Riello 40 FS10-TX 500 (564T30) - Forced Draught Gas Burner Manual

BURNER DESCRIPTION

Gas burner with one stage working.

• CE marking according to Gas Appliance Directive 90/396/EEC; PIN0063AP6680.
  According to Directives: EMC 89/336/EEC, Low Voltage 73/23/EEC and Efficiency 92/42/EEC.
• The burner meets protection level of IP X0D (IP 40), EN 60529.
• The burner is approved for intermittent operation as per Directive EN 676.
• Gas train according to EN 676.

Fig. 1

1. – Air-damper
2. – Screws for fixing the air-damper
3. – 7 pole socket for electrical supply and control
4. – 6 pole socket for gas train
5. – Cable grommet
6. – Screw for fixing the cover
7. – Air pressure switch
8. – Control box
9. – Reset button with lock-out lamp

NOTES

• The cable grommet (5) supplied with the burner, must be fitted to the same side of the gas train.
• After having installed the burner verify the access to the fixing screws of the cover.
  If necessary replace them with the fixing screws (6, fig. 1) supplied as equipment.

BURNER EQUIPMENT

COMBUSTION HEAD EQUIPMENT

TECHNICAL DATA

For gas family 3 (LPG) ask for separate kit.

OVERALL DIMENSIONS

min. 369

WORKING FIELD (as EN 676)

TEST BOILER

The working field has been defined according to EN 676 standard.

COMMERCIAL BOILERS

The burner-boiler matching is assured if the boiler conforms to EN 303 and the combustion chamber dimensions are similar to those shown in the diagram EN 676. For applications where the boiler does not conform to EN 303, or where the combustion chamber is much smaller than the dimensions given in EN 676, please consult the manufacturers.

CORRELATION BETWEEN GAS PRESSURE AND BURNER OUTPUT

To obtain the maximum output, a gas head pressure of 5.8 mbar is measured with the combustion chamber at 0 mbar using gas G20 with a net heat value of 10 kWh/Nm3 (8,570 kcal/Nm3).

INSTALLATION

THE BURNER MUST BE INSTALLED IN CONFORMITY WITH LEGISLATION AND LOCAL STANDARDS.

BOILER FIXING

The burner can be fixed to the boiler with a varying projection of the combustion head. Ensure that the combustion head passes through the entire thickness of the boiler door.

• Separate the combustion-head assembly from the burner body by removing nut (1) and removing group (A).
• Fix the head assembly group (B) to the boiler (2) insert the supplied insulating gasket (3).

PROBE - ELECTRODE POSITIONING

GAS FEEDING LINE

1. – Gas supply pipe
2. – Manual cock (supplied by the installer)
3. – Gas pressure gauge (supplied by the installer)
4. – Filter
5. – Gas pressure switch
6. – Safety valve
7. – Pressure governor
8. – Adjustment valve

M1 – Gas-supply pressure test point
M2 – Pressure coupling test point

GAS TRAIN ACCORDING TO EN 676

The gas train is supplied separately, for its adjustment see the enclosed instructions.

ELECTRICAL WIRING

STANDARD ELECTRICAL WIRING

ATTENTION

• Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth connection.
• The section of the conductors must be at least 1mm².(Unless requested otherwise by local standards and legislation).
• The electrical wiring carried out by the installer must be in compliance with the rules in force in the country.
• Verify that the burner stops by operating the boiler control thermostats and that the burner locks out by separating the red ionisation probe lead connector.

NOTES
The burners have been type-approved for intermittent operation. This means they must stop at least once every 24 hours in order to allow the electrical control box to check its efficiency on start-up. The boiler limit thermostat (TL) normally ensures the burner halts. If this does not happen a time switch halting the burner at least once every 24 hours must be applied in series to limit thermostat (TL).

ELECTRICAL WIRING WITH GAS LEAK CONTROL DEVICE (DUNGS VPS 504)

TO BE DONE BY THE INSTALLER

KEY TO LAY-OUT

X6 – 6 pin plug
X7 – 7 pin plug
B4 – Working signal
h1 – Hour counter
PG – Minimum gas pressure switch
S3 – Remote lock-out signal (230V - 0.5 A max.)
T6A – Fuse
TL – Limit thermostat
TS – Safety thermostat
V10 – Safety valve
V11 – Adjustment valve

WORKING

COMBUSTION ADJUSTMENT

In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO₂ concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, choose the proper setting of the combustion head, and the air damper opening.

COMBUSTION HEAD SETTING

Loose the screw (A), move the elbow (B) so that the rear plate of the coupling (C) coincides with the set point.
Tighten the screw (A).

Example:
The burner is installed on a 81 kW boiler with an efficiency of 90%, the burner input is about 90 kW using the diagram, the combustion set point is 3.
The diagram is to be used only for initial settings, to improve air pressure switch operation or improve combustion, it may be necessary to reduce this setting (set point toward position 0).

AIR DAMPER SETTING

The regulation of the air-rate is made by adjusting the air damper (1), after loosing the screws (2).
When the optimal regulation is reached, screw tight the screws (2).

COMBUSTION CHECK

It is advisable to set the burner according to the type of gas used and following the indications of the table:

EN 676		AIR EXCESS: max. output 1.2 – min. output 1.3
GAS	Theoretical max. CO2 0% O2	Setting CO2 %		CO mg/kWh	NOx mg/kWh
		λ = 1.2	λ = 1.3
G 20	11.7	9.7	9.0	≤ 100	≤ 170
G 25	11.5	9.5	8.8	≤ 100	≤ 170
G 30	14.0	11.6	10.7	≤ 100	≤ 230
G 31	13.7	11.4	10.5	≤ 100	≤ 230

IONIZATION CURRENT
The minimum current necessary for the control box operation is 3 µA.
The burner normally supplies a higher current value, so that no check is needed. However, if you want to measure the ionization current, you must open the connector fitted to the red wire and insert a microammeter.

AIR PRESSURE SWITCH

The air pressure switch is set after all other adjustments have been made. Begin with the switch at the lowest setting. With the burner working at the minimum output, adjust the dial clockwise, increasing its value until the burner shuts down. Now reduce the value by one set point, turning the dial anti-clockwise.
Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.

Attention
To comply with the EN 676 standard, the air pressure switch must operate when the CO value exceeds 1% (10,000 ppm). To check this, insert a combustion analyser in the flue, slowly reduce the burner air setting and verify that the burner shuts down by the action of the air pressure switch before the CO value exceeds 1%.

BURNER START-UP CYCLE

When flame-failure occurs during working, shut down takes place within one second.

START-UP CYCLE DIAGNOSTICS

During start-up, indication is according to the following table:

RESETTING THE CONTROL BOX AND USING DIAGNOSTICS

The control box features a diagnostics function through which any causes of malfunctioning are easily identified (indicator: RED LED).
To use this function, you must wait at least 10 seconds once it has entered the safety condition (lock-out), and then press the reset button.
The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second intervals.
Once you have seen how many times the light pulses and identified the possible cause, the system must be reset by holding the button down for between 1 and 3 seconds.

The methods that can be used to reset the control box and use diagnostics are given below.

RESETTING THE CONTROL BOX

To reset the control box, proceed as follows:

• Hold the button down for between 1 and 3 seconds.
  The burner restarts after a 2-second pause once the button is released.
  If the burner does not restart, you must make sure the limit thermostat is closed.

VISUAL DIAGNOSTICS

Indicates the type of burner malfunction causing lock-out. To view diagnostics, proceed as follows:

• Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit. A yellow light pulses to tell you the operation is done.
  Release the button once the light pulses. The number of times it pulses tells you the cause of the malfunction, indicated in the table below.

SOFTWARE DIAGNOSTICS

Reports the life of the burner by means of an optical link with the PC, indicating hours of operation, number and type of lock-outs, serial number of control box etc... To view diagnostics, proceed as follows:

• Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit. A yellow light pulses to tell you the operation is done.
  Release the button for 1 second and then press again for over 3 seconds until the yellow light pulses again.
  Once the button is released, the red LED will flash intermittently with a higher frequency: only now can the optical link be activated.

Once the operations are done, the control box's initial state must be restored using the resetting procedure described above.

The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table below.

SIGNAL	PROBABLE CAUSE
2 pulses	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 pulses	Minimum air pressure switch does not close: make sure VPS trips to produce lockout; air pressure switch faulty; air pressure switch incorrectly regulated; fan motor does not run; maximum air pressure switch operating.
4 pulses	Min. air pressure switch does not open or light in the chamber before firing: air pressure switch faulty; air pressure switch incorrectly regulated.
7 pulses	Loss of flame during operations: poor burner regulation (insufficient gas); faulty or soiled gas valves; short circuit between ionisation probe and earth.
10 pulses	Wiring error or internal fault.

WARNINGS TO AVOID BURNOUT OR BAD COMBUSTION OF THE BURNER

1. – When the burner is stopped, the smoke pipe must be opened and effect a natural draught in the combustion chamber. If the smoke pipe is closed, the burner must be drawn back till the extraction of blast tube from the furnace. Before operating in this way take the voltage off.
2. – The place, where the burner works, must have same openings suitable for the passage of air necessary for combustion. To be sure about this, you have to control CO2 and CO in the exhaust gases with all the windows and doors closed.
3. – If in the place, where the burner works, there are air-breathings, check the existence of air-input openings with dimensions suitable for the necessary air-exchange. In any case check that, when the burner is stopped, the air-breathings do not draw warm smokes from pipes through the burner.

MAINTENANCE

The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity with legislation and local standards.

Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and consequent pollution.

Before carrying out any cleaning or control always first switch off the electrical supply to the burner acting on the main switch of the system.

THE BASIC CHECKS ARE:
Leave the burner working without interruption for 10 min., checking the right settings of all the components stated in this manual. Then carry out a combustion check verifying:

• CO₂ (%) content
• Smoke temperature at the chimney
• CO content (ppm).

FAULTS / SOLUTIONS

Here below you can find some causes and the possible solutions for some problems that could cause a failure to start or a bad working of the burner. A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box.
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the burner functions correctly, the lock-out can be attributed to a temporary fault.
If however the lock out continues the cause must be determined and the solution found.

BURNER STARTING DIFFICULTIES

N.B.: If problems still occur after all of the above checks have been made, check the electrical connections on the plug and sockets, the damper and burner motor, gas control wiring ignition transformer and external interlocks, if the burner still fails to function, replace the control box.

NORMAL OPERATION / FLAME DETECTION TIME

The control box has a further function to guarantee the correct burner operation (signal: GREEN LED permanently 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:

SIGNAL	FLAME DETECTION TIME
1 blink	0.4s
2 blinks	0.8s
6 blinks	2.8s

This is updated in every burner start-up.
Once read, the burner repeats the start-up cycle by briefly pressing the control box button.

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.

KIT INTERFACE ADAPTER RMG TO PC Code 3002719

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