Riello GAS 4 Quick start guide

Installation, use and maintenance instructions
2915860 (4) - 07/2015
Forced draught gas burner
One stage operation
CODE MODEL TYPE
3751682 GAS 4 516 T80
GB

Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burner
Model: GAS 4
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 21.05.2015 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini

5860
1
TECHNICAL DATA
BURNER DESCRIPTION
OVERALL DIMENSIONS
Thermal output
180 - 470 kW 154.800 - 404.200 kcal/h
Fuel
Natural gas Pci 8 - 10 kWh/m
3
= 7000 - 8600 kcal/m
3
Minimum gas pressure
For maximum output 9.8 mbar are needed measured at the coupling
with nil pressure in the combustion chamber and gas with calorific val-
ue of 8600 kcal/m
3
Maximum gas pressure 150 mbar
Electrical supply Three phase 380 V + 10% - 10% ~ 60Hz with neutral
Motor 1.5 A / 380 V
Ignition transformer Primary: 1.8A / 220V - Secondary: 1 x 8 kV - 30 mA
Absorbed electrical power 0.6 kW
1– Air shutter control
2– Air shutter lock-nut
3– Control box re-set button
4– Fair leads
5– Wiring terminal block
6– Re-set push-button of the motor
overload relay
7– Air pressure switch
8– Gas pressure test-point Fig. 1
8
7
5
4
3
2 1
S7513
6
Boiler front-plate
drilling Burner
160
160
165 M10
D1785
410 610187
*
320
397
97
292
165
ø 150
Rp 1 1/2
S7497 S7498
* Length available with special blast tube to be separately required.

5860
2
STANDARD EQUIPMENT
ACCESSORIES
• RADIO DISTURBANCE PROTECTION KIT code 3010386
If the burner is installed in places particularly subject to radio disturbance (emission of signals exceeding 10
V/m) owing to the presence of an INVERTER, or in applications where the length of the thermostat
connections exceeds 20 metres, a protection kit is available as an interface between the control box and the
burner.
FIXING TO THE BOILER
GAS SUPPLY
Quantity Description
1 Flange
1 Gasket
8 Screws
1 Flange gasket
Separate the combustion head from the
burner body by loosening the screws 1)
and 2) and with drawing the group A)
from the holding bars 3).
Fix the group B) to the boiler front plate 4)
using the gasket 5) provided as acces-
sory.
2 3 5 4
1
A B
S7499
1- Gas pipe line 7- Gas shut off valve
2- Cock valve 8- Burner
3- Filter 9- Gas safety shut off valve
4- Pressure stabilizer 10 - Gas leak control device
5- Pressure test-point 11 - Isolator joint
6- Minimal gas pressure switch
5
8
7 9 5
6
4 3
10
2 1
S7514
11
5

5860
3
WORKING RANGE
COMBUSTION CHAMBER PRESSURE - MAXIMUM OUTPUT (in compliance with DIN 4788)
MINIMUM GAS PRESSURE - OUTPUT
Pressure: detected at the pressure test-point 7) (fig. 1) with nil mbar into the combustion chamber.
Should the combustion chamber be pressurized, the pressure necessary will be that of the
graph plus the pressurization value.
Example: to obtain 350 kW it is necessary a gas pressure of 7 mbar and the combustion head set as
indicated at page 7.
If the combustion chamber is pressurized at 2 mbar, the pressure detected at the test-point
7) is: 7 + 2 = 9 mbar.
If this value is too high, for very low gas pipework pressures, the gas gear 6) (page 7) could
be more open.
Do not decrease the pressure at the coupling under the values shown in the diagram.
Output: the maximum value is obtainable with gas Pci 8600 kcal/m
3
.
CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT
kW
kcal/h
mbar
D1786
kW
kcal/h
mbar
D1787

5860
4
BURNER ELECTRICAL WIRING
(carried out in the factory)
20107483
CMV Fan motor contactor
F1 Protection against radio interference
K1 Relay
MB Burner terminal strip
MV Fan motor
PA Air pressure switch
RMG Control box
RT Overload
SO Ionisation probe
TA Ignition transformer
TB Burner earth
A TTENTION
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.

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5
ELECTRICAL CONNECTIONS TO THE WIRING TERMINAL BLOCK
(to be carried out by the installer)
Notice
- Leads minimal section 1 mm
2
.
- TheelectricwiringcarriedoutbytheinstallermustbeincompliancewiththerulesinforceintheCountry.
FIXING OF THE ELECTRICAL WIRES
All the electrical wires, which are to be connected to the termi-
nal block 5) (fig. 1) shall pass through the fair leads 4) (fig. 1) as
for this scheme.
1- Single phase supply : fair lead Pg 13.5
2- Adjustment thermostat : fair lead Pg 13.5
3- Safety thermostat : fair lead Pg 13.5
4- Gas train : fair lead Pg 13.5,
sheath ø 13
5 / 6 / 7 /8 - Pre-sheared holes
Further prospective signals or controls can be connected to the burner wiring terminal board by removing
the metal weldnuts from the pre-sheared holes and inserting a commun fair lead for the passage and the
clamping of the leads.
NOTES
- Do not exchange the neutral wire with the phase (avoid the plug-pin connection).
- Carry out a safe earth connection.
- Check the stop of the burner,by opening the boiler thermostat and the burner lock-out, by disconnecting
the lead from the flame probe.
WARNING
When closing the burner on its slide-bars, pull towards the outside the high voltage cable and the cable
of the flame detection probe, till to little tension.
HRemote lock-out signal
H1 Remote lock-out signal of leak
detection control device
IN Burner manual stop switch
MB Burner terminal strip
PG Min. gas pressure switch
TL Limit control device system
TS Safety control device system
VPS Leak detection control device
VR Gas adjustment valve
VS Gas safety valve
XP7 Plug for leak detection control device
D2657
F Ampere T6
S mm
2
1
S7505

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6
BURNER START-UP CYCLE
Air-purge: loosen the screw placed on the minimal gas pressure switch mounted on the gas train .
AIR PRESSURE SWITCH 7) (fig.1)
The air pressure switch setting shall be carried out after having
set all other adjustment of the burner and the air pressure switch
shall be at its lowest set-point.
When the burner is operating, increase the adjustment pressure
by turning - slowly - clockwise the knob till reaching the burner
lock-out.
Thereafter, turn the knob anticlockwise for 1 mbar and repeat the
burner start-up for checking the regularity: if lock-out intervenes
turn the knob anticlockwise for 0.5 mbar.
CAUTION:
do not turn the ionization probe, maintain the drawing position; should it be close to the ignition elec-
trode, damage may occur to the control box amplifier.
Screw
Plug for pressure measure
Pressure switch
S7506
1 ÷ 10
mbar
Adjustment knob
S7507
0 - 1 mm
2 - 4 mm
Probe position Ignition electrode position
S7508

5860
7
COMBUSTION HEAD ADJUSTMENT
Two separate adjustments have to be made: air and gas.
These adjustments can be carried out when the burner is still open, during the installation (see page 2
- Fixing to the boiler).
Air setting
Loosen the two screws 1) and move the internal
part of the combustion head 2) so that its rear
edge 3) is coincident with the desired set-point
on the plate 4). Tighten the screws 1).
Gas setting
Loosen the screw 5), move the ring 6) so that the
pointer 7) is coincident with the desired set-point
8). Tighten the screw 5).
Attention:
the set-point number is the same for air and gas
setting and is given by the following diagram.
Example:
the burner is installed on a boiler of 270 kW, assuming an efficiency of 90% the burner output should
be 300 kW.
From the diagram it can be seen that the air and gas settings for this rating should be no. 3.
25681
3
4
7
S7518
kcal/h kW
Burner output
Set-point number = for air and gas
D1792

5860
8
COMBUSTION CHECKS
CO
2
It is advisable to not exceed 10% of CO
2
(gas with calorific value of 8600 kcal/m
3
), in order to avoid
the risk that small changes of the adjustments due, for instance, at draught variation, may cause com-
bustion with insufficient air and consequently formation of CO.
CO
For safety reason the value of 0.1% (one thousand p.p.m.) must not be exceeded.
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 a measurement of the ionization current is required, it is necessary to disconnect the
probe lead and insert a d.c. microamperometer.
MOTOR LOCK-OUT
This is caused by the thermal protector relay, in case of overloading, or by the lacking of the phase. To
clear, pushdown the appropriate knob, after having removed the protective cover
BURNER START-UP
If during operation the flame shuts off, lock-out occurs within 1 sec.
+ -
Lead Probe
S7511
Normal Lock-out because no ignition
Thermostat
Motor
Ignition transf.
Start valve
Adjust. valve
Lock-out
2 s 40 s 10 s 2 s 40 s 3 s max.
D1798

5860
9
BURNER STARTING DIFFICULTIES AND THEIR CAUSES
Signal Problem Possible cause Recommended remedy
2 blinks Once the pre-purg-
ingphase andsafety
time have passed,
the burner goes into
lockout without the
appearance 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
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 posi-
tion 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 Theburner goes into
lockout immediately
following the
appearance of the
flame
24 - The operation solenoid lets little gas.
through Increase
25 - Ionisation probe incorrectly adjusted. Adjust
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
lockout during oper-
ation
31 - Probe or ionisation cable grounded. . Replace worn parts

5860
10
10 blinks The burner does not
switch on, and the
lockout appears
32 - Incorrect electrical wiring. . . . . . . . . . Check
Theburner goes into
lockout 33 - Defective control box. . . . . . . . . . . . . Replace
34 - Presence of electromagnetic . . . . . .
disturbances in the thermostat lines
35 - Presence of electromagnetic. . . . . . .
disturbance
Filter or eliminate
Use the radio disturbance pro-
tection kit
No blink The burner does not
start 36 - No electrical power supply. . . . . . . . . Close all switches - Check con- nections
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
The burner contin-
ues to repeat the
start-up cycle, with-
out lockout
43 - The gas pressure in the gas mains
lies very close to the value to which
the minimum gas pressure switch has
been set. The sudden drop in pres-
sure after valve opening causes tem-
porary opening of the pressure switch
itself, the valve immediately closes
and the burner comes to a halt. Pres-
sure increases again, the pressure
switch closes again and the ignition
cycle is repeated. And so on
Reduce the minimum gas pres-
sure switch intervention pres-
sure. Replace the gas filter
cartridge.
Ignition with pulsa-
tions 44 - Poorly adjusted head. . . . . . . . . . . . . Adjust
45 - Ignition electrode incorrectly adjusted Adjust
46 - Incorrectly adjusted fan air damper:
too much air Adjust
47 - Output during ignition phase is too
high Reduce
Signal Problem Possible cause Recommended remedy

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11
NORMAL OPERATION / FLAME DETECTION TIME
The control box has a further function to guarantee the correct burner operation (signal: GREEN LED perma-
nently on).
To use this function, wait at least ten seconds from the burner ignition and then press the control box button for
a minimum of 3 seconds.
After releasing the button, the GREEN LED starts flashing as shown in the figure below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will measure the probe DETECTION TIME since the opening of gas valves, according to
the following table:
KIT INTERFACE ADAPTER RMG TO PC Code 3002719
BURNER START UP CYCLE DIAGNOSTICS
During start-up, indication is according to the following table:
SIGNAL FLAME DETECTION TIME This is updated in every burner start-up.
Once read, the burner repeats the start-up
cycle by briefly pressing the control box
button.
WARNING
If the result is > 2s, ignition will be retarded.
Check the adjustment of the hydraulic brake
of the gas valve, the air damper and the
combustion head adjustment.
1 blink 0.4s
2 blinks 0.8s
6 blinks 2.8s
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
▲ ❑ ▲ ❑ ▲ ❑ ▲ ❑ ▲ ❑ ▲
Key: ❍Off ● Yellow ❑Green ▲Red
GREEN LED on
wait at least 10s Press button for > 3s signal signal
Interval
3s

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12
OPERATING FAULT DIAGNOSTICS
The control box has a self-diagnostic system, which easily allows identifying the operating faults (RED LED
signal).
ITo use this function, wait at least ten seconds from the safety lock out, and then press the reset button for a
minimum of 3 seconds.
After releasing the button, the RED LED starts flashing as shown in the diagram below.
The pulses of the LED constitute a signal spaced by approximately 3 seconds.
The number of pulses will provide the information on the possible faults, according to the table below:
SIGNAL PROBABLE CAUSE
2 flashes 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 flashes Min. air pressure switch does not close:
– air pressure switch faulty;
– air pressure switch incorrectly regulated;
– max. air pressure switch triggered (if installed).
4 flashes Min. air pressure switch does not open or light in the chamber before firing:
– air pressure switch faulty;
– air pressure switch incorrectly regulated.
7 flashes Loss of flame during operations:
– poor burner regulation (insufficient gas);
– faulty or soiled gas valves;
– short circuit between ionisation probe and earth.
8 flashes – Not used.
10 flashes – Wiring error or internal fault.
RED LED on
wait at least 10 s Press button for > 3 s Signal Signal
Interval
3 s

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