Professional Documents
Culture Documents
Riello 40 FS20
Riello 40 FS20
Riello 40 FS20
One-stage operation
1 Declarations................................................................................................................................................................................ 3
5 Installation ................................................................................................................................................................................ 12
5.1 Notes on safety for the installation ............................................................................................................................ 12
5.2 Instructions to avoid burnout or bad combustion of the burner ................................................................................. 12
5.3 Handling .................................................................................................................................................................... 12
5.4 Preliminary checks .................................................................................................................................................... 13
5.4.1 Control of the supply ................................................................................................................................................. 13
5.4.2 Control of burner characteristics ............................................................................................................................... 13
5.5 Operating position ..................................................................................................................................................... 13
5.6 Securing the burner to the boiler ............................................................................................................................... 14
5.6.1 Hinge installation ....................................................................................................................................................... 14
5.7 Positioning the probe - electrode............................................................................................................................... 14
5.8 Combustion head adjustment.................................................................................................................................... 15
5.9 Air damper adjustment .............................................................................................................................................. 15
5.10 Gas feeding ............................................................................................................................................................... 16
5.10.1 Gas feeding line ........................................................................................................................................................ 16
5.10.2 Gas train.................................................................................................................................................................... 16
5.10.3 Gas train installation.................................................................................................................................................. 17
5.11 Electrical wiring ......................................................................................................................................................... 18
5.11.1 Notes on safety for the electrical wiring..................................................................................................................... 18
5.11.2 Standard wiring diagram ........................................................................................................................................... 19
5.11.3 Electrical wiring with valve seal control (DUNGS VPS 504)...................................................................................... 20
5.11.4 Ionisation current....................................................................................................................................................... 20
7 Maintenance.............................................................................................................................................................................. 23
7.1 Notes on safety for the maintenance......................................................................................................................... 23
7.2 Maintenance programme .......................................................................................................................................... 23
7.2.1 Maintenance frequency ............................................................................................................................................. 23
7.2.2 Safety test - with gas ball valve closed...................................................................................................................... 23
20063809
1 GB
Contents
20063809
2 GB
Declarations
1 Declarations
EC-0476CT2714
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 21.04.2018 Executive General Manager Research & Development Director
RIELLO S.p.A. - Burner Department RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
20063809
3 GB
Information and general warnings
20063809
4 GB
Information and general warnings
2.1.4 Delivery of the system and the instruction The system supplier must carefully inform the user about:
manual – the use of the system;
– any further tests that may be required before activating the
When the system is delivered, it is important that:
system;
the instruction manual is delivered to the user by the system
– maintenance, and the need to have the system checked at
manufacturer, with the recommendation to keep it in the
least once a year by a representative of the manufacturer
room where the heat generator is to be installed.
or another specialised technician.
The instruction manual shows:
To ensure a periodic check, the manufacturer recom-
– the serial number of the burner;
mends the drawing up of a Maintenance Contract.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
20063809
5 GB
Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with the type and pressure of the fuel, the voltage and frequency of the
current regulations and directives, applying the known technical electrical power supply, the minimum and maximum deliveries for
rules of safety and envisaging all the potential danger situations. which the burner has been regulated, the pressurisation of the
It is necessary, however, to bear in mind that the imprudent and combustion chamber, the dimensions of the combustion cham-
clumsy use of the equipment may lead to situations of death risk ber and the room temperature must all be within the values indi-
for the user or third parties, as well as the damaging of the burner cated in the instruction manual.
or other items. Inattention, thoughtlessness and excessive confi- Modification of the burner to alter its performance and desti-
dence often cause accidents; the same applies to tiredness and nations is not allowed.
sleepiness. The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
It is a good idea to remember the following:
be quickly eliminated.
The burner must only be used as expressly described. Any
Opening or tampering with the burner components is not
other use should be considered improper and therefore dan-
allowed, apart from the parts requiring maintenance.
gerous.
Only those parts envisaged by the manufacturer can be
replaced.
In particular:
The manufacturer guarantees safety and proper
it can be applied to boilers operating with water, steam, diather-
functioning only if all burner components are intact
mic oil, and to other uses expressly foreseen by the manufactur-
and positioned correctly.
er; WARNING
The user is the person, body or company that has acquired the In addition:
machine and intends to use it for the specific purpose. He is re-
must take all the measures necessary to pre-
sponsible for the machine and for the training of the people work-
vent unauthorised people gaining access to
ing around it.
the machine;
The user: the user must inform the manufacturer if
undertakes to entrust the machine exclusively to suitably faults or malfunctioning of the accident pre-
trained and qualified personnel; vention systems are noticed, along with any
undertakes to inform his personnel in a suitable way about presumed danger situation;
the application and observance of the safety instructions. personnel must always use the personal pro-
With that aim, he undertakes to ensure that everyone knows tective equipment envisaged by legislation
the use and safety instructions for his own duties. and follow the indications given in this man-
Personnel must observe all the danger and caution indica- ual.
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
20063809
6 GB
Technical description of the burner
Range: RIELLO 40 F
Size
F S 20 1/230/50
BASIC DESIGNATION
EXTENDED DESIGNATION
20063809
7 GB
Technical description of the burner
Flange Burner
170 350 120 389
° 45
45 °
Ø 125
11
Rp 3/4
298
152
170
230
5
15
0
20
33 67
D4257
Fig. 1
20063809
8 GB
Technical description of the burner
4.0
Combustion chamber
pressure - mbar
3.2
2.4
1.6
0.8
0
80 100 120 140 160 180 200 220 kW
4.6.1 Test boiler For applications where the boiler does not conform to EN 303, or
The firing rate has been defined according to EN 676 standard. where the combustion chamber is much smaller than the dimen-
sions given in EN 676, please consult the manufacturers.
To obtain the maximum burner output (Fig. 3), 6.9 mbar meas-
ured at the pipe coupling are needed (M2, Fig. 14 on page 16)
with the combustion chamber at 0 mbar and gas G20 - Ncv = 10
kWh/Nm3 (8,570 kcal/Nm3).
D5213
8
combustion head - mbar
7
Gas pressure at
3
80 100 120 140 160 180 200 220 kW
20063809
9 GB
Technical description of the burner
20066434
Fig. 4
1 Air damper 12 Flange
2 Damper fixing screws 13 Pressure test point (+)
3 Pressure test point (-) 14 Combustion head
4 Cover fixing screw 15 Electrode-probe
5 Air pressure switch 16 Gas train elbow
6 Motor 17 7-pole socket for power supply and remote controls
7 Lock-out signal with reset button
The cable grommet, supplied as standard, should
8 Control box be assembled on the same part as the gas train.
9 6 pole socket for gas train
Check that it is possible to access the cover fixing
10 Capacitor WARNING
screws once the burner has been installed. If nec-
11 Grommet essary, replace them with the ones supplied as
standard.
20063809
10 GB
Technical description of the burner
Warnings
To avoid accidents, material or environmental
damage, observe the following instructions!
The control box is a safety device! Avoid opening
WARNING
or modifying it, or forcing its operation. Riello
S.p.A. cannot assume any responsibility for dam-
age resulting from unauthorised interventions!
20063809
11 GB
Installation
5 Installation
After carefully cleaning all around the area where the burner will
The installation of the burner must be carried out
be installed, and arranging the correct lighting of the environ-
by qualified personnel, as indicated in this manual
ment, proceed with the installation operations.
and in compliance with the standards and regula-
WARNING tions of the laws in force.
All the installation, maintenance and disassembly
operations must be carried out with the electricity Combustion air inside the boiler must be free from
supply disconnected. hazardous mixes (e.g.: chloride, fluoride, halo-
DANGER
gen); if present, it is highly recommended to carry
DANGER out cleaning and maintenance more frequently.
1 The burner can not be installed outside as it is suitable for are big enough to ensure the required air change; In any
operation in closed rooms only. case, check that when the burner stops the extractors do
2 The premises the burner operates in must have openings not draw hot fumes from pipes through the burner.
for the air need for the combustion. 4 When the burner is stopped, the smoke pipe must be kept
To be sure about this, you have to control CO2 and CO in open and a natural draft created in the combustion chamber.
the exhaust gases with all the windows and doors closed. If the smoke pipe is closed, the burner must be drawn back
3 If there are air extractors in the premises the burner works, till the extraction of blast tube from the furnace. Before oper-
make sure that there are openings for air to be taken in that ating in this way take the voltage off.
5.3 Handling
20063809
12 GB
Installation
5.4.1 Control of the supply A burner label that has been tampered with, re-
After removing all the packaging, check the integ- moved or is missing, along with anything else that
rity of the contents. prevents the definite identification of the burner
In the event of doubt, do not use the burner; con-
WARNING makes any installation or maintenance work diffi-
CAUTION
tact the supplier. cult.
1 2 3 4 5
20065196
Fig. 7
20063809
13 GB
Installation
D5097
4 A B
Fig. 9
S7393
Fig. 8
~ 47 mm
Electrode Probe
Probe
Electrode
3.7
Diffuser =
D5104
=
2.0 - 3.0 mm
Fig. 10
20063809
14 GB
Installation
Example: C S7015
kcal/h kW
D5109
240
200,000
220
180,000
200
160,000
180
172
140,000 160
120,000 140
100,000 120
100
80,000
70,000 80
0 1 2 3 4 5
Notch No.
Fig. 12
The adjustment of the air flow rate is carried out using the fixed
damper 1)(Fig. 13) after having loosened the screws 2).
Once optimal adjustment has been attained, fully screw in the
screws 2).
It is advisable to carry out an analysis of the com-
bustion values with the cover assembled. 1
WARNING
D5231
Fig. 13
20063809
15 GB
Installation
Explosion danger due to fuel leaks in the pres- The fuel supply line must be installed by qualified
ence of a flammable source. personnel, in compliance with current standards
Precautions: avoid knocking, attrition, sparks and and laws.
WARNING
heat.
Make sure the fuel interception tap is closed be-
fore performing any operation on the burner.
1 2 3 M1 4 5 6 7 8
D5099
M2 Fig. 14
Key (Fig. 14) M1 Gas-supply pressure test point on the pressure switch
1 Gas input pipe M2 Pressure coupling test point
2 Manual gate (the responsibility of the installer)
3 Gas pressure gauge (the responsibility of the installer) 5.10.2 Gas train
4 Filter
Approved according to standard EN 676 and provided separately
5 Gas pressure switch
from the burner. Supplied separately for its adjustment, see the
6 Safety valve enclosed instructions.
7 Pressure stabiliser
The train-burner combination is indicated in Tab. E.
8 Adjustment valve
Connections
Code Model Use
Gas train Burner
3970531 MB 407/1 - RSD 20 Rp 3/4 Rp 3/4 Natural gas 180 kW and LPG
3970532 MB 410/1 - RSD 20 Rp 1 Rp 3/4 Natural gas and LPG
Tab. E
20063809
16 GB
Installation
20065572
The gas train 1)(Fig. 15) can be installed on both the left side and
the right side of the burner.
Fig. 15
Connection between the gas supply line and the train must be
made using the gas-in flange 3) supplied, and fastening screws.
It is best to tighten screws in a criss-cross pattern.
Do not, under any circumstances, install the valve
with the coil facing down.
WARNING
To carry out the electrical wiring to the terminal board of the burn-
er:
unscrew the screws of the 6 pin plug 2)(Fig. 15) of the gas
train;
connect the flying leads as shown in “Standard wiring dia-
gram” on page 19.
20063809
17 GB
Installation
If the cover is still present, remove it and proceed with the electri-
cal wiring according to the wiring diagrams.
After carrying out maintenance, cleaning or
checking operations, reassemble the cover and
all the safety and protection devices of the burner.
20063809
18 GB
Installation
RMG88.62C2
20066045
Fig. 16
20063809
19 GB
Installation
D4199
Fig. 17
20063809
20 GB
Start-up, calibration and operation of the burner
Check the adjustment of the head as shown in page 15. Purge the air from the gas line.
Check the adjustment of the air damper as shown in We recommend using a plastic tube routed outside the build-
page 15. ing and to purge air until gas is smelt.
Slowly open the manual valves situated upstream from the
Before starting up the burner, it is good practice to
gas train.
adjust the gas train so that ignition takes place in
Adjust the air pressure switch (Fig. 19) to the start of the
conditions of maximum safety, i.e. with gas deliv-
scale. CAUTION ery at the minimum.
In conformity with EN 676 the application of the burner on the and CO2 concentration in the flue gases, their temperatures and
boiler, adjustment and testing must be carried out observing the the average temperature of the water in the boiler.
instruction manual of the boiler, including verification of the CO It is advisable to set the burner according to the type of gas used
and following the indications in Tab. F.
EN 676 Air excess: max. output. 1.2 – min. output 1.3
Theoretical Setting CO2 %
CO NOx
GAS max CO2
0 % O2 = 1.2 = 1.3 mg/kWh mg/kWh
Adjust the air pressure switch (Fig. 19) after performing all other
burner adjustments with the air pressure switch set to the start of
the scale.
With the burner operating at minimum output, turn the knob coun-
ter-clockwise, increasing its value until the burner switches off.
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.
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
WARNING gases exceeding 1% (10,000 ppm).
D7404
To check this, insert a combustion analyser in the Fig. 19
flue, slowly reduce the burner air setting (for ex-
ample with a piece of cardboard) and verify that
the burner locks out before the CO value in the
flue gases exceeds 1%.
20063809
21 GB
Start-up, calibration and operation of the burner
6.5.2 Normal operation / flame detection time The number of pulses will measure the probe detection time
The control box has a function through which it is possible to as- since the opening of gas valves, according to: Tab. I.
certain the correct functioning of the burner (signal: GREEN LED This is updated in every burner start-up.
permanently on). Once read, the burner repeats the start-up cycle by briefly press-
To use this function, it is necessary to wait at least 10s. from the ing the control box button.
time the burner switches on and press the button on the control If the result is > 2 s, ignition will be retarded. Then
box for at least 3 seconds. check the adjustment of the hydraulic brake on the
Once the button is released, the GREEN LED starts to flash, as gas valve, the adjustment of the air damper and
shown in Tab. H. WARNING the combustion head.
The pulses of the LED constitute a signal spaced by approxi-
mately 3 seconds.
Tab. H
Signal Flame detection time
1 blink 0.4 s
2 blinks 0.8 s
6 blinks 2.8 s
Tab. I
20063809
22 GB
Maintenance
7 Maintenance
The periodic maintenance is essential for the good operation, Before carrying out any maintenance, cleaning or checking oper-
safety, yield and duration of the burner. ations:
It allows you to reduce consumption and polluting emissions and
to keep the product in a reliable state over time. Disconnect the electrical supply from the burner
The maintenance interventions and the calibration by means of the main system switch.
DANGER
of the burner must only be carried out by qualified,
authorised personnel, in accordance with the con-
DANGER tents of this manual and in compliance with the
Turn off the fuel interception tap.
standards and regulations of current laws.
DANGER
20063809
23 GB
Maintenance
Let the burner run at full power for about 10 minutes, correctly
calibrating all the components indicated in this manual. Then car-
ry out a combustion check verifying:
– Percentage of CO2 (%);
– CO content (ppm)
– NOx content (ppm)
– Ionisation current (µA)
– Smoke temperature at the flue
20063809
24 GB
Maintenance
20063809
25 GB
Faults - Possible causes - Solutions
The control box features a diagnostics function through which The control box generates a sequence of pulses (1 second
any causes of malfunctioning are easily identified (indicator: RED apart), which is repeated at constant 3-second intervals.
LED). Once you have seen how many times the light blinks and identi-
To use this function, you must wait at least 10 seconds once it fied the possible cause, the system must be reset by holding the
has entered the safety condition (lockout), and then press the re- button down for 1 - 3 seconds.
set button.
Tab. K
Below is a list of the possible methods for resetting the control
box and for using the diagnostics.
Pressing the button Control box status
From 1 to 3 seconds Reset of the control box without visualisation of the visual diagnostics.
More than 3 seconds Visual diagnostics of the lockout condition:
(LED blinks at 1-second intervals).
More than 3 seconds starting from the Diagnostic software using an optical interface and PC
condition of visual diagnostics (possibility of displaying the hours the machine has been running, faults, etc..).
Tab. L
8.1.1 Control box reset Once the operations have been carried out, it is necessary to re-
To carry out the control box reset, proceed as follows: set the initial state of the control box using the reset procedure.
press the button for between 1 and 3s.
The burner restarts 2 seconds after the button is released.
In case the burner does not restart it is necessary to check if
the limit thermostat (TL) is closed.
20063809
26 GB
Faults - Possible causes - Solutions
goes into lockout with- Gas pressure too low Increase pressure at governor
out the appearance of Ignition electrode incorrectly adjusted Adjust it
the flame Electrode grounded due to broken insulation Replace
High voltage cable defective Replace
High voltage cable deformed by high tempera- Replace and protect
ture
Faulty ignition transformer Replace
Incorrect valve or transformer electrical wiring Check
Defective control box Replace
A closed valve upline the gas train Open
Air in pipework Bleed air
Gas valves unconnected or with interrupted coil Check connections or replace coil
20063809
27 GB
Faults - Possible causes - Solutions
20063809
28 GB
Faults - Possible causes - Solutions
20063809
29 GB
Appendix - Accessories
A Appendix - Accessories
LPG kit
Burner Code
RIELLO 40 FS20 3000886
Burner Code
RIELLO 40 FS20 3000893
Projection
Burner Code
(mm)
RIELLO 40 FS20 + 23 3000919
Faults kit
Burner Code
RIELLO 40 FS20 3001180
Burner Code
RIELLO 40 FS20 3010094
Burner Code
RIELLO 40 FS20 20027581
Burner Code
RIELLO 40 FS20 3000945
Burner Code
RIELLO 40 FS20 3002719
20063809
30 GB
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: +39.0442.630111
http:// www.riello.it
http:// www.riello.com
Subject to modifications