40 SERIES GAS BURNER
MODEL 400 NATURAL GAS/PROPANE
INSTALLATION INSTRUCTIONS AND OWNER’S HANDBOOK
CAUTION: All gas burners MUST be installed by trained and licensed technicians.
WARNING: Installation of this burner must conform with local codes or, in the absence of local codes, with
the Standard for the Installation of Domestic Gas Conversion Burners, ANSI Z21.8-1984, and Addendum,
Z21.8a-1989, and the National Fuel Gas code, ANSI Z223.1-1984, and CAN/CGA B149.1 &.2. If an external
electrical source is utilized, the conversion burner, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the national Electrical Code, ANSI/NFPA
No. 70-1990 and CSA Electrical Code.
Owner is required to retain this manual for future reference.
TECHNICAL SPECIFICATIONS
FIRING RATE 170,000 TO 400,000 Btu/hr
NATURAL PROPANE
GAS SUPPLY PRESSURES
MANIFOLD PRESSURES
POWER 120 VOLTS 60 Hz 1 PHASE
MOTOR 232T 2.2 AMPS 3250 RPM
CONTROL MODULE 525 SE/A ELECTRONIC
MIN. 4" w.c.
MAX. 10" w.c.
MIN. 0.90" w.c.
MAX. 1.80" w.c.
MIN. 8" w.c.
MAX. 13" w.c.
MIN. 1.04" w.c.
MAX. 3.04" w.c.
WARNING: If 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.
WHAT TO DO IF 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) Immediately call your gas supplier from a neighbour's phone. Follow the gas
supplier's instructions.
4) If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency
or the gas supplier.
C6505020 STD G400 Manual Rev.5 -06/10/2002 1
TABLE OF CONTENT
PRINCIPAL BURNER COMPONENTS .................................................................................................4
DIMENSIONS..........................................................................................................................................4
ELECTRODE & FLAME PROBE ADJUSTMENTS ..............................................................................5
TYPICAL GAS TRAIN LAYOUT...........................................................................................................6
INSTALLING THE BURNER .................................................................................................................7
INSTALLATION OF SEDIMENT TRAP & BURNER SUPPLY ...........................................................9
FIELD WIRING DIAGRAM..................................................................................................................10
FACTORY WIRING DIAGRAM...........................................................................................................10
SETTING UP THE BURNER ...........................................................................................................11-12
OPERATING FAULTS ..........................................................................................................................12
AIR GATE ADJUSTMENT ...................................................................................................................12
COMBUSTION HEAD SETTING ........................................................................................................13
MANIFOLD PRESSURES ................................................................................................................13-14
PRESSURE WORKING CHART...........................................................................................................14
COMBUSTION CHECKS .....................................................................................................................15
STARTING CYCLE ..............................................................................................................................16
PROBLEM SOLVING GUIDE .........................................................................................................16-17
OWNER INFORMATION & ROUTINE MAINTENANCE............................................................17-18
INSTALLATION DATA........................................................................................................................18
SPARE PARTS LIST..............................................................................................................................19
SPARE PARTS DIAGRAM ..................................................................................................................20
Burner Start-up Form………………………………………………………………………………...21
C6505020 STD G400 Manual Rev.5 -06/10/2002 2
The following pages contain information, descriptions and diagrams for the proper
Year of
BI-week of
Burner produc
t
installation and wiring of the burner. Please read carefully before attempting final
installation.
The responsibility for ensuring that this manual is complete rests with the holder of these
instructions.
SERIAL NUMBER IDENTIFICATION
The Riello 15 character serial number, example, 99 A 8511111 00025, is identified as follows:
99 = last two digits of the year of manufacture; A = BI-week of manufacture; 8511111 = burner product code;
00025 = increment of 1 for each burner produced – specific to product code – reset to zero each January 1st.
manufacture
(99) (A) (8511111) (00025)
manufacture
code
Increment
C6505020 STD G400 Manual Rev.5 -06/10/2002 3
PRINCIPAL BURNER COMPONENTS
1. Air Damper (Optional Delete)
2. Air Gate Lock-screws
3. Wiring Terminal Block
4. Air Pressure Switch
5. Motor
6. Lockout Lamps and Reset Button
7. Cover Screw
8. Rubber Grommet
9. Capacitor
BURNER DIMENSIONS
Model 400
inches 10 5/16 12 1 3/8 13 11/16 3 3/4 10 4 1/8
mm 2262 305 35 347 95 255 61
A B C F G *G1 H
*G1 is for LBT version
Gasket thickness is 4 millimeters
C6505020 STD G400 Manual Rev.5 -06/10/2002 4
UNIVERSAL MOUNTING FLANGE
UNIVERSAL MOUNTING FLANGE DIMENSIONS
inches 1 1/4 1/4 7/16 2 3/16
millimeters 32 6 11 56
A B C D
ELECTRODE AND FLAME PROBE ADJUSTMENTS
IMPORTANT: Do not turn the ignition electrode. Leave it as shown in the drawing. If the ignition
electrode is put near the ionization probe, the amplifier of the control box may be damaged.
C6505020 STD G400 Manual Rev.5 -06/10/2002 5
TYPICAL GAS TRAIN LAYOUT
FIELD SUPPLIED
RIELLO SUPPLIED
1 2 3 5 6
4
7
8
SEE GAS
SUPPLY
Ø
RANGE
NOTE: ITEMS 5,6 & 7 COMBINATION GAS VALVE(S) ASSEMBLIES MAY BE UTILIZED WHERE APPROVED.
GAS TRAIN LEGEND
1) GAS SUPPLY & FLOW DIRECTION OF GAS
2) GAS SUPPLY MAIN SHUTOFF MANUAL VALVE (FIELD
SUPPLIED)
3) GAS SUPPLY PRESSURE TEST POINT (FIELD SUPPLIED)
4) GAS TRAIN PIPE DIAMETER SIZE(S):
BURNER G120 1/2" NPT (REDUCED AT COMBUSTION HEAD
TO 3/8")
BURNER(S) G200 & G400 3/4" NPT
GAS SUPPLY PRESSURE RANGES:
NATURAL GAS PRESSURE:
MIN. = 4.0" WC
MAX. 10.5" WC
L.P. PROPANE GAS PRESSURE:
MIN. = 8.0" WC
MAX. 13.0" WC
5) GAS APPLIANCE PRESSURE REGULATOR
6) SAFETY SHUTOFF GAS VALVE (VS) 24V OR 120V
OPERATED
7) MAIN GAS VALVE (V1) 24V OR 120V OPERATED
SINGLE STAGE
8) GAS BURNER MANIFOLD TEST POINT
C6505020 STD G400 Manual Rev.5 -06/10/2002 6
INSTALING THE BURNER
Wet Base Illustration
A) Burner Chassis
B) Combustion Head Assembly
1. Locking Nut
2. Appliance Mounting Plate Insulation
3. Insulation Gasket
Use this checklist prior to installation:
1) Check the input/output requirements
of the appliance. We suggest that the
appliance output should be
approximately 85% of input (85%
efficiency).
2) Check the dimensions of the combustion chamber for correct sizing against the input requirements
of the application.
3) Check that there is sufficient air for proper combustion and adequate ventilation. Local codes
should be followed. In the absence of local codes, refer to the NFPA Manual No. 31, CAN/CGA B149.1
&.2, ANSI Z223.1-1984 and Addendum 221.8A 1989.
4) Check that you have adequate space for servicing the equipment. The Riello burner requires a
minimum of 13 inches clear space behind the red cover. This is required to allow easy removal of the
cover for servicing and periodic maintenance.
5) Check that the chimney is of sufficient area to handle the exhaust gases. Make sure the chimney is
clear and there are no obstructions.
6) Barometric draft regulators must be of the double acting type, and must be installed in accordance
with the draft regulator manufacturer's instructions. Single acting barometric dampers are not
permitted. For further clarification, refer to ANSI Z21.8-1984 and Z21.17A-1993.
NOTE: A vent shutoff system shall be applied to a barometric damper installed in the venting
system at the time of conversion of the appliance. This will electrically disconnect the burner
should there be a blockage in the vent (chimney).
IMPORTANT:
The installer must identify the main electrical power switch and manual gas shut off valve, for emergency
conditions. The burner cover must be in place and secured before the burner is placed in operation.
GENERAL INFORMATION
Your Riello gas burner comes to you completely assembled and factory wired, ready for installation.
Models equipped with the short combustion head have a fixed flange, which bolts directly to the front of the
appliance. When equipped with the long combustion head, the burner comes with a universal flange, which
when bolted to the appliance, allows the burner to be adjusted for exact positioning in the combustion zone.
C6505020 STD G400 Manual Rev.5 -06/10/2002 7
STEP -BY-STEP PROCEDURE
1) Remove the burner from the carton, taking care not to lose any of the supplied accessories. Check for
signs of physical damage.
2) Bolt the combustion head and burner to the appliance. Be sure to install the supplied mounting
gasket. Ensure that the burner is level (we suggest using a spirit level) and that the combustion head is
centred in the appliance port. Refer to Page 7 for positioning of combustion head relative to the chamber.
3) Check that all gas train connections are tight and make your connections to the incoming gas supply.
a) A sediment trap must be provided. See pg. 9.
b) If not already installed, a manual shutoff valve must be supplied. This valve must be upstream of
the burner gas train supply connection.
c) A 1/8" NPT plugged tapping must be installed immediately upstream of the burner gas train
supply connection and must be accessible for a test gauge.
d) If required by local codes, provide gas vent lines at the gas regulators and valve.
e) Perform required gas pressure test on incoming gas supply lines.
NOTE: Details of sediment trap, manual gas valve, pressure test point, and line pressure test point can
be found on Page 9.
4) To make electrical connections, refer to field wiring diagram on p age 10. A manual disconnect switch
must be installed in the incoming lines. Wiring to the low voltage -switching relay, if used, (Honeywell
R8038A) must be rigid conduit or flexible approved cable.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation. Verify proper operation after servicing (Step 5 (e) below).
CAUTION: The phase (HOT) wire must be connected to the black lead of the 24v relay if used; neutral
to the white lead. Do not reverse the polarity. The burner will not operate with the Phase/Neutral reversed,
and the control box may be damaged.
5) Check the burner functions as follows:
a) Make a final check on both the gas and electrical connections.
b) Loosen the screw in the manifold gas test point and install an appropriate manometer.
c) Set the thermostat at its highest setting.
d) Switch on power.
e) With the manual gas valve turned off, press the burner reset button (see page 4), and allow the burner to
run through a complete cycle to ensure that the sequence of operations is correct, (see page 16). A full
starting cycle should take approximately 70 seconds from a no power condition until burner lockout,
when equipped with motorized air damper, otherwise refer to the start-up cycle chart found on page 16.
f) Once the burner is operational (up and running) a final gas leak check must be completed on the gas
train.
6) If the burner is installed on a central warm air furnace, affix the mandatory warning labe ls to the
furnace fan cover door (inside and outside).
C6505020 STD G400 Manual Rev.5 -06/10/2002 8
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 located outside the appliance jacket, and the pressure gauge port must be accessible.
PRESSURE TEST -OVER 1/2 PSIG.
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 1/2 PSIG.
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 1/2 PSIG.
C6505020 STD G400 Manual Rev.5 -06/10/2002 9
FIELD WIRING DIAGRAM
120 V controlled 24 V controlled
V1 V2 L N L N
24 Volts
operating
control
Gnd.
Green
red
operating
control
white
black
Optional 24 V
controlled
24 Volt Relay *
Green
Gnd.
T T
F
service
switch
L
N
120 Volts 60 Hz.
F
service
switch
L N
FACTORY WIRING DIAGRAM
RIELLO POWER GAS BURNER
MODELS G120, G200 & G400
INTERNAL FACTORY WIRING DIAGRAM:
A) Standard burner come with 120/24 volt transformer for 24v
operated gas valves, for 120V operated gas valves delete
transformer.
B) Optional AIR DAMPER MOTOR
C) Remote sensing of 525 SE/A control box lock out. Installer
supplied and wired.
525 SE/A
9
CONTROL
BOX
3
681
NL
2
7
4
125
NO
NC
PA
C
Air damper motor
B
C
Optional wiring
Remote lock out
sensing wiring
Capacitor
A
MM
White
Brown
Blue
White
Black
Black
Black
Black
V2V1
NOTE:
1) This burner is approved for use without the motorized air damper. In these instances optional wiring is used
2) The SAFETY SWITCH on the 525 SE CONTROL BOX is equipped with a contact allowing remote sensing of
burner lockout. The electrical connection is located on the CONTROL BOX terminal 4 as indicated. Should
C6505020 STD G400 Manual Rev.5 -06/10/2002 10
burner lockout occur, the 525 SE CONTROL BOX will supply a power source of 120 Vac to the connection
terminal. The maximum allowable current draw on this terminal is 1 A.
IMPORTANT
Terminal 4 is to be used only for the connection of a remote sensing device. If a neutral or ground lead is
attached to terminal 4 the control box will be damaged should lockout occur
SETTING UP THE BURNER
After burner output has been determined, use TABLE 1 below AS AN INITIAL GUIDE for burner settings.
Table 1
Approximate Btu/hr
burner output
Natural Gas
Head Air gate Manifold
setting setting pressure
170, 000 0.0 1.6 0.90”w.c.
216, 000 1.0 1.8 0.90”w.c.
262,000 2.0 2.2 1.00”w.c.
308,000 3.0 2.5 1.20”w.c.
354,000 4.0 2.8 1.42”w.c.
400,000 5.0 3.4 1.80 w.c.
Propane
170, 000 0.0 1.6 1.04”w.c.
216, 000 1.0 1.8 1.16”w.c.
262,000 2.0 2.2 1.48”w.c.
308,000 3.0 2.5 1.80”w.c.
354,000 4.0 3.0 2.42”w.c.
400,000 5.0 3.6 3.04”w.c.
STEP BY STEP PROCEDURE
1) Set air gate. See AIR GATE ADJUSTMENT on pg. 13/14.
2) Set combustion head. See COMBUSTION HEAD SETTING on pg. 13.
3) Set the manifold pressure using the following method.
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 manifold pressure.
If the burner lights and continues to run, go to step (d).
b) Compare the observed manifold pressure from step (a) to the required value from TABLE 1.
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 appli ance 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 page12). This test must be done by a qualified technician. The maximum
recommended CO2 level for natural gas is 10%; the maximum recommended level for propane gas is
12%. 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 page18. 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 page17 and 18 for information on burner maintenance procedures.
All settings in this table were
obtained under the following
conditions.
?? 0 (zero) draft in the combustion
zone.
?? Small DIN test boiler.
?? 7” supply pressure for natural
gas.
?? 11” supply pressure for
propane.
?? steady state (HOT) operating
conditions
NOTE: Do not assume the heating system is operating at optimum performance.
C6505020 STD G400 Manual Rev.5 -06/10/2002 11
THERE IS NO SUBSTITUTE FOR PROPER COMBUSTION TESTING
OPERATING FAULTS
The integrated control system is self checking. The cycle from start up to flame establishment, takes
approximately 70 seconds.
The burner will go into lockout under the following circumstances:
a) Burner fails to ignite.
b) The ionization probe is grounded.
c) Opening of the air pressure switch or the normally open contacts of the air pressure switch not
Should overheating of the appliance occur, shut off the manual gas valve to the burner. Do NOT
shut off the switch to the circulating pump or blower fan.
SHUT DOWN PROCEDURE
Switch off electrical power to the unit. Close the manual supply gas valve.
START UP PROCEDURE
See page 8, Item 5
NOTE: If an external electrical source is utilized, the conversion burner, when installed, must be electrically
grounded in accordance with local codes. In the absen ce of local codes, refer to the National Electrical Code,
ANSI/NFPA 70-1990.
In Canada follow the Canadian Electrical Code Part 1 CSA C22.1.
making.
AIR GATE ADJUSTMENT
The mobile air damper (1), operated by the air damper motor (2), assures the complete opening of the air
intake. To regulate the combustion air, adjust the
manual air gate (3), by loosening the locking screws (4).
Once the optimal adjustment is reached, tighten the
locking screws(4), to assure free movement of the mobile
air damper.
EXAMPLE SETTING
(for natural gas)
To set the air intake for a desired burner
output of 308,000 Btu/hr, use TABLE 2 to
determine the correct air gate setting. In this
case, the setting would be 2.5 for natural gas.
Turn the manual air gate (3) until the arrow
points to 2.5 on the scale. Tighten locking
screws (4).
C6505020 STD G400 Manual Rev.5 -06/10/2002 12
All settings in table 2 are obtained with
Table 2
Table 3
zero (0) pressure in the combustion
zone and at normal operating
temperatures. i.e., steady state hot
conditions.
Please Note: Burner must be fired ONLY with
fuel that is listed on the burner serial label.
Burner Output Air Gate Setting
Btu/hr x 1000 Natural Propane
Riello 40 Model 400 N/P
Air Gate Settings
170.0 1.6 1.6
216.0 1.8 1.8
262.0 2.2 2.2
308.0 2.5 2.5
354.0 2.8 3.0
400.0 3.4 3.6
COMBUSTION HEAD SETTING( Stop Gate)
Loosen the Allen screw (A). Slide the elbow (B) so
that the number on the indicator scale (D) aligns
with the back edge of the air tube (C). See
TABLE 3 for set points. Tighten the Allen screw (A).
NOTE: To disassemble remove the combustion head,
use the procedure below.
1) Remove the Allen screw completely.
2) Withdraw the head.
3) Pull the head straight out.
Example (for natural gas):
For a desired burner output of 308,000 Btu/hr,
the combustion head setting would be 3.0
NOTE:
This table is designed to ensure a good
working pressure for the air proving switch.
If a problem is encountered with the air
switch proving combustion air flow, we
suggest moving the head closer to the
zero (0) set point.
For a boiler or furnace with positive
pressure in the combustion zone, we
suggest moving the head closer to the zero
(0) set point.
All settings in table 3 are obtained with zero
(0) pressure in the combustion zone and at
(1) normal
operating temperatures. i.e.; steady state hot conditions.
Please Note: Burner must be fired ONLY with fuel that is listed on the burner serial label.
Combustion Head Settings (STOP GATE)
Burner Output
Btu/hr x 1000 Natural Propane
Riello 40 Model 400 N/P
Head Setting
170.0 0.0 0.0
216.0 1.0 1.0
262.0 2.0 2.0
308.0 3.0 3.0
354.0 4.0 4.0
400.0 5.0 5.0
C6505020 STD G400 Manual Rev.5 -06/10/2002 13
MANIFOLD PRESSURES
Table
4
Manifold gas pressure for various firing rates must be set by adjusting the gas regulator of the gas valve. To
check manifold gas pressure, attach a manometer to the manifold test point, shown on typical gas train layout
on page 6. Approximate manifold pressure settings are indicated in TABLE 4.
Example (for natural gas):
For a burner to be fired at 308,000 Btu/hr, the manifold pressure would be approximately 1.20" w.c. (inches
of water column).
Riello 40 Model 400 N/P
Manifold Pressure Inches of w.c.
Burner Output Inches of w.c.
Btu/hr x 1000 Natural Propane
170.0 0.90 1.04
216.0 0.90 1.16
262.0 1.00 1.48
308.0 1.20 1.80
354.0 1.42 2.42
400.0 1.80 3.04
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 at
elevations above sea level . If an increase in combustion air is insufficient, the burner must then be derated by
approximately 4% for every 1000 feet above sea level.
Manifold pressure will have to be
adjusted to compensate for varying
application conditions.
All settings in table 4 are obtained with
zero (0) pressure in the combustion
zone and at normal operating
temperatures. i.e.; steady state hot
conditions.
Please Note: Burner must be fired ONLY
with fuel that is listed on the burner serial
label.
PRESSURE WORKING CHART
The chart below shows effects of pressure in the combustion zone on the minimum/maximu m burner outputs.
In this example, with a maximum operating pressure of 0.6 inches water column in the combustion zone, you
will be able to obtain a maximum of 370,000 Btu/hr burner output.
In/wc
3.5
3.0
2.5
2.0
1.5
PRESSURE
1.0
0.5
0.0
170 210 250 290 330 370 410
PRESSURE WORKING CHART
Natural and LPG gas
INPUT (000's) BTUH
C6505020 STD G400 Manual Rev.5 -06/10/2002 14
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.
COMBUSTION CHAMBER SIZE
28
26
24
22
Recommended Minimum Sizes
20
Inches
18
16
14
12
10
150 200 250 300 350 400
INPUT (000's) BTUH
LENGTH
DIAMETER
NOTES:
1) Sizes shown above are for cylindric al or wet base boilers, or air cooled heat exchangers.
2) To size the chamber in applications other than wet base boilers, you must calculate area in square inches
of the combustion zone required to give you a grate area or floor area to match the BTU inputs according to
the local authority. Refer to CAN/CGA B149.1 & .2 ANSI Z21.8-1984, and ANSI Z223.1-1984.
3) Fire brick or cerafelt chamber materials should have a continuous run temperature rating of 2400 degrees
Fahrenheit and a melting point of 3000 degrees Fahrenheit.
COMBUSTION CHECKS
CO
2
It is advisable not to exceed a measured reading of 10% CO2 for Natural Gas or 12% CO2 for Propane Gas.
CO
For safety reasons, the value of .02% (200ppm) free air sample must not be exceeded.
IONIZATION CURRENT
The minimum amount of current necessary for the control box to operate properly is 5 microamps DC.
To measure the ionization current, disconnect the red wire connector and insert a DC micro ampmeter in
series with control box terminal 2 and the ionization probe which senses the flame. Refer to the diagram
below.
C6505020 STD G400 Manual Rev.5 -06/10/2002 15
Burner Start-up Cycle
Ionization Current Check
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.
C6505020 STD G400 Manual Rev.5 -06/10/2002 16
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 24 vo lt 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 d efective.
i) The control box is defective.
j) The air pressure switch is not in the normally closed position
4) The burner continues to repeat the starting cycle without going into lockout.
This is a very specific situation caused when gas pressure in the gas main lines is very close to the
value at which the gas pressure switch has been set. This can be corrected by resetting the gas
pressure switch to a lower level. The gas pressure switch, if required, may be supplied, or may have to
be field in stalled.
5) The burner does not go through prepurge, and the control module goes to lockout. The air pressure switch
does not change over from normally closed to normally open contacts.
This condition exists because there is insufficient air pressure in the combustion head.
OWNER INFORMATION AND ROUTINE MAINTENANCE
SAFETY LOCKOUT
This burner is equipped with multiple interlocking safety devices. In the event of a failure in the flame, or any
blockage of the combustion air supply, the burner will "lock out" in a safety condition. In such an event, an
illuminated red button will show on the centre front of the red cover. To restart the burner, press the button
once only. Should the burner return to the lock out condition, call a qualified service technician or your gas
company for assistance.
NOTE: Keep the area around the burner free and clear of all combustible materials, gasoline and other
flammable vapours and liquids. Do not allow any obstructions which may prevent the free flow of air to the
burner.
MAINTENANCE
Like all precision equipment, your burner will require periodic maintenance. At an interval of 2 months, you
should:
1) Visually check the flame if your heating appliance has an observation port.
2) Check and clean the air intake louver to remove any build up of fluff, dust, pet hair etc.
3) The motor is permanently lubricated and does not need oiling.
For any maintenance or repairs over and above those listed, contact your service technician or gas company.
THERE ARE NO OWNER SERVICEABLE PARTS INSIDE THE BURNER COVER.
Once a year, you should have the burner serviced as indicated below. This service should be
performed by your local authorized dealer.
1) Check burner distributor head and mixing plates. Clean if necessary.
2) Check ignition electrode. Clean, adjust, or replace as necessary.
C6505020 STD G400 Manual Rev.5 -06/10/2002 17
3) Check the flame sensor rod (ionization rod) for dirt or carbon build up. Clean, adjust, or replace as
necessary.
4) Check manifold gas pressure.
5) Check all burner adjustments.
6) Generally clean all exposed parts and components.
7) Do a complete combustion test with the burner cover in place and the air gate locking screws secure.
Your Riello 40 gas burner is only part of your heating system. Once every year you sho uld have your heating
appliance serviced by a qualified service technician. You should also have the chimney checked, and cleaned
if necessary.
INSTALLATION DATA
Note: This label is supplied in the package with the burner
and should be filled out and affixed to the appliance when the
conversion burner is installed.
C6505020 STD G400 Manual Rev.5 -06/10/2002 18
SPARE PARTS
GAS BURNER SYSTEM
RIELLO 40 N400
REVISED: 10/01
No.
1 3007238
2 C7020008
3 3001162
4 3002307
5 C7020006
6 3007288
7 3007310
8 3007293
9 3006688
10 3007223
11 3007279
12 3006930
13 3007205
SPARE
PARTS
CODE
DESCRIPTION
Burner back cover
Air switch
Primary control box 525 SE/A
Primary control sub -base
120/24 volt transformer
Air switch tube and connector
Ionization lead
Air tube cover plate
Chassis mounting collar
Chassis front plate
Air damper motor
Motorized air damper
Manual air shutter(air gate)
No.
21 3950371 Short combustion head (279T1)
22 3006696
23 3007275
24 3007265
25 3006708
26 3006702
27 3006699
28 3007299
29 3006693
30 3005447
31 3000870
33 3950372 Long combustion head (279T2)
SPARE
PARTS
CODE
DESCRIPTION
Drawer assembly elbow
Electrode assembly
Electrode and ionization clamp
Ionization assembly
Natural gas orifice
Distributor head and mixing plate
Manifold
End cone
Gas test point
Hinge assembly
14 3007209
15 3005788
16 3005834 Capacitor 10? F 36 3007265
17 3005843
18 3005856
19 3006356
20 3007448
49 C7010003
ACCESSORIES 45 3007303
C7020004
Air intake housing
Fan
Burner motor
Mounting gasket
Universal mounting flange
Ground lead and connector
Mounting bracket -Transformer
Honeywell R8038A 24 v
switching relay
34 3006696
35 3007276
37 3007277
38 3007300
39 3007290
40 3005854
41 3006693
42 3007282
43 3006702
44 3006699
46 3007285
47 3005447
48 3000870
Drawer assembly elbow
Electrode assembly
Electrode & ionization clamp
Ionization assembly
Manifold
Natural gas tube
Semi flange 2 required
E nd cone
E nd cone adapter
Natural gas orifice
Distributor head and mixing plate
Electrode support
Air tube -long
Gas test point
Hinge assembly
C6505020 STD G400 Manual Rev.5 -06/10/2002 19
C6505020 STD G400 Manual Rev.5 -06/10/2002 20
Hingham, MA 02043
8292
7637
Mississauga,On L5H 3R2
0303
3898
Two
35 Pond Park Rd.
Phone: 781-749-
Toll Free: 800-992-
Fax: 781-740-2069
2165 Meadowpine Blvd.
Phone: 905-542-
Toll Free: 800-387-
Fax: 905-542-1525
BURNER START- UP FORM *
Burner S/N. or
Model:
Installer name:
Appliance:
Company: Installation date:
Address:
Phone: Fax:
Owner Name:
Address:
Phone: E-mail:
Burner Start-up Info (OIL)
Burner Start-up Info (GAS)
Nozzle Info: Gas Supply Pressure:
Pump Pressure: Pump pressure:
Turbulator
Air Setting:
setting:
Air Setting: Head Setting:
Draft
Draft Overfire:
breech:
Draft Overfire: Draft breech:
CO2:
CO:
O2:
CO2: CO: O2:
Smoke density: (Bacharach)
Manifold pressure:
Single Line:
Lines:
Ionization Reading µAdc:
Input BTU/Hr:
* This form was designed and provided in the installation manual for reference and also for providing technical
information which can be faxed or mailed to our technical hot -line coordinator when technical assistance is required.
Please complete this form, fax it or mail it at the address/fax above, or send an e-mail with the information listed below
to: techservices@riellocanada.com
C6505020 STD G400 Manual Rev.5 -06/10/2002 21
35 Pond Park Road
Hingham, MA 02043
Phone 781-749-8292
Toll Free 800-992-7637
Fax 781-740-2069
www.riellousa.com
2165 Meadowpine Blvd
Mississauga, ON L5N 6H6
Phone 905-542-0303
Toll Free 800-387-3898
Fax 905-542-1525
www.riellocanada.com
Technical Support Hotline
1-800-4-RIELLO
1-800-474-3556
C6505020 STD G400 Manual Rev.5 -06/10/2002 22
Loading...