- lnstallation & Operatino Manual alffie'ffi

Single stage operation forced draught natural gas/propane burner

.@n
G) (ffi)
'J/- Wl'

The following pages contain information, descriptions and diagrams for the proper instal-
lation and wiring of the burner. Please read carefully before attempting final installation.

This manual is to remain with the final installation designation. lt is the installer's responsibil-
ity to ensure that the burner installation and operation instructions mentioned in this manual
are followed and operated within local code authority limits.

RrElro 4@
CODE TYPE

371i7125 G200 5717

V
2903333 (6) - 03i201 1
 \t
TABLE OF CONTENTS

lnstallation instructions and owner's handbook

General information
Step by steP Procedure . . .

Serial number identification . . . .

4
Burner components identification
5
Burner dimensions
Electrode & flame probe adjustments.
Typical gas train laYout.
lnstalling the burner
lnstallation of sediment trap & burner supply ' ' ' ' '

Factorywiring diagram' . . .
Field wiring diagram.
10
Setting up the burner
10
Step by step Procedure . . .
11
Operating faults .
11
Air gate adjustment
12
Diaphragm installation and combustion head setting
12
Manifold pressures
Pressure working chart. .
IJ V
Combustion chamber size . '
14
Combustion checks
14
Burner start-uP cycle
14
Problem solving guide '
15
Owner information & routine maintenance
15
lnstallation data . .

to
Propane burner aPPlication.
18
Exploded spare Parts list . . '
10
Spare parts list. . .

20
Burner start-uP form . .

u-
 INSTALLATION INSTRUCTIONS AND OWNER'S HANDBOOK
A .ou'o*,
All gas burners MUST be installed by trained and licensed technicians.
y'\ wanNrnc'
lnstallation of this burner must conform with local codes or, in the absence of local codes, with the
Standard for the Installation of Domestic Gas Gonversion Burners, ANSI 221.8'1984, and Addendum'
221.8a-1989, and the National Fuel Gas code, ANSI 2223.1-1984, and GAN/CGA 8149.1 &-2. lf an ex'
ternal electrical source is utilized, the conversion burner, when installed, must be electrically ground'
ed in accordance with local codes or, in the absence of local codes, with the national Electrical Gode,
ANSI/NFPA No.70-1990 and GSA Electrical Gode.

Owner is required to retain this manual for future reference.

TECHNICAL SPECIFICATIONS
FIRING RATE 70,000 TO 200,000 Btu/hr
NATURAL GAS PROPANE

MlN. 5" wc MlN. 12" wc

GAS SUPPLY PRESSURES MAX. 7" wc MAX. 14" wc

MlN. 3" wc MlN. 3" wc

MANIFOLD PRESSURES MAX. 5" wc MAX. 5" wc

POWER 120 Volts 60 Hz 1 Phase

MOTOR 232T 2.2 Amps 3250 rPm

v CONTROL MODULE 525 SE/A ELECTRONIC

,/i\ wlnutruc,
lf the information in these instructions is not followed exactly, a fire or explosion may result causing
property damage, personal injury or death.

Do not store or use gasoline or any other flammable vapours or liquid in the vicinity of this or any
other appliance.

/i\ *tot ro Do tF You sMELL GAS:

1) Do not try to light anY aPPliance.
2) Do not touch electrical switches; do not use any phone in your building.
3) lmmediately call your gas supplier from a neighbour's phone'
Follow the gas supplier's instructions.
4) lf you cannot reach your gas supplier, call the fire department'

lnstallation and service must be performed by a qualified installer, service agency or the
gas
supplier.
 ,,w(;
v
GENERAL INFORMATION installation'
assembled and, factory wired' ready for
Your Riello gas Durner comes to you completely the front of the appri-
Moders equipped wi*r tne snort c'ombustion
r,Llo have a fixed frange, *rri"rr oott" directly-to

ance.Whenequippedwiththe|ongcombustionhead,theburner"o'".withauniversalf|ange,whichwhenbo|t-
ior exact positioning in the combustion zone'
the appliance, allows the burner to be adlusted
ed to

STEP.BY.STEP PROCEDU RE
not to lose any of the supplied accessories'
1) Remove the burner from the carton, taking care
to the appriance. Be.sure. to instarrthe suppried mounting gasket'
,, 3:;:[J"J"1tfl'J:ffinffiT3:"";,suggest ;i;g spirit rever) and that the combustion head is centred in the
Ensure that the burner is rever 1we " fread relative to the chamber'
of"com'bustion
appliance port. Reteito page Z'for poJitioning your connections to the incoming gas supply'
make
3) Check that all gas tiain corinections are tight-and
-' the burner
be suppried rhis varve must be upstream of
;l t;:l'1,::u?l#T,:l::llll,lil;,i,iif3lii,,"
must be.ins_tal:d immediaterv upstream or
the burner sas train supplv connec-
X",ijl1;1'3flff"Tffi'.:"!
"l (Rierro sas trains are
rines at the sas regurators and varve
o' Hi"Affii:';lin:ffifi:;ffiJ:'Hslt"?r
equipped witir vent limiting diaphragms)'
e) Perform required g"s p'"j"t" test on incoming
gas supply lines'

and pressure test point, and line pressure

test point can be
NorE: Details of sediment trap, manual gas valve,
found on Page 8'

4) To make electrical connections, refer to field

wiring diagram. on.page 9. A manual disconnect
switch must be in-
if used, (Honeywell R8038A) must be v
sta'ed in the incoming lines. wiring t" in" r"* ""ltag6-switchiig;ruv,
rigid conduit or flexible approved cable'

/N
"outto*,
Label all wiresprior to disconnection when servicing controls'
operation'
Wiring errors can cause improper and dangerousbelow')
(Step 5 e
Verify proper op"t"li"n after servicing'

A -1- r--r ^a rh^ aart tatav if rrsed: neutral to the

"ort,o*t
Thephase(HoT)wiremustbeconnectedtotheblack|eadofthe24vre|ayifused;neutra|totl
reversed, and the contror box mav be
damased'
Yf"ti,1?ll;;;,Hl:J"",i:tlifliTit^ase/Neutrar
5) Check the burner functions as follows: connections'
a) Make a final check on both the gas and electrical install an appropriate manometer'
b) Loosen the screw in the maniforo gu" G"t point and
S"t the thermostat at its highest setting'
"i t#lliir:"J:I#, allow the burner to run
press the burner reser button (e, pase 4), and
:l sas vatve.turned off,'in"uitn" of ;;;ilt; is' A f ull starting cycle should
through a comptete cycte to ensure ""quence burner "o-tt""i
rockout; referto the start-up cycle
tro,n no power condition'untir
take approxrmatery 40 seconds "
on the sas train'
(up and runnins) a finargas.reak check TTl.g:..:"":t]eted
u 3.i:t;Jilinl?T"1l"ar on a centrar *u* ull furnacJ, affix the mandatory warning labels to the furnace fan
6) rf the burner is instared
cover door (inside and outside)'

t-
v SERIAL NUMBER IDENTIFIGATION
Your Riello burner may have been manufactured in more than one location and therefore there are two possible serial
number identification.
The Riello 9 character serial number, example,
06 01 12345. is identified asfollows:
(06) (01) (12345)
06 = Last two digits of the year of manufacture; ,/\\
01 = Week of manufacture;
_|
12US = Increment of 1 for each burner produced - specific
t Y"* -l FBt-week of | |
to product code - reset to zero each Januarv 1sI. "f Increment
lmanuracturel lmanufacturel I I

The Riello 15 character serial number, example.

06 A 851'l't11 00025, is identified as follows:
(06) (A) (8511111) (00025)
06 = Last two digits of the year of manu- \\\
A=
facture;
\\\
Bl-week of manufacture:
8511111 = Burner product code;
l-Et-*""k;il I Bl-week or] rncrement
00025 = Increment of 1 for each burner pro- lmanutacturel lmanufacturel I I

duced - specific to product code -

reset to zero each Januarv 1sI.

BURNER COMPONENTS IDENTIFICATION

v
1 - Control box
2- Air pressureswitch
3- Screw for fixing the cover
4- Cable grommet
5- Wiring terminal block
6- Screws for fixing the air-damper
7- Air damper
8- Capacitor
9- Reset button with lock-out lamp
10 - Gas valve transformer 12OY | 24Y

v
 ;6Bf,
v
BURNER DIMENSIONS

N
(v)

c)
a{)

71\c" - 190 mm
g15tn" - 215 mm

G1 H J
ModelG200 A B c D E F G
zt 2tr32
11 5/u 3 tulro 1o 33/6a 3 e/ro c-7r /16
inches 9 3/ro 1o 11/ru 1 u'luo 1'luo
295 100 267 91 138 180
233 272 48 28 13
mm

NoTE:Actua|avai|ab|einsertion|engthmustbemeasuredfromtipofendconetofaceofmountinggasket.

v
ELECTRODE AND FLAME PROBE ADJUSTMENTS
lonization Probe lgnition electrode

'rll
Diffuser
F---r
L--l @ -r
A B
Propane sleeve ProPane orifice mm 8t0.5 4+0.5
inch 5/t o" 5lsz"

,/i\ wnRMnc, :- aL^ i.

Donotturntheignitione|ectrode.Leaveitasshowninthedrawing. of the control box may be damaged'
probe, the amplifLr
ignition electrode is put near the ionization
lf the
L
 6.Gff
TYPICAL GAS TRAIN LAYOUT

/i\ rne cAS TRAIN LEAVEs rHE FAcroRy sET AT 3.5,,wc.

ATTENTION
This gas train scope of supply meets the minimum controls requirements according to CSA Canada and
USA regulations. Any additional requirements needed to meet local codes are the responsibility of others.

FIELD SUPPLIED RIELLO SUPPLIED

+
VALVE LEGEND
-
1 Gas supply & flow direction of gas
-
2 Gas supply main shtoff manual valve (field supplied)
-
3 Gas supply pressure test point (field supplied)
4 - Valve
5 - Gas burner manifold test point
- GAS SUPPLY PRESSURE RANGES:

TOP VIEW OF GAS CONTROL NATURAL GAS PRESSURE:

min,5" wc - max,7" wc
PfiTSSUftE FEGTJI.ATffi
ADJUSruEHT WIRINC LP PROPANE GAS PRESSURE
{UNDEF CAP TERfuIIHALS
min. 12" wc - max. 14" wc
INLET OUTJ.ET
PffESSUFIE TAF
PRESgUFIE
TAP

tNLET l ) ourlrr
 *,ffi'
v.
INSTALLING THE BURNER
A) Burner Chassis
B) Combustion Head AssemblY
1) Locking Nut
2) Mounting Plate surface
3) lnsulation Gasket
the chassis
Separate the combustion head of the burner from
ilj nV the locknut (1). lnstall the combustion head
t"touing
into the boiler.
iypicat insertion depth,thefront edge of the combustion head
sur-
is itusn with the inside surface of the appliance mounting
face (2).

Use this checklist prior to installation: L--1--J L---1/--J

i;' Check the input/output requirements of the appliance' A B
We suggest that the appliance output should be ap-
proximaGty 85% ol input (85% efficiency)'
sizing against the input requirements of the application'
2) check the dimensions of the combustion chamber for correct
and adequate ventilation'
3) check that there is sufficient air for proper combustion
of |ocal codes, refer to the NFPA Manua| No' 31, cAN/cGA
Loca| codes shou|d be fo||owed. In the absence
1989'
8149.1 &.2, ANSI 2223j-1984 and Addendum 221'8A
the equipment'
4) Check that you have adequate space for servicing
a minimum of 13 inches clear space behind the red cover'
The Riello burner,"qrit"J periodic maintenance (.
This is required ,o easy removal of the cover for servicing and
"rio*
5)CheckthatthechimneyisofsufficientareatohandIetheexhaustgaSeS.
Make sure the chimney is clear and there are no obstructions'
6)Barometricdraftregu|atorsmustbeofthedoub|eactingtype,andmustbeinsta||edinaccordancewiththe
draft regulator man uf actu rer's instructions'
Single icting barometric dampers are not
permitted'
and 221'17A-1993'
For f urther clarification, refer to ANSI 221 '8-1984

.A tmronrANT
Aventshutoffsystemsha|lbeapp|iedtoabarometricdamperinsta||edintheventingsystematthe
time of conversion of the appliance'
there be a blockage in the vent (chimney)'
This will electrically disconnect the burner should
power switch and manual gas shut off valve' for emergency
The installer must identify the main electrical
secured before the burner is placed in operation'
conditions. The burner c6ver must be in place and
INSTALLATION OF SEDIMENT TRAP AND BURNER SUPPLY

Gas piping to the burner must be 1/2-inch minimum. Install only a full-ported shutoff valve. The valve must be lo-
cated outside the appliance jacket, and the pressure gauge port must be accessible.

PRESSURE TEST-OVER 1/, tSte.

The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of the system at a test pressure in excess of 11, PStG.

PRESSURE TEST-1/2 PSIG OR LESS

The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve
during any testing of the gas supply piping system at test pressures equal to or less than '/2 PSIG.

Dircction of flow

To check for gas leaks

use a oas detector or
apply 5 soap solution to Manual Shutoff valve
the joints Height of shutoff valve above ground
leve-l to conform to local codes, if any.

\ \Pressure gauge port

( 118'NPT Plugged)

Male union 3/4" NPT

l=
\Bu.ne, g"s train
=
z
=
(Yt

\ Pipe cap
 ffi
w
FACTORY WIRING DIAGRAM
NOTE:
BOX is
The SAFETY SWITCH on the 525SE CONTROL
of burner
equipped with a contact allowing remote sensing
lockout.
ter-
in" Lr".tti."l connection is located on the CONTROLtheBOX
525SE
tituf + as indicated. Should burner lockout occur'
CONTROL BOX willsupply a power source
of 120 Vac to the
connection terminal.
terminal is 1A'
The maximum allowable current draw on this
T

Control box
525SE/A

/i\ ,*to*rANr: of a
Terminal 4 is to be used onlY for the connection
remote sensing device
4'
lf a neutral or ground iead is attached to terminal
occur'
the control nox wift be damaged should lockout

Remote
lock-out
signal

FIELD WIRING DIAGRAM

120V controlled 24V controlled

LEGEND
C - CaPacitor
II

--
CN... - Connectors
E - lgnition electrode
MB - Terminal board
MV - Motor
TB
PA - Air Pressure switch
SO - lonization Probe
Operating Operating
control
control
TB - Burner earth
Fuse Fuse TV - Transformer 24V

Service Service
switch switch

1 20VAC 60Hz
J SETTING UP THE BURNER
After burner output has been determined, use TABLE 1 below AS AN lNlTlAL GUIDE for burner settings.
All settings in this table were obtained under the following conditlons.
o 0 (zero) draft in the combustion zone; o
Standard lab test boiler;
o Inlet gas pressure range as in table 1; o
Steady state (HOT) operating conditions.

u as manrToro Eumer neao $rr ga!€

1nt,EJ,.,.,.,...,.,
Diaphragm
pressure'range gas piessure output setting
.

.$ettinul
"wc Marking lvc Btu/hr Nocth Notch
,o B1 75,OOO U 1.5
<: 82 95,052 1.85
'o: 0
Jr B3 '14,589 a
1.9
,{, 5.0 - 7.0 3.5
1 t

u B4 139,010 2 2.O

fz
f
B5 159,673 5 2.3
B6 200.000 4 3.75

Burner input decreases with increasing the combustion chamber pressure.

Once installed, a higher or lower burner input can be achieved by raising or lowering the manifold pressure from - 0.5"
wc. to +1 .5" wc. Pressure changes can only be made when the burner is running. The typical working manifold pressure
is 3.5" wc. (both for natuaral gas and propane).

STEP BY STEP PROCEDURE

1) Set air gate. See AIR GATE ADJUSTMENT on page 11.
2) Set gas diaphragm and combustion head.
See DIAPHRAGM INSTALLATION AND COMBUSTION HEAD SETTING on page 12.
3) Set the manifold pressure using the following method.
v a) In order to determine existing manifold pressure, start the burner.
At the end of the prepurge cycle (approx. 30s), the gas valve is energized.
During the 5 sec. trial for ignition, note the observed manifold pressure. lf the burner lights and continues to
run, go to step (d).
b) Comparetheobservedmanifoldpressurefromstep(a) totherequiredvaluefromTABLEl.
c)
Repeat step (a), making adjustments to the gas valve, until flame is established.
d) Once flame has been established, set your manifold pressure to the desired value from TABLE 1.
4) Check combustion gases using proper combustion analysis equipment to ensure safe levels of CO2 and CO
during appliance heat up.
The gas valve should be used to make any necessary adjustments to ensure safe combustion.
At this point do not adjust the air or head settings unless absolutely necessary.
5) Allow burner to run until normal operating temperatures and conditions have been achieved.
6) a) Clock the gas meter to determine actual burner output.
b) Set the manifold pressure, by adjusting the gas valve, to achieve desired output.
c) Check combustion gases once again to ensure safe operation.
Make sure the burner cover is in place and air gate locking screws are secure for all combustion analysis.
Adjust air gate if necessary (refer to page 11). A qualified technician must do this test.
The maximum recommended CO2 level for natural gas is 10%; the maximum recommended level for pro-
pane gas is 12'k. The recommended flue gas temperature is from 350'F to 550'F.
7) After completing the adjustments, remove the manometer and tighten the screw inside the manifold test point.
Replace the regulator cap on the gas valve.
8) Complete the adjustment data tag, described on page 15.
Explain the burners essential functions (starting and stopping) to the owner.
Do not forget to give the dealer or service company's name and address.
Please see page 15 for information on burner maintenance procedures.

A ,Or=, Do not assume the heating system is operating at optimum per{ormance.

THERE IS NO SUBSTITUTE FOR PROPER COMBUSTION TESTING!
v
10
 #ffiA
L
OPERATING FAULTS
The integrated control system is self-checking-
takes approximately 70 seconds'
The cycle from start up io ttame establishment'
following circumstances:
The burner will go into lockout under the
a) Burner fails to ignite;
b) The ionization probe is grounded; pressure switch not making'
normally open contacts of the air
c) opening of the air pr"."ur" switch or the
Shou|doverheatingoftheapp|ianceoccur,shutoffthemanua|gasva|vetotheburner.
pump or blower fan'
Do NOT shut off tne switcn io the circulating

SHUT DOWN PROCEDURE

Switchoffe|ectrica|powertotheunit.C|osethemanua|supp|ygasva|ve.

START UP PROCEDURE
See Page 7.

A, nOfer ^--..^-^i^h rrrrrnar urhan installed. must be electrically ground-

|fanexterna|e|ectrica|Sourceisuti|ized,theconversionburner,wheninsta||ed,mul
70-1eeo
if,'[H::i::""1il:: to the Nationar Erectricarcode, ANsr/NFPA
::x|"".:iff;,.
CSA C22'1'
ln Canada tof roi tn" Cunadian Electrical Code Part 1

AIR GATE ADJUSTMENT

the manual air gate (3)' by
To regulate the combustion air, adjust
tooseiing the locking screws (4)'
tighten the locking
Once the optimal ao;ustmeni is reached'
screws (4).
gas)
EXAMPLE SETTING '(for natural
foia desired burner output of 114'500 Btu/hr'
To set the air intake
air gate setting'
useTABLE 1 to determine the correct gas'
the setting would be 1'9 for natural
in tni,
""t", g'ai" (3) until the arrow points to 1'9 on the
Turn the manual
scale.
"i,
Tighten locking screws (4)'
with zero (0)p-'-"^t:1'^1in,tl"
All settings in TABLE 1 are obtained l'e''
temperatures'
combustion zone and at normal operating
steadY state hot conditions'

gNty with fuer that is risted on the burner

serial label.
u;rT;, must be fired

11
 DIAPHRAGM INSTALLATION AND GOMBUSTION HEAD SETTING
- A proper diaphragm (C) has to be installed
in the combustion head gas line, according
to TABLE 1. A complete set of gas dia-
phragms is delivered with the burner pack-
aging as equipment. The burner leaves the
factory with the 86 diaphragm already
installed. In case another diaphragm has
to be installed, following the instructions
below.
To remove the drawer assembly from the
manifold (B), follow the procedure below:
1) Disconnect 24v leads at the gas valve.
I
2) Separate the burner chassis from the
combustion head by removing the lock-
nut.
3) Loosen the two Allen screws (A) with-
out taking them out.
4) Withdraw the head, turning it 180
degrees.
5) Pull out head, leaning it towards the bottom.
6) Remove the ignition electrode (D) and the ionization probe (E).
7) Unscrew the screw (F) and remove the gas diffuser (G).
8) Installthe proper diaphragm (C) and sealaccording to TABLE 1.
9) Retit following the above procedure in the reverse order (verify the ignition electrode and the ionization probe
positions according to page 5).
Slide the elbow (B) so that the number on the indicator scale aligns with the back edge of the air tube.
Y See TABLE 1 for set points. Tighten the two Allen screws (A).
Example (for natural gas):
For a desired burner output of 1 '14,500 Btu/hr, the diaphragm would be 83 and the combustion head setting would be 1.
All settings in TABLE 1 are obtained with zero (0) pressure in the combustion zone and at normal operating tem-
peratures. i.e.; steady state hot conditions.
Note: Burner must be fired ONLY with fuel that is listed on the burner serial label.

MANIFOLD PRESSURES
Manifold gas pressure for various firing rates should be set by adjusting the gas regulator of the gas valve, (see
figure at page 6). To check manifold gas pressure, attach a manometer to the manifold test point, shown on typical
gas train layout. Approximate manifold pressure settings are indicated in TABLE 1.
Example (for natural gas):
For a burner to be fired at 114,500 Btu/hr, the manifold pressure would be approximately 3.5" wc.
In case of lower or higher manifold pressure, install an diaphragm with a respectively smaller or bigger hole.
All settings in TABLE 1 are obtained with zero (0) pressure in the combustion zone and at normal operating tem-
peratures. i.e.; steady state hot conditions.
Note: Burner must be fired ONLY with fuel that is listed on the burner serial label.
HIGH ALTITUDE SETTINGS
It should be noted that for higher altitudes more air for combustion is required.
All settings in this manual have been obtained at approximately sea level. Special attention should be paid to air
for combustion for elevations above sea level. lJ an increase in combustion air is insufficient, the burner must then
be de-rated by approximately 41" for every 1000 feet above sea level.

12
,-

PRESSURE WORKING CHART

The chart below shows effects of pressure in the combustion zone on the minimum/maximum burner outputs. ln
this example, with a maximum operating pressure of 0.16 inches water column in the combustion zone, you will be
able to obtain a maximum of 165,500 Btu/h burner output.

PRESSURE WORKING CHART

Pressure Natural and Propane Gas
In/wc M/bar

0.40 1.0 L
o.32 0.8

0.24 0.6

0.16 0.4

0.08 0.2

0.0 0.0
20 50 60 kwh
07411

34,000 68,000 1 02,000 1 37,000 171,000 205,000 Btu/h

Any change from zero (0) pressure in the combustion zone will affect the Btu output of the burner. To supply the
required input to the appliance, manifold pressure will have to be adjusted to compensate for this condition.

NOTES:
1) Sizes shown above are for cylindrical or wet base boilers, or air cooled heat exchangers.
2) To size the chamber in applications other than wet base boilers, refer to the authority having jurisdiction.
Refer to CAN/CGA 8149.1 &. 2, ANSI 221 .8-1984, and ANS| 2223-1-1984.
3) Fire brick or cerafelt chamber materials should have a continuous run temperature rating of 24OO degrees Fahr-
enheit and a melting point of 3000 degrees Fahrenheit.

13
 J COMBUSTION CHECKS
Goz
It is advisable not to exceed a measured reading of 10"k COz for Natural Gas or 12/" COz for Propane Gas.

co
For safety reasons, the value ol .O2/" (200ppm) free air sample must not be exceeded.

IONIZATION CURRENT
Red wire connect
The minimum amount of current necessary for
the control box to operate properly is 3 micro
Amps DC.
To measure the ionization current, disconnect
the red wire connector and insert a DC microme-
N ter in series with control box terminal 2 and the
ionization probe, which senses the flame. Refer
to the diagram below.

BURNER START.UP CYCLE

Normal Lock-out, due to light-failure
Thermostat Thermostat
Motor Motor
lgnition transformer lgnition transformer
Valve Valve
Flame Flame
Lock-out Lock-out
v
PROBLEM SOLVING GUIDE
Burner starting difficulties and their causes:
1) The burner goes through the prepurge period normally. The flame ignites, but the burner goes to lockout within
five seconds.
a) The phase/neutral lines are reversed.
b) The wiring to ground is absent or ineffective.
c) The ionization probe is grounded, or not in contact with the flame, or the circuit to the control box is broken.
d) The spark interferes with the flame signal due to incorrect setting of the electrode.

2) The burner goes to lockout after the prepurge period because the flame does not ignite.
a) Air has not been fully bled from the gas lines.
b) The gas valve is passing too little gas.
c) The spark is irregular or not present.
3) The burner does not start when the thermostat calls for heat.
a) The gas pressure switch (if supplied) does not close contact due to low gas pressure.
b) The 24volt switching relay is defective.
c) The line switch is off.
d) There is a blown fuse in the panel.
e) Terminals on the control module are bent or loose
f) The motor is defective.
g) The capacitor is defective.
h) The end switch on the air damper is defective.
i) The control box is defective.
v j) The air pressure switch is not in the normally closed position.

't4
 {;,w
4)Theburnercontinuestorepeatthestartingcyc|ewithoutgoinginto|ockout.
This is a very speciiic situation caused uun"n
ga" pr"r=,ir" in tne gas main lines.is very close to the value at
the gas pressure switch has been set. ihis'can be
correctei by resetting the gas pressure switch to a
which
may be supplied, or may have to be field installed'
lower level. The gas pressure switch, it requireJ,
pressure switch does
the control module goes to lockout' The air
5) The burner does not go through prepu.rge, and
' not change over froti normally closed to normally
open contacts'

pressure in the combustion head'

This condition exists because there is insufficient air

OWNER INFORMATION AND ROUTINE MAINTENANCE

SAFETY LOCKOUT r^..i^^^ rh +h6
-^r^r.. devices'..|n event nf
the arranr of a failrrre flame, or an)
failure in the flame' any
This burner is equipped with multiple interlocking safety In such an event' an
blockage of the combustion air supply, the burier
will "lock oul" in a safety condition'
of the red cover. To restart the burner, press the button once
iiluminated red button wiil show on the centre front for
call a qualified service technician or your gas company
only. should the burner return to the lock out condition,
assistance.
flammable
clear of all combustible materials' gasoline and other
NOTE: Keep the area around the burner free and the free' flow of air to the burner'
which may prevent
vapours and liquids. Do not allow any obstructions,

flffiequipment,yourburnerwiIlrequireperiodicmaintenance.Ataninterva|of2months,youshou|d:
1)Visuallychecktheflameifyourheatingappliancehagal,observationport'
builds up of fluff ' dust' pet hair etc'
2) Check and clean the air intake louver ib t"tou" any
oiling'
gi fne motor is permanently lubricated and does not need

Foranymaintenanceorrepairsoverandabovethose|isted,contactyourservicetechnicianorgascompany.
INSIDE THE BURNER COVER'
THERE ARE NO OWNER dENVICEEELE PARTS

onceayear,youshou|dhavetheburnerservicedasindicatedbe|ow.Thisserviceshou|dbeperformedbyyour
local authorized Riello dealer'
1)Checkburnerdistributorheadandmixingp|ates.C|eanifnecessary.
as necessary'
ziCneck ignition electrode' Clean, adjust' or replace necessary'
rod (ionization loJl tor dirt or carbon buiid up. clean, adjust, or replace as
3) check the flame sensor
4) Check manifold gas Pressure'
5) Check all burner adjustments'
Oj Generally clean all exposed parts and components
in ptace and the air gate locking screws secure'
7) Do a comptete."*;;"ti;;i,iJ *itn tn" !:ll"^1.::":r
system'
Youi Rietlo 40 gas burner is only part of your heating ADJUSTMENT DATA TAG
year you should hive your heating appliance serviced by a aNsr 7?1-17b-1994
Once every
INPUT C,F.H
qualif ied service technician.
chimney checked, and cleaned if necessary'
'iou snouta also have the MANIFOLD PRES-

AIR DAMPER

AIR/GAS RATIO No.

INSTALLATION DATA
FLUE GAS TEMP.
Note:
ini, t"b"l is supplied in the package with thetheburner and should be 02 LEVEL %

applianle when conversion burner is

filled out and affixed to the CO2 LEVEL %

installed. CO LEVEL P.P.M

DATE:

COMPLETED BY

INSTALATION
^ANITRACTOR

15
 J PROPANE BURNER APPLICATION
The burner leaves the factory to run on
natural gas. ll is available a kit, on
request, that allows the burner to run on
propane.

TECHNICAL FEATURES
The thermal output and operating range
of burners converted to use propane are
the same as for burners runnino on natu-
ral gas.

GAS Family 3:
Net calorific value: 24 - 34 kWh/mo
21,000 + 29,300 kcalim3
Min. pressure 25 - max. 50 mbar.

LIST OF KIT'S COMPONENTS

Quantity Component Adhesive data plate
supplied as equipmenl
1 Reducer
1 Ditfuser 1,3
1 Adhesive label
.l
lnstruction
4 Diaphragm

CONVERSION
v On the combustion head of the burners, diaphragm (4)
should be replaced. and natural gas nozzle (1) replaced
with the one used for propane, and a reducer (3) should be
added.
Proceed as follows, (fig. A):
) Disassemble the ignition electrode and the ionisation probe.
) Replace diaphragm (4) and replace natural gas nozzle (1) (marked 2) with the one supplied used for propane
(marked 1.3).
) Remove the distributor - diffuser disc once the screws have been removed.
> Inserl reducer (3), refit the distributor-diffuser disc and then tighten the fastening screws.
) Reassemble the electrode and the ionisation probe in the position foreseen in the instructions for the natural gas.
> Affix the adhesive label as illustrated in fiq. B.

t
J V

16
l':
-

GUrpE for burner setinss.

iil'fr:"::JJfrlH*-rTn determined, use rABLE berow AS AN rNrlAL
the following conditions'
All settings in this table were obtained under o
o 0 (zero) draft in the combustion zone; Standard lab test boiler;

o table; o
Steady state (HoT) operating conditions'
Inlet gas pressure range as in

cii itlet
pressufe fange
, oi"pt,iiem' ', $?f; :

;
I

trlotch
il -"wc , i Marting " ,
. ,tnrc I BtUnr .

1.5
.

75,000 0
811
0 1.8
812 91,529
1 1.5
813 108,341
3.5 2
12.0 - 14.0 129,822 2
814
158,776 3 2.25
815
4 3.5
816 200,000

17
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 )J 35 Pcnd Park Rd.
-i _6ram, MA 02043
anr€ 781-749-8292
-rC ='ee:800-992-7637
7w:781-740-2069
-l
RIBIO

B{N'{ERS
2165 Meadowpine Blvd.
Mississauga,On L5H 3R2
Phone: 905-542-0303
Toll Free: 800-387-3898
Fax:905-542-1525

BURNER START. UP FORM *

3-rrer S/N. or Model: Appliance:

rsiardfrer name:

a:roany: Installation date:

.lrffieSs

>'re: Fax:

lwrer Name:

r{fire$S:

qrr€ E-mail:
J

Burner Start-up lnfo

a** s-fpV pressure: Manifold pressure:

&r $*rE: Turbolator setting:

lrut *€rfire: Draft breech:

-!2 Oz'. Smoke density: (Bacharach)

ar'mqr reading pAdc: Input BTUihr: -

- -

*"rs
I
trt was designed and provided in the installation manual for reference and also for providing tech-
'rue nh'Ertion
I which can be faxed or mailed to our technical hot-line coordinator when technical assis-
iarw s'eqcrired. Please complete this form, fax it or mail it at the address/fax
UO
I
above, or send an e-mail
orf :t.e rfurmation listed below to: techservices@riellocanada.com

20
 it

RtE110

]
BURNERS

35 Pond Park Road 2165 Meadowpine Blvd

Hingham, MA 02043 Mississauga, ON LsN 6Ho
Phone 781-749-8292 Phone 905-542-0303
Toll Free 800-992-7637 Toll Free 800-387-3898
Fax781-74O-2069 Fax 905-542-'1525

www.riellousa.com www.riellocanada.com

Technical Support Hotline

1-800-4-RIELLO
1 -800-474-3556 =l