Riello GS10D User manual

The Riello 40 GSD series of two stage gas burners, is a complete range of products developed
to respond to any request for home heating. The Riello 40 GSD series is available in two
different models, with an output ranging from 29 to 220 kW, divided in two different
structures.
All the models use the same components designed by Riello for the Riello 40 GSD series.
The high quality level guarantees safe working.
In developing these burners, special attention was paid to reducing noise, to the ease of
installation and adjustment, to obtaining the smallest size possible to fit into any sort of
boiler available on the market.
All the models are approved by the EN 676 European Standard and conform to European
Directives for EMC, Low Voltage, Machinery and Boiler Efficiency.
All the Riello 40 GSD burners are tested before leaving the factory.
TS0026UK02
TWO STAGE GAS BURNERS
RIELLO 40 GSD SERIES GS10D 29/41 ÷106 kW
GS20D 58/81 ÷220 kW

TECHNICAL DATA
Fuel / air dataElectrical dataEmissions
Approval
Model
Burner operation mode
Modulation ratio at max. output
run time
Working temperature
Net calorific value G20 gas
G20 gas density
G20 gas delivery
Net calorific value G25 gas
G25 gas density
G25 gas delivery
Net calorific value LPG gas
LPG gas density
LPG gas delivery
Fan
Air temperature
Electrical supply
Auxiliary electrical supply
Control box
Total electrical power
Auxiliary electrical power
Protection level
Motor electrical power
Rated motor current
Motor start up current
Motor protection level
Ignition transformer
Operation
Sound pressure
Sound power
CO emission
NOx emission
Directive
Conforming to
Certification
Servomotor type
s
kW
Mcal/h
°C min./max.
kWh/Nm3
kg/Nm3
Nm3/h
kWh/Nm3
kg/Nm3
Nm3/h
kWh/Nm3
kg/Nm3
Nm3/h
type
Max. °C
Ph/Hz/V
Ph/Hz/V
type
kW
kW
IP
kW
A
A
IP
type
V1 - V2
I1 - I2
dB(A)
W
mg/kWh
mg/kWh
Heat output
Since the Company is constantly engaged in the production improvement, the aesthetic and dimensional features,
the technical data, the equipment and the accessories can be changed.
This document contains confidential and proprietary information of RIELLO S.p.A. Unless authorised, this information
shall not be divulged, nor duplicated in whole or in part.
Reference conditions:
Temperature: 20 °C
Pressure: 1013,5 mbar
Altitude: 100 m a.s.l.
Noise measured at a distance of 1 meter.
GS10D GS20D
2
Two stage
--
BERGER
13
29/41 - 106 58/81 - 220
25/35 - 91 50/70 - 189
0 /40
10
0,71
2,9/4,1 - 10,6 5,8/8,1 - 22
8,6
0,78
3,4/4,8 - 12,3 6,7-9,4 - 25,6
25,8
2,02
1,1/1,6 - 4,1 2,2/3,1 - 8,5
Centrifugal with forward curve blades
40
1/50/230 ±10%
--
RMG 88.620A2
0,130 0,250
--
40
0,09 0,15
0,7 1,4
2,8 5,6
20
Separated from the control box
230 V - 8 kV
1,8 A - 30 mA
Intermittent (at least one stop every 24 h)
65 72
--
<40
≤120
90/396/EEC, 89/336/EEC, 73/23/EEC, 98/37/EEC, 92/42/EEC
EN 676
CE - 0063 AP6680

3
FIRING RATES
0
1
kW
50
0
10
20
30
40
2
3
4
5
40 60 80 100 120 140 160 180 200 220
6
60
40 60 80 100 120 140 160 180
0
0,5
kW
25
0
5
10
15
20
1
1,5
2
2,5
4020 60 80 100 120 140
3
30
20 40 60 80 100 120
Test conditions conforming to EN 676 standards:
Temperature: 20 °C
Pressure: 1013.5 mbar
Altitude: 100 m a.s.l.
Useful working field for choosing the burner
1st stage operating rate
GS20D
GS10D
hPa (mbar)
mm H2O
hPa (mbar)
mm H2O
Mcal/h
Mcal/h

FUEL SUPPLY
Depending on the gas output and the available pressure
in the supply line, you should check the correct gas train
to be adapted to the system requirements.
The gas train is Multibloc type, containing the main
components in a single unit and it can be fitted with the
valves seal control (as accessory).
GAS TRAIN
MULTIBLOC
MBZRDLE 405 - 407 - 410
L1 L
LEAK DETECTION CONTROL DEVICE
MULTIBLOC
The burners are set for fuel supply from either the right or left
hand sides.
Name
MBZRDLE 405
MBZRDLE 407
MBZRDLE 410
Code
3970084
3970537
3970534
Ø i
Rp 1/2”
Rp 3/4”
1”
Øo
Rp 1/2”(*)
Rp 3/4”
Rp 3/4”
X mm
321
371
405
Y mm
257
257
315
Z mm
120
120
145
W mm
46
46
55
(*) With 1/2” - 3/4” reduction nipple supplied.
5
9
6
78
123
4
P2
10
11 12
P1
Y
Z
X
W
The dimensions of the gas trains vary depending
on their construction features.
The following table shows the dimensions of the
gas trains that can be fitted to Riello 40 GSD burners,
intake and outlet diameters.
1
2
3
4
5
6
7
8
9
10
11
12
P1
P2
L
L1
Gas delivery pipe
Manual valve
Vibration damping joint
Gas pressure gauge
Filter
Gas pressure switch
Safety solenoid
Adjustment solenoid 1st and 2nd stage:
firing delivery adjustment (rapid opening)
maximum delivery adjustment (slow opening)
Pressure regulator
Leak detection control device for valves 7 and 8 (accessory)
Gas train-burner adapter
Burner
Combustion head pressure
Upstream pressure from the filter
Gas train supplied separately
To be performed by the installer
4
Øi
Øo

PRESSURE DROP DIAGRAM
The diagrams indicate the minimum pressure drop of the burners with the various gas trains that
can be combined with them; the value thus calculated represents the minimum required input
pressure to the gas train.
NATURAL GAS LPG
GS10D
0
GS10D
NATURAL GAS LPG
GS20D GS20D
For pressure levels different from those indicated above, please
contact Riello Burners Technical Office.
In LPG plants, Multibloc gas trains do not operate below 0 ° C.
They are only suitable for gaseous LPG (liquid hydrocarbons destroy
the seal materials).
note
Gas train
MBZRDLE 407
MBZRDLE 410
Code
3970537
3970534
Plug and
socket
•
•
Output
kW
≤180 (*)
(*) With natural gas.
Gas train
MBZRDLE 405
MBZRDLE 407
Code
3970084
3970537
Plug and
socket
•
•
Output
kW
≤80 (*)
-
(*) With natural gas.
ΔP
combustion head + gas train combustion head
Pressure loss
kcal/h X 1000
kW
0
29
mbar
M
B
Z
RD
L
E
4
0
7
G20 G25
kW
106
10 50 70 90 110
30 40 50 60 70 80 91,22510
ΔP
combustion head + gas train combustion head
Pressure loss
mbar
MBZRDLE 405
MBZRDLE 410
kW120
0
100 200
5
10
15
20
25
30
35
140 180160
220
10080 120 140 1891606040
58
40
kcal/h x 1000
0
5
15
25
30
35
20
10
40
45
G20 G25
80
MBZRDLE 4
07
50
ΔP
combustion head + gas train combustion head
Pressure loss
kcal/h X 1000
kW
0
29
mbar
M
BZ
RDL
E
40
7
LPG
kW
106
10 50 70 90 110
30 40 50 60 70 80 91,22510
MBZRDLE 405
4
2
6
10
8
ΔP
combustion head + gas train combustion head
Pressure loss
mbar
MBZRDLE 410
kW120
0
100 200
5
10
15
20
25
30
35
140 180160
220
10080 120 140 1891606040
58
40
kcal/h x 1000
LPG
80
MBZRDLE 407
50
2
8
10
6
4
2
6
10
8
4
12
12
14
12
5

SELECTING THE FUEL SUPPLY LINES
6
0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 1234510620
50 60 10080 200 400 800 1000600
3
6
9
12
15
22
30 45 61 76 95 122 152
V
PRESSURE DROP (mbar)
1234567810
20 30 40
PIPE DIAMETER
1,4
PIPE LENGTH (m)
1/2
3/4
1"
1" 1/2
6"
1" 1/4
4"
3"
2" 1/2
2"
= G as output N mc /h
f
1 - G20
= 0,62 - G25
1,18 - G31
{
f
V
15,34
Figure A
The following diagram enables pressure drop in a pre-existing gas line to be calculated and to select the
correct gas train.
The diagram can also be used to select a new gas line when fuel output and pipe length are known. The
pipe diameter is selected on the basis of the desired pressure drop. The diagram uses methane gas as
reference; if another gas is used, conversion coefficient and a simple formula (on the diagram) transform
the gas output to a methane equivalent (refer to figure A). Please note that the gas train dimensions must
take into account the back pressure of the combustion chamber during operations.
Control of the pressure drop in an existing gas line or selecting a new gas supply line.
The methane output equivalent is determined by the formula fig. A on the diagram and the conversion
coefficient.
Once the equivalent output has been determined on the delivery scale ( ), shown at the top of the
diagram, move vertically downwards until you cross the line that represents the pipe diameter; at this
point, move horizontally to the left until you meet the line that represents the pipe length.
Once this point is established you can verify, by moving vertically downwards, the pipe pressure drop
of on the botton scale below (mbar).
By subtracting this value from the pressure measured on the gas meter, the correct pressure value will
be found for the choice of gas train.
Example: - gas used G25
- gas output 9.51 mc/h
- pressure at the gas meter 20 mbar
- gas line length 15 m
- conversion coefficient 0.62 (see figure A)
- equivalent methane output = 9.51 = 15.34 mc/h
0.62
- once the value of 15.34 has been identified on the output scale ( ), moving vertically downwards you
cross the line that represents 1" 1/4 (the chosen diameter for the piping);
- from this point, move horizontally to the left until you meet the line that represents the length of 15 m
of the piping;
- move vertically downwards to determine a value of 1.4 mbar in the pressure drop botton scale;
- subtract the determined pressure drop from the meter pressure, the correct pressure level will be found
for the choice of gas train;
- correct pressure = ( 20-1.4 ) = 18.6 mbar
V
V
V

7
COMBUSTION HEAD
The combustion head in Riello 40 GSD burners is the result of an
innovative design, which allows combustion with low polluting
emissions, while being easy to adapt to all the various types of
boilers and combustion chambers.
Combustion head Flange
Simple adjustment
allows the internal
geometry of the
combustion head to be
adapted to the burner
output.
VENTILATION
Air suction
The different ventilation circuits always ensure low noise levels
with high performance of pressure and air delivery, inspite of their
compact size.
The burners are fitted with an adjustable air pressure switch,
conforming to EN 676 standards.
Air pressure switch
Dimensions of the flame
Example:
Burner thermal output
= 350 kW;
L
flame (m) = 1,2 m (medium value);
D
flame (m) = 0,6 m (medium value)
Burner output (kW)
Flame length (m)
Flame diameter (m)
0 200
1
100 300
2
400 500
00
0,5
1
D
L
L
max
L
min
D
max
D
min

ADJUSTMENT
All these models are two stage operation. The Riello 40 GSD series
of two stage burners allows
operating at both full and
reduced output, with
consequent reduction in
turning the burner on and off,
their giving better performance
to the boiler.
During stand-by, the air
damper is completely closed
(controlled by an electric
servomotor) and prevents heat
loss due to the flue draught.
BURNER OPERATION MODE
Air damper adjustment
Output Checked Variable
bar
°C
ON
OFF
time
time
ON
OFF
Two stage operation
1°st
2°st
This series burners are fitted with a new microprocessor control panel for the supervision during
intermittent operation.
For helping the commissioning and maintenance work, there are two main elements:
The lock-out reset button is the central operating element for resetting the burner control
and for activating / deactivating the diagnostic functions.
The multi-color LED is the central indication element for visual diagnosis and interface
diagnosis.
Both elements are located under the transparent cover of lock-out reset button, as showed below.
There are two diagnostic choices, for indication of operation and diagnosis of fault cause:
- visual diagnosis :
- interface diagnosis :
by the interface adapter and
a PC with dedicated software
or by a predisposed flue gas
analyzer (see paragraph
accessories).
Switch
Switch
COMPUTER
or
FLUE GAS
ANALYSER
INTERFACE ADAPTER
8

Indication of operation :
In normal operation, the various statues are
indicated in the form of colour codes according
to the table below.
The interface diagnosis (with adapter) can be
activated by pressing the lock-out button for
> 3 seconds.
Diagnosis of fault causes :
After lock-out has occurred, the red signal lamp is steady on. In this status, the visual fault diagnosis
according to the error code table can be activated by pressing the lock-out reset button for > 3 seconds.
The interface diagnosis (with adapter) can be activated by pressing again the lock-out button for > 3
seconds.
The blinkers of red LED are a signal with this sequence :
(e.g. signal with n ° 3 blinks – faulty air pressure monitor)
Lock-out
If the 1st stage flame does not light within the safety limit (3s max.)
the burner locks-out.
When flame-failure occurs during working, shut down takes place
within one second.
START UP CYCLE
Correct operation
0s The burner begins
the ignition cycle
0s-2s Safety time
2s-42s Pre-purge with
opened air damper
42s-45s Ignition 1st stage
52s Ignition 2nd stage.
TR
M
V1
2 s max.
Ignition
transformer
40 s
1
Lock-out
Normal
3 s max.
Lock-out due to ignition failure
2
V2
10 s
time (s) time (s)
3 s max. 2 s max.
40 s
Error code table
Possible cause of fault
No establishment of flame at the end of safety time : - faulty or soiled fuel valves
- faulty or soiled flame detector
- poor adjustment of burner, no fuel
- faulty ignition equipment
Faulty air pressure monitor
Simulation of flame on burner start up
Loss of flame during operation : - faulty or soiled fuel valves
- faulty or soiled flame detector
- poor adjustment of burner
Wiring error or internal fault
Blink code
Color code table
Operation statues
Stand-by
Pre-purging
Ignition phase
Flame OK
Poor flame
Undervoltage, built-in fuse
Fault, alarm
Extraneous light
Color code table
LED off
LED off
3 sec. 3 sec. 3 sec.
9

Electrical connections must
be made by qualified and
skilled personnel in
conformity with the local
regulations in force.
The 7-pole socket, the 4-pole
socket (for connecting the 2nd stage thermostat and the hour
meter) and the 6-pole socket (for connection to the gas train)
are connected to the equipement and fixed into the burner.
The 7 and 4-pin plugs are supplied for connection to the boiler.
WIRING DIAGRAMS
Appliance fitted with 7-pole, 6-pole
and 4-pole sockets
The following table shows the
supply lead sections and types
of fuse to be used.
TWO STAGE OPERATION
(*) Connect 2nd stage thermostat between
clamps T6 and T8 removing the bridge.
Electrical wiring with gas leak
control device (DUNGS VPS 504)
P
PG
V11V10
V12
PTS
FUSE
(*)
P
PG
V10V11
VPS
B5
N
L1
T6
T8
T7
V12
GS10D - GS20D
XP4 - 4 pole socket
XP6 - 6 pole socket
XP7 - 7 pole socket
X4 - 4 pin plug
X6 - 6 pin plug
X7 - 7 pin plug
B4 - 1st stage working signal
B5 - 2nd stage working signal
h1 - 1st stage hour counter
h2 - 2nd stage hour counter
PG - Minimum gas pressure switch
S3 - Remote lock-out signal
(230V - 0,5A max.)
TL - Limit thermostat
TR - 2nd stage thermostat
TS - Safety thermostat
V10 - Safety valve
V11 - 1st stage valve
V12 - 2nd stage valve
X6
321
321
X7
XP7
S3
N L
B4 B5
X4
XP4
X6
321
321
32 N Ph1
ϑ
B4 S3 T2 N L1 T1
TL
P
ϑ
h1
~
230V 50Hz
XP6
32 N Ph1
GS10D
Model
A
mm2
F
L
230V
T6
1
F = Fuse L = Lead section
GS20D
230V
T6
1
h1
B5T8 T7 T6
TR
P
ϑ
10

OVERALL DIMENSIONS (mm)
These models are distinguished by their reduced size, in relation to
the outputs achieved, which means they can be fitted to any boiler
actually on the market.
BURNER
PACKAGING
X
Z
Y
EMISSIONS
Special attention has been paid to noise reduction. All models are
fitted with sound-proofing material inside the cover.
Q
O
11
P
45°
45°
N
O11
R
45°
45°
N
Model NPO
GS10D
GS20D
160
170
185
170
-
155
130
-
-
200
QR
GS10D GS20D
11
A
D
FE
I
N
V
M
E
H
BURNER-BOILER MOUNTING FLANGE
Z
485
525
473
525
17
22
320
365
Model
GS10D
GS20D
XY kg
The emission data have been measured in the various models at
maximum output, in conformity with EN 676 standard.
NO
2
EMISSIONS
mg/kWh
50
60
70
80
90
100
110
120
130
GS20DGS10D
CO EMISSIONS
mg/kWh
10
15
20
25
30
35
GS20DGS10D
NOISE EMISSIONS
(sound pressure)
dB(A)
56
72
58
60
62
64
66
68
70
GS20DGS10D
74
Model AM DH
GS10D
GS20D
262
298
368
413
105
125
33
33
Rp 3/4”
Rp 3/4”
E
346
389
FZ
110
120
V
142
152
I
204
230
N
61
67

INSTALLATION DESCRIPTION
Installation, start up and maintenance must be carried
out by qualified and skilled personnel.
All operations must be performed as described in the
technical handbook supplied with the burner.
The burner is set in the factory on standard calibration
(minimum output). If necessary adjustments can be made
on the basis of the maximum output of the boiler.
Head setting is easy and aided by a graduated scale; a
test point allows reading the air pressure in the
combustion head.
The air damper position can be adjusted without
removing the burner cover.
The maintenance position is easily carried out by hinge
that joins the body of burner to the flange.
Riello 40 GSD burners are fitted with an air pressure
switch which, in accordance with EN 676 standards,
can be adjusted by the installer using a graduated
selector, on the basis of the effective working conditions.
BURNER SETTING
MAINTENANCE
12

BURNER ACCESSORIES
13
End cone with turbulator disk
Code
3000918
3000919
GS10D
GS20D
Burner
End cone with turbulator disk
Projection (mm)
+18
+23
Town gas kit
Kit code
3000891
3000893
GS10D
GS20D
Burner
Town gas transformation kit
Interface adapter kit
To connect the flame control panel to a personal computer for the transmission of operation, fault
signals and detailed service information, an interface adapter with PC software are available.
Burner Kit code
3002719
Interface adapter
GS10D - GS20D
Extended head kit
“Standard head” burners can be transformed into “extended head”
versions by using the special kit.
Below the KITS available for the various burners are listed, showing
the original and the extended lengths.
Kit code
3000864
3000873
GS10D
GS20D
Burner
Extended head kit
Extended
head length
(mm)
170
280
Standard
head length
(mm)
110
120
7-pin plug kit
If necessary a 7-pin plug kit is available (in packaging of n. 5 pieces).
Kit code
3000945GS10D - GS20D
Burner
7-pin plug kit
Kit code for
extended
head
Kit code for
standard
head
LPG kit
For burning LPG gas, a special kit is available to be fitted to the combustion head on the burner, as
shown in the following table:
3000884
3000886
GS10D
GS20D
Burner
LPG kit
3000884
3000886

SPECIFICATION
A special index guides your choice of boiler from the various models
available in the Riello 40 GSD series.
Below is a clear and detailed specification description of the product.
14
GAS TRAIN ACCESSORIES
Kit code
3010123GS10D - GS20D
Burner
Seal control kit
Seal control kit
To test the valve seals on the gas train, a special “seal control kit” is available.
Continuous ventilation kit for RMG control box
If the burner requires continuous ventilation in the stages without flame, a special kit is available as
given in the following table.
Kit code
3010094GS10D - GS20D
Burner
Continuous ventilation kit for RMG control box
Ground fault interrupter kit
A “Ground fault interrupter kit” is available as a safety device in case of electrical system fault. It is
supplied with burners with pin plug.
GS10D - GS20D
Burner Kit code
3001180
Ground fault interrupter kit
Size
DESIGNATION OF SERIES
GS10
Series: G
Optional variation: D Two stage output adjustment
D1/230/50
Fuel : S Natural gas
Electrical supply to the system : 1/230/50 1/230V/50Hz

Burner
Monoblock, gas burners, completely automatic, with two stage settings fitted with:
- Fan with forward curve blades
- Cover lined with sound-proofing material
- Air damper, completely closed in stand by, driven by an electric servomotor
- Air damper with 1st and 2nd stage adjustement
- Single phase electric motor 230 V, 50 Hz
- Combustion head fitted with:
- stainless steel head cone, resistant to high temperatures
- ignition electrodes
- ionisation probe
- gas distributor
- flame stability disk
- Adjustable air pressure switch, with graduated selector, to guarantee burner lock out in the case
of insufficient combustible air
- Protection filter against radio interference
- IP 40 electric protection level.
Gas train
Fuel supply line in the Multibloc configuration, fitted with:
- Filter
- Pressure stabiliser
- Minimum gas pressure switch
- Safety valve
- Two stage working valve with ignition gas output regulator.
Approval:
- EN 676 standard.
Conforming to:
- 90/396/EEC (gas)
- 73/23/EEC (low voltage)
- 89/336/EEC (electromagnetic compatibility)
- 92/42/EEC (efficiency)
- 98/37/EEC (machines).
Standard equipment:
- Insulating gasket
- Screws and nuts for fixing the flange to the boiler
- 7-pin plug
- 4-pin plug
- Hinge
- Cable grommet
- Instruction handbook for installation, use and maintenance
- Spare parts catalogue.
Available accessories to be ordered separately:
- Extended head kit
- End cone with turbolator disk
- Town gas kit
- LPG kit
- Interface adapter kit
- 7-pin plug kit
- Ground fault interrupter kit
- Continuous ventilation kit for RMG control box
- Seal control kit.
PRODUCT SPECIFICATION
AVAILABLE BURNER MODELS
GS10D 1/230/50
GS20D 1/230/50
15

ISO 9001 Cert. n. 0061
Since the Company is constantly engaged in the production improvement, the aesthetic and
dimensional features, the technical data, the equipment and the accessories can be changed.
This document contains confidential and proprietary information of RIELLO S.p.A.
Unless authorised, this information shall not be divulged, nor duplicated in whole or in part.
Lineagrafica.it
RIELLO S.p.A. - Via Ing. Pilade Riello, 5 - 37048 San Pietro di Legnago (VR) Italy
Tel. ++39.0442630111 - Fax ++39.044221980
Internet: http://www.rielloburners.com - E-mail: [email protected]