Riello GS10 Quick start guide

20008491 (1) - 11/2008
Installation, use and maintenance instructions
Instrucciones para la instalación, uso y mantenimiento
Forced draught gas burner
Quemador de gas de aire soplado
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
20007527 GS10 554T80
GB
E
One stage operation
Funcionamiento de una llama

1 20008491
GB
Index
1. Burner description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.1 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.4 Correlation between gas pressure and burner output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2 Probe-electrode positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.3 Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.4 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Combustion head setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2 Air damper setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3 Combustion check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.4 Burner start-up cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.5 Start-up cycle diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.6 Resetting the control box and using diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6. Faults / Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.1 Burner starting difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.2 Normal operation / Flame detection time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7. Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7.1 Burner identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7.2 Basic safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

20008491 2 GB
1 Burner description
Gas burner with one stage working.
³The burner is approved for intermittent operation as per Directive EN 676.
³The burner meets protection level of IP X0D (IP 40), EN 60529.
1 – Air damper
2 – Screws for fixing the air damper
3 – 7 pole socket for electrical supply
and control
4 – Cable grommet
5 – Screw for fixing the cover
6 – Air pressure switch
7 – 6 pole socket for gas train
8 – Control box
9 – Reset button with lock-out lamp
10 – Flange
NOTES:
– Gas train can be installed on the right or on the left of the burner.
– The cable grommet (4) Fig. 1 and the screw for fixing the cover (5) supplied with the burner, must be fitted
to the same side of the gas train.
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
7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
1.2 Accessory
Kit interface adapter RMG to PC Code 3002719
2
1
2
D4182
5 4 3
9
8
6
7
10
Fig. 1

3 20008491
GB
2 Technical description
2.1 Technical data
2.2 Overall dimensions
2.3 Firing rate
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 µF
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.
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°
Fig. 2
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
Fig. 3

20008491 4 GB
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).
3 Installation
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL
STANDARDS.
3.1 Boiler fixing
Boiler door must have a max. thickness of 90 mm, refractory lining
included.
If thickness is greater (max. 150 mm), a combustion head exten-
sion must be fitted, which is supplied separately.
OSeparate the combustion-head assembly from the burner body
by removing nut (1) and removing group (A) Fig. 6.
OFix the head assembly group (B) Fig. 6 to the boiler (2) insert the
supplied insulating gasket (3).
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
Fig. 4
WARNING
S7392
HINGE ASSEMBLY
Fig. 5
132
AB
D5108
Fig. 6

5 20008491
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
=
=
Fig. 7
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
Fig. 8

20008491 6 GB
3.4 Electrical wiring
KEY TO LAY-OUT
B4 – Working signal
CN3 – Connector
h1 – Hour counter
PG – Minimum gas pressure switch
S3 – Remote lock-out signal
(220V - 0.5 A max.)
T6A –Fuse
TB – Burner earth
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
X6 – 6 pin plug
X7 – 7 pin plug
XP6 – 6 pole socket
XP7 – 7 pole socket
Ionization probe Ignition transformer
Electrode
Motor
Capacitor
220V ~ 60Hz
Air pressure
White
Blue
Brown
Control box
D9128
Connector
Black
switch
CARRIED-OUT
IN THE FACTORY
³Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth
connection.
³The section of the conductors must be at least 1mm². (Unless requested otherwise by local standards and leg-
islation).
³The electrical wiring carried out by the installer must be in compliance with the rules in force in the country.
³Verify 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).
WARNING
TO BE DONE BY
THE INSTALLER

7 20008491
GB
Electrical wiring with gas leak control device (DUNGS VPS 504)
4 Working
4.1 Combustion head setting
Loose the screw (A) Fig. 9.
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 (Fig. 10) is to be used only
for initial settings, to improve air pressure
switch operation or improve combustion,
it may be necessary to reduce this set-
ting (set point toward position 0).
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
(220V - 0.5 A max.)
T6A –Fuse
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
220V ~ 60Hz
D4199
TO BE DONE BY
THE INSTALLER
S7015
C
A
B
Fig. 9
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
Fig. 10

20008491 8 GB
4.2 Air damper setting
The regulation of the air-rate is made by adjusting the air damper (1)
Fig. 11, after loosing the screws (2).
When the optimal regulation is reached, screw tight the screws (2).
4.3 Combustion check
CO2It 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 cur-
rent value, so that no check is needed.
However, if you want to measure the ioni-
zation current, you must open the
connector fitted to the red wire and insert a
microammeter.
4.4 Burner start-up cycle
When flame-failure occurs during working, shut down takes place within one second.
1
D5231
2
2
Fig. 11
Probe
Connector
Terminal board
of control-box
D5006
10
Fig. 12
3s40s40smax. 2s max. 2s
D4172
Lock-out, due to ignition failureNormal
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out
Fig. 13