Riello GAS 6/2 Quick start guide

Installation, use and maintenance instructions
2915868 (5) - 07/2015
Forced draught gas burner
Two stage operation
CODE MODEL TYPE
3752482 GAS 6/2 524 T80
GB

Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burner
Model: GAS 6/2
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 21.05.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

5868
1
TECHNICAL DATA
ELECTRICAL DATA
BURNER DESCRIPTION
STANDARDS EQUIPMENT
ACCESSORIES
• RADIO DISTURBANCE PROTECTION KIT code 3010386
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10
V/m) owing to the presence of an INVERTER, or in applications where the length of the thermostat
connections exceeds 20 metres, a protection kit is available as an interface between the control box and the
burner.
Thermal output 2
nd
stage 520 - 1050 kW - 447.200 - 903.000 kcal/h
Operation Two stages, high and low flame
Fuel Natural gas Pci 8 - 10 kWh/m
3
= 7000 - 8600 kcal/m
3
Minimum gas pressure For maximum output 12.3 mbar are needed measured at the coupling with nil pressure in the combustion chamber and gas with calorific value of
8600 kcal/m
3
Maximum gas pressure 150 mbar
Electrical supply 3N ~ 380V - 60 Hz
Fan motor rpm
V
kW
A
3500
220/380
1.5
5.5 - 3.2
Ignition transformer V1 - V2
I1 - I2 220 V - 1 x 8 kV 1.8 A - 30 mA
Electrical power consumption kW max 1.9
Quantity Description
1 Flange
1 Gasket
8 Screws
1 Flange gasket
1 Pipe fitting for gas train
1– Air damper controlling motor
2– Control box re-set button
3– Fair leads
4– Wiring terminal block
5– Re-set push-button of the
motor overload relay
6– Air pressure switch
7– Gas pressure test-point Fig. 1
6
3
4
5
2
1
S7530
7

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OVERALL DIMENSIONS
FIXING TO THE BOILER
FIRING RATE
COMBUSTION CHAMBER PRESSURE 2nd STAGE OUTPUT
(in compliance with DIN 4788)
Min. output at 1
st
stage: 300 kW - 258.000 kcal/h.
Boiler front-plate
drilling
* Length available with special blast tube to be separately required.
Burner
195
195
185 M12
410 770227
*
360
485
131
370
195
ø 175
Rp 2
S7515 S7520
D1785
Separate the combustion head from the
burner body by loosening the screws 1)
and 2) and withdrawing the group A) from
the holding bars 3).
Fix the group B) to the boiler front plate 4)
using the gasket 5) provided as accessory.
2 3 5 4
1
A B
S7499
kcal/h
mbar
D1795
kW

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MINIMUM GAS PRESSURE - OUTPUT
Pressure: detected at the pressure test-point 7) (fig. 1) with nil mbar into the combustion chamber.
Should the combustion chamber be pressurized, the pressure necessary will be that of the
graph plus the pressurization value.
Example: to obtain 800 kW it is necessary a gas pressure of 11 mbar and the combustion head set
as indicated at page 8.
If the combustion chamber is pressurized at 2 mbar, the pressure detected at the test-
point 7) is: 11 + 2 = 13 mbar.
If this value is too high, for very low gas pipework pressures, the gas gear 6) (page 8)
could be more open.
Do not decrease the pressure at the coupling under the values shown in the diagram.
Output: the maximum value is obtainable with gas Pci 8600 kcal/m
3
.
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
GAS SUPPLY
kW
kcal/h
mbar
D1796
5
10
8 11 5
94 3 12 2 1
S7534
5
6
1- Gas pipe line 7- Gas safety shut off valve
2- Cock valve 8- 1
st
stage gas shut off valve
3- Filter 9- 2
nd
stage gas shut off valve
4- Pressure stabilizer 10 - Burner
5- Pressure test-point 11 - Gas leak control device
6- Minimal gas pressure switch 12 -Isolator joint
7

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BURNER ELECTRICAL WIRING
(carried out in the factory)
P
CMV Fan motor contactor
F1 Protection against radio interference
K1 Relay
MB Burner terminal strip
MV Fan motor
PA Air pressure switch
RMG Control box
RT Thermal overload
SM Servomotor
SO Ionisation probe
TA Ignition transformer
TB Burner earth
A TTENTION
In the case of phase-phase feed, a
bridge must be fitted on the control box
terminal board between terminal 6 and
the earth terminal.
20107484

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ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK
(to be carried out by the installer)
NOTICE
- The electric wiringcarried out bythe installer must bein compliancewith the rules in force in the Country.
- Leads minimal section 1 mm
2
.
- Burners with non-stop operation. For safety reasons, this type of burner must be stopped every 24
hours of operation, by means of an hours-counter to be connected in series with the adjustment
devices.
FLAME MODULATION
The flame modulation is obtainable through the thermostat, controlling the second valve, connected
to the terminals 10 and 11.
2662
HRemote lock-out signal
H1 Remote lock-out signal of leak detection control device
MB Burner terminal strip
PG Minimum gas pressure swicth
TL Limit control device system
TR 2
nd
stage remote control system
TS Safety control device system
VS Gas safety shut off valve
VPS Leak detection control device
V1 1
st
stage gas shut off valve
V2 2
nd
stage gas shut off valve
XP7 Plug for leak detection control device
220V 380V
F Ampere T16 T10
S mm
2
1,5 1,5

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FIXING OF THE ELECTRICAL WIRES
All the electrical wires, which are to be connected to
the terminal block 4) (fig. 1) shall pass through the fair
leads 3) (fig. 1) as for this scheme.
1 - Three phase supply :fair lead Pg 21
2- Single phase supply : fair lead Pg 13.5
3- Adjustment thermostat : fair lead Pg 13.5
4- Safety thermostat : fair lead Pg 13.5
5- Gas train : fair lead Pg 13.5,
sheath ø 13
6-2
nd
stage thermostat : fair lead Pg 13.5
7 / 8 - Pre-sheared holes
Further prospective signals or controls can be connected to the burner wiring terminal board by
removing the metal weldnuts from the pre-sheared holes and inserting a commun fair lead for the
passage and the clamping of the leads.
NOTES
- Do not exchange the neutral wire with the phase (avoid the plug-pin connection).
- Carry out a safe earth connection.
- Check the stop of the burner, by opening the boiler thermostat and the burner lock-out, by
disconnecting the lead from the flame probe.
WARNING
When closing the burner on its slide-bars, pull towards the outside the high voltage cable and the
cable of the flame detection probe, till to little tension.
BURNER START-UP CYCLE
Air-purge: loosen the screw placed on the
minimal gas pressure switch mounted on the
gas train .
AIR PRESSURE SWITCH
The air pressure switch 6)(fig. 1) setting shall
be carried out after having set all other adjust-
ments of the burner and the air pressure
switch shall be at its lowest set-point.
When the burner is operating, increase the
adjustment pressure by turning - slowly -
clockwise the knob till reaching the burner
lock-out.
Thereafter, turn the knob anticlockwise for 1
mbar and repeat the burner start-up for
checking the regularity: if lock-out intervenes
turn the knob anticlockwise for 0.5 mbar.
S7535
Screw
Plug for pressure
Pressure switch
S7506
measure
1 ÷ 10
mbar
Adjustment knob
S7507

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PROBE - IGNITION ELECTRODE POSITION
CAUTION:
do not turn the ionization probe, maintain the drawing position; should it be close to the ignition
electrode, damage may occur to the control box amplifier.
COMBUSTION HEAD ADJUSTMENT
Two separate adjustments have to be made: air and
gas.
These adjustments can be carried out when the burn-
er is still open, during the installation (see page 2 -
Fixing to the boiler).
Air setting
Loosen the two screws 1) and move the internal part of
the combustion head 2) so that its rear edge 3) is coin-
cident with the desired set-point on the plate 4). Tighten
the screws 1).
Gas setting
Loosen the screw 5), move the ring 6) so that the point-
er 7) is coincident with the desired set-point 8). Tighten
the screw 5).
Attention:
the set-point number is the same for air and gas setting
and is given by the following diagram.
Example:
the burner is installed on a boiler
of 810 kW, assuming an efficiency
of 90% the burner output should
be 900 kW.
From the diagram it can be seen
that the air and gas settings for
this rating should be no. 5.
3 - 4 mm
2 - 4 mm
Probe position Ignition electrode position
S7524
2
5
6
8
1 3 4 7
S7496
kcal/h kW
Burner output
Set-point number = for air and gas
D1797

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COMBUSTION CHECKS
CO
2
It is advisable to not exceed 10% of CO
2
(gas with calorific value of 8600 kcal/m
3
), in order to avoid
the risk that small changes of the adjustments due, for instance, at draught variation, may cause com-
bustion with insufficient air and consequently formation of CO.
CO
For safety reason the value of 0.1% (one thousand p.p.m.) must not be exceeded.
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 a measurement of the ionization current is required, it is necessary to disconnect the
probe lead and insert a d.c. microamperometer.
MOTOR LOCK-OUT
This is caused by the terminal protector relay, in case of overloading, or by the lacking of the
phase. To clear, pushdown the appropriate knob, after having removed the protective cover.
BURNER START-UP
If during operation the flame shuts off, lock-out occurs within 1 sec
+ -
Lead Probe
S7511
Normal Lock-out because no ignition
Thermostat
Motor
Ignition transf.
1
st
valve
1
st
flame
2
nd
valve
2 s 40 s 10 s 2 s 40 s 3 s max.
D1799
2
nd
flame
Lock-out