Riello GS5 Quick start guide

2902773 (2) - 09/2014
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
3755281 GS5 552 T80
GB
E
One stage operation
Funcionamiento de una llama

2773 1GB
INDEX
1. BURNER DESCRIPTION
Gas burner with one stage working.
OThe burner meets protection level of IP 40, EN 60529.
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. 3
Hinge . . . . . . . . . . . . . . . . . . . . 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 of the electrical wiring . . . . . . . . . 6
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Air damper setting . . . . . . . . . . . . . . . . . 6
4.2 Combustion head setting . . . . . . . . . . . . 6
4.3 Combustion check . . . . . . . . . . . . . . . . . 7
4.4 Burner start-up cycle . . . . . . . . . . . . . . . 7
5. MAINTENANCE. . . . . . . . . . . . . . . . . . . 7
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . 7
1- Reset button with lock-out lamp
2- Control box
3- Air pressure switch
4- Screw fixing burner cover
5- Cable grommet
6- Terminal board
7- Cable clamp
8- Screw for fixing the air damper
9- Air damper
NOTES:
–Gas train can be installed on the right or on the left of the burner.
–The cable grommet (5) and the screw for fixing the cover (4) supplied with the burner, must be fitted to
the same side of the gas train.
D4290
9
5
8
4
1
Fig. 1
8
6 7
2
3

2773 2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 OVERALL DIMENSIONS
2.3 WORKING FIELD
Thermal power (1) 23 – 65 kW – 20,000 – 56,000 kcal/h
Natural gas (Family 2) Net heat value: 8 – 12 kWh/Nm3-7,000 – 10,340 kcal/Nm3
Pressure: min. 15 mbar - max. 100 mbar
Electrical supply Single phase, 220V ±10% ~60Hz
Motor 220V / 1A
Capacitor 2.5 F
Ignition transformer Primary 220V / 0.2A - Secondary 8 kV / 30 mA
Absorbed electrical power 1A
(1) Reference conditions: Temp. 20°C - Barometric pressure 1013 mbar – Altitude 0 m above sea level.
Flange Burner
272 100 295ø 170
130 28 48
ø 91
233
10
140
Rp 1/2
180
138
*125
D4293
*Lenght available using an extended head kit
==
45°
45°
Pressure in the combustion
chamber – mbar
0.8
0.2
0.4
0.6
1.0
D4291
Thermal power
0
20,000 30,000 40,000 50,000 kcal/h
20 4030 50 60 kW

2773 3GB
2.4 CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, a gas head pressure of 5.2 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
D4292
Thermal power
Gas pressure in the
combustion head – mbar
5
1
2
3
4
20.000 30.000 40.000 50.000 kcal/h
20 4030 50 60 kW
6
Boiler door must have a max. thickness of 80 mm,
refractory lining included.
If thickness is greater (max. 105 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).
HINGE
S7392
ASSEMBLY
132
AB
D4294

2773 4GB
3.2 PROBE - ELECTRODE POSITIONING
3.3 GAS FEEDING LINE
D5033
Ignition electrodeDiffuser
WARNING 2.5 – 3.5 mm
probe
Probe Electrode
Put the ceramic
near the diffuser disc
2
Do not turn the starting electrode but leave it as shown in the drawing; if the starting electrode is put near
the ionization probe, the amplifier of the control box might be damaged.
IMPORTANT
Ionization
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

2773 5GB
3.4 ELECTRICAL WIRING
NOTES:
– Do not exchange the neutral with the phase and connect exactly the above wiring.
– Wires of min. 1 mm2section. (Unless requested otherwise by local standards and legislation).
– Carry out a safe earth connection.
– 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.
– The electric wiring carried out by the installer must be in compliance with regulations in force in the
Country.
LEGEND
BO - Ionization probe
C- Capacitor
E- Elecrode
F- Fuse T6A
H3 - Remote lock-out signal
(220V - 0.5A max.)
MV - Motor
SG - Gas pressure switch
SL - Limit thermostat
SPA - Air pressure switch
ST - Safety thermostat
XB - Burner terminal board
XT - Burner earth
X1 - Probe connector
X2 - Connector
YS - Safety valve
Y1 - Adjustment valve
D4287
CONTROL BOX
525SE/5
CARRIED-OUT
BY THE INSTALLER
220V ~ 60Hz

2773 6GB
3.5 FIXING OF THE ELECTRICAL WIRING
All the electrical wires, which are to be connected into the terminal board (6, fig. 1, page 1) should pass
through the cable grommet (5, fig. 1).
All the electrical wires, which are to be connected into the terminal board must be gripped in the cable
clamps (7, fig. 1). This is molded on both sides to allow the use of various diameter cables.
4. WORKING
4.1 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).
4.2 COMBUSTION HEAD SETTING
(See fig. 3)
Loose the screw (A), move the elbow (B) so that the rear
plan of the coupling (C) coincides with the set point.
Tight the screw (A).
Example:
The burner is installed on a 40 kW boiler with an efficiency
of 90%, the burner input is about 44 kW using the diagram
below, 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 posi-
tion 0).
AC
BACB
A = ø8B=ø11 C = ø16
D5052
Cable clamps
1
D5231
2
2
Fig. 2
S7015
Fig. 3
A
B
C
02134
70
50
40
30
20
10
60
40,000
50,000
30,000
20,000
10,000
kcal/h kW
N° set point
D5137
60,000
5
44

2773 7GB
4.3 COMBUSTION CHECK
CO2
It 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 conse-
quently formation of CO.
CO
Not exceeding 100 mg/kWh (93 ppm).
IONIZATION CURRENT
The minimum current necessary for the control box operation is 5 µA.
The burner would normally have a higher current value than this, but if a check is required, open the con-
nector fitted in the red probe lead and insert a microammeter as shown.
4.4 BURNER START-UP CYCLE
When flame-failure occurs during working, shut down takes place within one second; and the cycle starts
again; a lock-out follows if the flame do not start.
5. 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
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the
burner 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).
6. 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 (1, 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.
Ionization probe
Connector
2
Control box
terminal board D5006
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valves
Flame
Lock-out
35s min. 5s max. 35s min. 5s max.
D5048

2773 8GB
BURNER STARTING DIFFICULTIES
OPERATING FAULTS
Re-cycle and lock-out may occur, because of : – Flame failure
– Ionization probe earthed
The burner goes to lock-out because of . . . . .: – Opening of the air pressure switch
Burner stop because of . . . . . . . . . . . . . . . . . .: – Gas pressure switch opening
DIFFICULTIES CAUSES
The burner goes through the
pre-purge period normally,
the flame ignites, but the
burner goes to lock-out with-
in 5 seconds after the igni-
tion.
The ionization probe is earthed or not in contact with the flame, or its
wiring to the control box is broken, or there is a fault on its insulation to
earth.
The connection of the phase and neutral leads has been inverted: you
need to exchange it.
The wiring to the earth is lacking or ineffective.
The burner goes to lock-out,
after the pre-purge period,
because the flame does not
ignite.
The valves are passing too little gas (low pressure in the gas pipe-
work).
The valves are defective.
It is irregular or the ignition arc is not present; in this case remove the
control box and insert it again, taking care that the electrode push-rod
is in the proper seat.
The pipe has not been purged from the air.
The burner does not pass
through the pre-purge period
and the control box goes to
lock-out.
The air pressure switch does not change over: it has failed or the air
pressure is too low (combustion head bad set).
Flame simulation exists (or the flame really lights).
The burner does not start at
the limit thermostat closing.
Gas is not supplied.
The gas pressure switch does not close its contact due to incorrect set-
ting or a faulty switch.
The air pressure switch is changed over to the operational position.
Before to replace the control box, check that short-circuits are not pres-
ent on the power-line: of the motor, of the gas electrovalve/s and on the
external signaling devices.
The burner continues to re-
peat the starting cycle with-
out going on lock-out.
This concerns a very particular irregularity, caused by the fact that the
gas pressure in the gas-mains lies very close to the value to which the
gas pressure switch has been set.
As a result of this, the sudden falling-off of pressure at the opening of
the valves causes the opening of the pressure switch.
However this only temporarily, because the valves immediately close
again, so then does the pressure switch, because the pressure builds-
up again the cycle to be repeated over and over.
This can be remedied by lowering the setting of the pressure switch.