Riello Riello 40 GS5 LME Quick start guide

20037556 (1) - 04/2011
Installation, use and maintenance instructions
Forced draught gas burner
CODE MODEL TYPE
20037201 GS5 LME 37201X
GB
One stage operation

20037556 1GB
TECHNICAL DATA
For gas family 3 (LPG) ask for separate kit.
OThe burner meets protection level of IP X0D (IP 40) as EN 60529.
OBurner in compliance with EC Directives: CEM 2004/108/EC, Low Voltage 2006/95/EC.
OGas train according to EN 676.
NOTE
The grommet (3) and the hood fixing screw (4), supplied as accessories, should be assembled on
the same side as the gas train.
TYPE 552T1
Thermal power 18 – 58 kW – 15,500 50,000 kcal/h
Natural gas
(Family 2) Pci 8 – 12 kWh/Nm3– 7.000 10.340 kcal/Nm3
Pressure min. 10 mbar – max. 40 mbar
Electrical supply Single phase, 230V ± 10% ~50Hz/60Hz
Motor 0.75 A run current - 2800 rpm. - 294 rad/s
Capacitor 2 F
Ignition transformer primary 230V / 0.2A – secondary 8 kV
Absorbed electrical power 0.15 kW
COUNTRY DE DK - AT - GR - SE GB - IE LU NL
GAS CATEGORY II2ELL3B/P II2H3B/P II2H3P II2E3B/P II2L3B/P
1 – Air dampers
2 – Damper fixing screws
3 –Grommet
4 – Hood fixing screw
5 – Air pressure switch
6 –Motor
7 – Lockout light with
reset button
8 – Control box
9 – 6 pole socket for gas train
10 – Capacitor
11 – Air damper opening motor
12 – 7 pole socket
1
3
2
2
4
9
8
7
D11402
510 6
Fig. 1
11
12

20037556 2GB
DIMENSIONS
BURNER EQUIPMENT
ACCESSORIES
SOFTWARE DIAGNOSTIC KIT
A special kit is available that, by an optical link to a PC, shows the burner life together with oper-
ating hours, type and number of lockout, serial number, etc...
Do the following to display the diagnostic:
Connect the kit supplied separately to the appropriate socket on the control box.
The information is read after the software program in the kit is booted.
RESET KIT
The use of a connection available as an accessory is provided for remote resetting of the control
box.
Flange Burner
272 100 295 ø 170
130 28 48
45°
45°
ø 91
233
10
140
Rp 1/2
180
138
*125
D5066
Long combustion head upon request
*
Quantity Description
4
1
3
1
1
1
Screws with nuts
Insulating gasket
Screws for fixing the fairing
Grommet
Hinge
7 pin plug

20037556 3GB
BOILER FIXING
FIRING RATE
TEST BOILER
The firing rate has been defined according to EN 676 standard.
COMMERCIAL BOILERS
The burner-boiler matching is assured if the boiler conforms to EN 303 and the combustion chamber
dimensions are similar to those shown in the diagram EN 676.
For applications where the boiler does not conform to EN 303, or where the combustion chamber
is much smaller than the dimensions given in EN 676, please consult the manufacturers.
Separate the combustion head from the burner body
by removing the nut (1) and pulling back the group (A).
Fix the group (B) to the boiler plate (2), inserting the
supplied insulating gasket (3).
132
AB
D5067
HINGE ASSEMBLY
S7392
Pressure in combustion
chamber – mbar
Thermal power
D5135
0.8
0.2
0.4
0.6
20,000 30,000 40,000 50,000 kcal/h
1.0
15,000
020 4030 50 60 kW16

20037556 4GB
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
To obtain the maximum output, it is necessary to have 4.6 mbar measured on the pipe coupling,
with the combustion chamber at 0 mbar and gas G20 - Pci = 10 kWh/Nm3(8,570 kcal/Nm3).
GAS FEEDING LINE
The gas train is supplied separately, for its adjustment see the enclosed instructions.
Gas pressure at combustion
head in mbar
Thermal power
4
1
2
3
5
6D5136
20,000 30,000 40,000 50,000 kcal/h
20 4030 50 60 kW16
15,000
0
GAS TRAIN ACCORDING TO EN 676
MULTIBLOC CODICE CONNECTIONS USE
TRAIN BURNER
MBC 65 DLE 3970569 Rp 1/2 Rp 1/2 Natural gas and LPG
MBDLE 405 B01 3970530 Rp 1/2 Rp 1/2 Natural gas and LPG
1– Gas arrival pipe
2– Manual cock (supplied by the installer)
3– Gas pressure gauge (supplied by the installer)
4– Filter
5– Gas pressure switch
6– Safety valve
7– Pressure governor
8– Adjustment valve
M1 – Gas-supply pressure test point
M2 – Pressure coupling test point
1
D5069
M2
2 3 M1 4 5 6 7 8
D7279
678
MBC 65 DLE

20037556 5GB
ELECTRICAL WIRING
All the installation, maintenance and disassembly operations must be carried out with the
electricity supply disconnected.
The burner requires periodic maintenance carried out by a qualified and authorised technician
in conformity with legislation and local standards.
ATTENTION:
Do not swap neutral and phase over, follow the diagram shown carefully and carry out a
good earth connection.
The section of the conductors must be at least 1 mm2. (Unless requested otherwise by local stand-
ards 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
(IN) halting the burner at least once every 24 hours must be applied in series to limit thermostat (TL).
STANDARD ELECTRICAL WIRING (see page 13).
ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504)
WARNING
DANGER
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
(230V - 0.5 A max.)
T6A-Fuse
TL - Limit thermostat
TS - Safety thermostat
V10- Safety valve
V11- Adjustment valve
230V ~ 50Hz
D4199
TO BE DONE BY
THE INSTALLER

20037556 6GB
COMBUSTION HEAD ADJUSTMENT
Loosen 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 in a 40 kW boiler.
Considering efficiency of 90% the burner must
supply around 44 kW.
The diagram shows that for this
output the adjustment must be
made on notch 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 position 0).
AIR DAMPER ADJUSTMENT
The air damper opening motor (1) controls the damper
(6); the burner does not start until the damper (6) is com-
pletely open.
To adjust the fixed damper (4) it is necessary to:
loosen the screws (3 and 5) and rotate the damper as
far as the required point (2).
Once optimum adjustment has been reached, fix the
screws (3 and 5).
The adjustment of the damper varies in each single appli-
cation, so it is necessary to use a calibration tool to obtain
an efficient combustion result.
Important:
It is advisable to carry out an analysis of the combustion
values with the hood assembled.
S7015
C
A
B
Set point
02134
70
50
40
30
20
10
60
40,000
50,000
30,000
20,000
10,000
kcal/h kW D5137
60,000
5
44
D7305
1
5
4
3
2
6

20037556 7GB
COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC, the application of the burner on the boiler,
adjustment and testing must be carried out by observing the instruction manual of the boiler,
including verification of the CO and CO2concentration in the flue gases, their temperatures and
the average temperature of the water in the boiler. It is advisable to set the burner according to
the type of gas used and following the indications of the table:
PROBE - ELECTRODE POSITIONING
IMPORTANT
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.
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.
EN 676 AIR EXCESS: max. output 1.2 – min. output 1.3
GAS Theoretical max. CO2
0 % O2
Setting CO2% CO
mg/kWh NOx
mg/kWh
= 1.2 = 1.3
G 20 11.7 9.7 9.0 100 170
G 25 11.5 9.5 8.8 100 170
G 30 14.0 11.6 10.7 100 230
G 31 13.7 11.4 10.5 100 230
D5033
Ignition electrode
Diffuser
WARNING 2.5 – 3.5 mm
Probe
Probe Electrode
Put the ceramic
near the diffuser disc
2
Legend
C- Capacitor 100...470µF; DC 10...25V
ION- Ionization probe
M -Microammeter, Ri max. 5000 
S8270

20037556 8GB
AIR PRESSURE SWITCH
The air pressure switch is set after all other adjustments have been
made. Begin with the switch at the lowest setting. With the burner
function at the required power, turn the knob slowly in a clockwise di-
rection until burner lockout.
Then turn the knob anticlockwise to an extent that is around 20% of
the adjusted value and then check that the burner starts up properly.
If the burner locks out again turn the knob slightly in an anticlockwise
direction.
Attention:
In conformity with the standard, the air pressure switch must prevent
the air pressure falling below 80% of the adjusted value and the CO
in the flue gases exceeding 1% (10,000 ppm). To check this, insert a
combustion analyser in the flue, slowly reduce the burner air setting
(for example with a piece of cardboard) and verify that the burner
locks out before the CO value in the flue gases exceeds 1%.
D7404

20037556 9GB
0.1 BURNER START-UP CYCLE
Only when air damper is open the control box start with the cycle.
When flame-failure occurs during working, shut down takes place within one second.
0.2 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
WARNING
S8271
AL - Error message (alarm)
BV - Fuel valve
FS - Flame signal
GP - Gas pressure switch
LP - Air pressure switch
LR - Load controller
M- Fan motor
R- Control thermostat / pressurestat
SB -Safetylimiter
W- Limit thermostat / pressure switch
Z- Ignition transformer
AStart command (switching on by «R»)
B-B´ Interval for establishment of flame
COperating position of burner reached
C-D Burner operation (generation of heat)
DControlled shutdown by «R»
Burner will immediately be shut down
Burner control will immediately be ready
for new startup

20037556 10 GB
0.3 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 ...
(WITH KIT INTERFACE ADAPTER LME TO PC Code 3002719).
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

20037556 11 GB
The sequence of pulses issued by the control box identifies the possible types of malfunction, which are
listed in the table below.
1. 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).
SIGNAL PROBABLE CAUSE
2 pulses

The flame does not stabilise at the end of the safety time:
– faulty ionisation probe;
– faulty or soiled gas valves;
– neutral/phase exchange;
– faulty ignition transformer
– poor burner regulation (insufficient gas).
3 pulses

Minimum air pressure switch does not close:
– make sure VPS trips to produce lockout;
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– fan motor does not run;
– maximum air pressure switch operating.
4 pulses

Min. air pressure switch does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
5 pulses

Time out “LP”:
– “LP” is welded working position.
7 pulses

Loss of flame during operations:
– poor burner regulation (insufficient gas);
– faulty or soiled gas valves;
– short circuit between ionisation probe and earth.
10 pulses


– Wiring error or internal fault.

20037556 12 GB
2. 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 (9, 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.
BURNER STARTING DIFFICULTIES
Signal Problem Possible cause Recommended remedy
2 blinks Once the pre-purging
phase and safety time
have passed, the
burner goes into lock-
out without the appear-
ance of the flame
1 - The operation solenoid lets little . . . . . . .
gas through Increase
2 - One of the two solenoid valves does . . .
not open. Replace
3 - Gas pressure too low. . . . . . . . . . . . . . . . Increase pressure at governor
4 - Ignition electrode incorrectly adjusted . . . Adjust, see page 4
5 - Electrode grounded due to broken . . . . .
insulation Replace
6 - High voltage cable defective . . . . . . . . . . Replace
7 - High voltage cable deformed by high . . .
temperature Replace and protect
8 - Ignition transformer defective . . . . . . . . . Replace
9 - Incorrect valve or transformer . . . . . . . . .
electrical wiring Check
10 - Defective control box . . . . . . . . . . . . . . . . Replace
11 - A closed valve upline the gas train . . . . . Open
12 - Air in pipework . . . . . . . . . . . . . . . . . . . . . Bleed air
13 - Gas valves unconnected or with . . . . . . .
interrupted coil Check connections or replace coil
3 blinks The burner does not
switch on, and the
lockout appears
14 - Air pressure switch in operating position . Adjust or replace
The burner switches
on, but then stops in
lockout
- Air pressure switch inoperative due to
insufficient air pressure:
15 - Air pressure switch incorrectly adjusted. . Adjust or replace
16 - Pressure switch pressure test point . . . .
pipe blocked Clean
17 - Poorly adjusted head. . . . . . . . . . . . . . . . Adjust
18 - High pressure in the furnace . . . . . . . . . . Connect air pressure switch to fan
suction line
Lockout during pre-
purging phase 19 - Defective motor control contactor . . . . . . (only three-phase version) Replace
20 - Defective electrical motor . . . . . . . . . . . . Replace
21 - Motor lockout (defective electrical motor) Replace
4 pulses The burner switches
on, but then stops in
lockout
22 - Flame simulation . . . . . . . . . . . . . . . . . . . Replace the control box
Lockout when burner
stops 23 - Permanent flame in the combustion . . . . head or flame simulation Eliminate persistence of flame or replace control box
7 blinks The burner goes into
lockout immediately
following the appear-
ance of the flame
24 - The operation solenoid lets little . . . . . . .
gas through Increase
25 - Ionisation probe incorrectly adjusted. . . . Adjust, see page 4
26 - Insufficient ionisation (less than 5 A) . . . . Check probe position
27 - Earth probe . . . . . . . . . . . . . . . . . . . . . . . Withdraw or replace cable
28 - Burner poorly grounded. . . . . . . . . . . . . . Check grounding
29 - Phase and neutral connections inverted . Invert them
30 - Defective flame detection circuit . . . . . . . Replace the control box
Burner goes into lock-
out during operation 31 - Probe or ionisation cable grounded. . . . . Replace worn parts

20037556 13 GB
N.B.: If problems still occur after all of the above checks have been made, check the electrical connec-
tions on the plug and sockets, the damper and burner motor, gas control wiring ignition transformer
and external interlocks, if the burner still fails to function, replace the control box.
10 blinks The burner does not
switch on, and the
lockout appears
32 - Incorrect electrical wiring. . . . . . . . . . . . . Check
The burner goes into
lockout 33 - Defective control box . . . . . . . . . . . . . . . . Replace
34 - Presence of electromagnetic . . . . . . . . .
disturbances inthe thermostat lines Filter or eliminate
No blink The burner does not
start 35 - No electrical power supply. . . . . . . . . . . . Close all switches - Check connec- tions
36 - Air damper is not open with electrical . . .
power supply and limiter or safety control
device is closed
Check connector air damper adjust
or replace air damper
37 - A limiter or safety control device is open . Adjust or replace
38 - Line fuse blocked. . . . . . . . . . . . . . . . . . . Replace
39 - Defective control box . . . . . . . . . . . . . . . . Replace
40 - No gas supply . . . . . . . . . . . . . . . . . . . . . Open the manual valves between
contactor and train
41 - Mains gas pressure insufficient . . . . . . . . Contact your GAS COMPANY
42 - Minimum gas pressure switch fails . . . . .
to close Adjust or replace
43 - Servomotor fails to move to min. . . . . . .
ignition position Replace
The burner continues
to repeat the start-up
cycle, without lockout
44 - The gas pressure in the gas mains lies
very close to the value to which the mini-
mum gas pressure switch has been set.
The sudden drop in pressure after valve
opening causes temporary opening of the
pressure switch itself, the valve immedi-
ately closes and the burner comes to a
halt. Pressure increases again, the pres-
sure switch closes again and the ignition
cycle is repeated. And so on
Reduce the minimum gas pressure
switch intervention pressure.
Replace the gas filter cartridge.
Ignition with pulsations 45 - Poorly adjusted head. . . . . . . . . . . . . . . . Adjust. See page 6
46 - Ignition electrode incorrectly adjusted . . . Adjust, see page 4
47 - Incorrectly adjusted fan air damper: . . . .
too much air Adjust
48 - Output during ignition phase is too high . Reduce
Burner stops with air
damper open 49 - Defective servomotor. . . . . . . . . . . . . . . . Replace
Signal Problem Possible cause Recommended remedy

STANDARD ELECTRICAL WIRING
20037556 14
2
Sheet no
/1.A1
Co-ordinates
1
2
INDEX
3
Indication of references
LME Operational layout
Indication of references
4
Elecrical connections set by installer

20037556 15 GB
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20037556 17
KEY TO ELECTRICAL LAYOUT
A– Control box
B– Suppresor
B4 – Working signal
C– Capacitor
CN1– Connector
h1 – Hour counter
IN – Switch
ION – Ionisation probe
Y– Valve assembly
PA – Air pressure switch
PGMin– Minimum gas pressure switch
Q2 – Main disconnecting swich
S3 – Remote lock-out signal (230V - 0.5 A max.)
SM – Servomotor
T6A–Fuse
TA – Ignition transformer
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve
XM – Motor connector
X6 – 6 pole plug
X7 – 7 pole plug
XP6– 6 pole socket
XP7– 7 pole socket
XSM– Servomotor connector
XTM– Burner ground (earth) connection
XTZ– Burner shelf
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.
WARNING

Subject to modifications
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.riello.it
http:// www.rielloburners.com