-out lamp
10 – Gas valve transformer 120V / 24V
7
6
8
2
3
1 9
4 5
D7337
10

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BURNER DIMENSIONS
ELECTRODE AND FLAME PROBE ADJUSTMENTS
WARNING:
Do not turn the ignition electrode. Leave it as shown in the drawing.
If the ignition electrode is put near the ionization probe, the amplifier of the control box may be damaged.
NOTE: Actual available insertion length must be measured from tip of end cone to face of mounting gasket.
Model 200 A B C D E F G G1 H I J
inches 9 3/16 10 11/16 1 57/64 1 7/64 1/211 5/83 15/16 10 33/64 3 9/16 5 7/16 7 2/32
mm 233 272 48 28 13 295 100 267 91 138 180
A
B
D
GF
G1
H
J
I
C
D7332
E
5 1/2”-140mm
7 1/2” - 190 mm
8 15/32” - 215 mm
7 3/32” - 180 mm
3 31/32”
101 mm
60°
45°
30°
D7351
15
44
0
-1
Ionization probe Ignition electrode
Propane sleeve Propane orifice
Probe Electrode
A
B
A B
mm 8 ± 0.5 4 ± 0.5
inch 5/16”5/32”
D7323
1.3
Diffuser
1.7

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TYPICAL GAS TRAIN LAYOUT
THE GAS TRAIN LEAVES THE FACTORY SET AT 3.5” wc.
ATTENTION
This gas train scope of supply meets the minimum controls requirements according to CSA Canada and
USA regulations. Any additional requirements needed to meet local codes are the responsibility of others.
VALVE LEGEND
1- Gas supply & flow direction of gas
2- Gas supply main shtoff manual valve (field supplied)
3- Gas supply pressure test point (field supplied)
4-Valve
5- Gas burner manifold test point
GAS SUPPLY PRESSURE RANGES:
NATURAL GAS PRESSURE:
min. 5” wc - max. 7” wc
LP PROPANE GAS PRESSURE
min. 12” wc - max. 14” wc
TOP VIEW OF GAS CONTROL
FIELD SUPPLIED RIELLO SUPPLIED
1 2 3 4 5
D7343

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INSTALLING THE BURNER
A) Burner Chassis
B) Combustion Head Assembly
1) Locking Nut
2) Mounting Plate surface
3) Insulation Gasket
Separate the combustion head of the burner from the chassis
(A) by removing the locknut (1). Install the combustion head
into the boiler.
Typical insertion depth, the front edge of the combustion head
is flush with the inside surface of the appliance mounting sur-
face (2).
Use this checklist prior to installation:
1) Check the input/output requirements of the appliance.
We suggest that the appliance output should be ap-
proximately 85% of input (85% efficiency).
2) Check the dimensions of the combustion chamber for correct sizing against the input requirements of the application.
3) Check that there is sufficient air for proper combustion and adequate ventilation.
Local codes should be followed. In the absence of local codes, refer to the NFPA Manual No. 31, CAN/CGA
B149.1 &. 2, ANSI Z223.1-1984 and Addendum 221.8A 1989.
4) Check that you have adequate space for servicing the equipment.
The Riello burner requires a minimum of 13 inches clear space behind the red cover.
This is required to allow easy removal of the cover for servicing and periodic maintenance.
5) Check that the chimney is of sufficient area to handle the exhaust gases.
Make sure the chimney is clear and there are no obstructions.
6) Barometric draft regulators must be of the double acting type, and must be installed in accordance with the
draft regulator manufacturer's instructions.
Single acting barometric dampers are not permitted.
For further clarification, refer to ANSI Z21.8-1984 and Z21.17A-1993.
IMPORTANT:
A vent shutoff system shall be applied to a barometric damper installed in the venting system at the
time of conversion of the appliance.
This will electrically disconnect the burner should there be a blockage in the vent (chimney).
The installer must identify the main electrical power switch and manual gas shut off valve, for emergency
conditions. The burner cover must be in place and secured before the burner is placed in operation.
13 2
AB

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INSTALLATION OF SEDIMENT TRAP AND BURNER SUPPLY
Gas piping to the burner must be 1/2-inch minimum. Install only a full-ported shutoff valve. The valve must be lo-
cated outside the appliance jacket, and the pressure gauge port must be accessible.
PRESSURE TEST-OVER 1/2PSIG.
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of the system at a test pressure in excess of 1/2PSIG.
PRESSURE TEST-1/2PSIG OR LESS
The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve
during any testing of the gas supply piping system at test pressures equal to or less than 1/2PSIG.

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FACTORY WIRING DIAGRAM
NOTE:
The SAFETY SWITCH on the 525SE CONTROL BOX is
equipped with a contact allowing remote sensing of burner
lockout.
The electrical connection is located on the CONTROL BOX ter-
minal 4 as indicated. Should burner lockout occur, the 525SE
CONTROL BOX will supply a power source of 120 Vac to the
connection terminal.
The maximum allowable current draw on this terminal is 1A.
Blue
White
Black
D4703
LEGEND
C- Capacitor
CN... - Connectors
E- Ignition electrode
MB - Terminal board
MV -Motor
PA - Air pressure switch
SO - Ionization probe
TB - Burner earth
TV - Transformer 24V
Brown
Control box
Remote
lock-out
signal
Fuse Fuse
Service
D4704
switch
Service
switch
120V controlled 24V controlled
Operating
control
TB
TB
Operating
control
FIELD WIRING DIAGRAM
IMPORTANT:
Terminal 4 is to be used only for the connection of a
remote sensing device.
If a neutral or ground lead is attached to terminal 4,
the control box will be damaged should lockout occur.