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