Riello GS20 Quick start guide

Installation, use and maintenance instructions
Instrucciones de instalación, montaje y funcionamiento
2902754 (4) - 09/2014
Forced draught gas burner
Quemador de gas de aire soplado
One stage operation
Funcionamiento de una llama
CODE - CÓDIGO MODEL - MODELO TYPE - TIPO
3755683 GS20 556T80
GB
ES

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INDEX
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 Screw for fixing the cover. . . . . . . . . . . . . . . . . . . No. 1
Hinge. . . . . . . . . . . . . . . . . . . . . . No. 1 Pipe fitting for gas train . . . . . . . . . . . . . . . . . . . . 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
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 . . . . . . . . . . . . . . . . . . . . . . . 8
5. MAINTENANCE. . . . . . . . . . . . . . . . . . . 9
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 10
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
D4178
5 4 3
9
8
7
6
❱The burner meets protection level of IP X0D (IP 40), EN 60529.
❱
The burner is approved for intermittent operation as per Directive EN 676.

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2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD
Thermal power (1) 81 – 220 kW - 70,000 – 189,000 kcal/h
Natural gas (Family 2) Net heat value: 8 – 12 kWh/Nm
3
-7,000 – 10,340 kcal/Nm
3
Pressure: min. 20 mbar - max. 100 mbar
Electrical supply Single phase, 220V ±10% ~ 60Hz
Motor 220V / 2.2A
Capacitor 4 µF
Ignition transformer Primary 220V / 1.25A - Secondary 8 kV / 25 mA
Absorbed electrical power 0.43 kW
(1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.
FlangeBurner
350 120 389 170
155
33 67
45°
45°
ø
125
298
11
170
Rp 3/4
230
152
■
280
D4257
200
■
Combustion head extension, supplied separately.
D5212
0
Thermal power
0.8
1.6
2.4
3.2
4.0
4.8
70,000 90,000 110,000 130,000 kcal/h
80 120100 140 160 kW180
170,000
200 220
150,000 190,000
Pressure in the combustion
chamber – mbar

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2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, a gas head pressure of 6.9 mbar is measured with the combustion chamber at
0 mbar using gas G20 with a net heat value of 10 kWh/Nm
3
(8,570 kcal/Nm
3
).
3. INSTALLATION
THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.
3.1 BOILER FIXING
3
D5213
4
5
6
7
8
Thermal power
70,000 90,000 110,000 130,000 kcal/h
80 120100 140 160 kW180
170,000
200 220
150,000 190,000
Gas pressure in the
combustion head – mbar
Boiler door must have a max. thickness of 100 mm,
refractory lining included.
If thickness is greater (max. 260 mm), a combustion
head extension must be fitted, which is supplied
separately.
IMPORTANT
■
Separate the combustion-head assembly
from the burner body by removing nut (1) and
removing group (A).
■
Fix the head assembly group (B) to the boiler
(2) insert the supplied insulating gasket (3).
HINGE
S7393
ASSEMBLY
1 3 2
A B
D5097

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3.2 PROBE - ELECTRODE POSITIONING
3.3 GAS FEEDING LINE
D5104
Ignition electrode
WARNING 2 – 3 mm
Ionization probe
Probe
Electrode
3.7
~
47 mm
Diffuser
=
=
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
D5959
6432
9
5 7 8

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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 between terminal 6 and
the earth terminal.
ATTENTION
switch
ATTENTION:
❱
Do not swap neutral and phase over, follow the diagram shown care-
fully 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).
TO BE DONE BY
THE INSTALLER
CARRIED-OUT
IN THE FACTORY

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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.
4. WORKING
4.1 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 155 kW boiler with an efficiency of
90%, the burner input is about 172 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 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).
When the optimal regulation is reached, screw tight the screws (2).
Cable clamps
ACB A CB
A = ø 8 B = ø 11 C =
ø 16
D5052
S7015
C
A
B
1
D5231
2
2
Fig. 2
kcal/h kW
Set point
0 21 3 4
240
140
120
100
80
160
200,000
140,000
120,000
100,000
70,000
D5109
5
180
200
220
80,000
160,000
180,000
172

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4.3 COMBUSTION CHECK
CO
2
It is advisable to not exceed 10% of CO
2
(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.
4.4 BURNER START-UP CYCLE
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 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
Probe
Connector
Terminal board
of control-box
D5006
10
3s40s40smax. 2s max. 2s
D4172
Lock-out, due to ignition failureNormal
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out

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4.6 RESETTING THE CONTROL BOX AND USING DIAGNOSTICS
The control box features a diagnostics function through which any causes of malfunctioning are easily iden-
tified (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 mal-
function, 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 ...
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