Riello RLAS 1000 EV Quick start guide

Installation, use and maintenance instructions
20146383 (1) - 04/2019
Dual fuel air atomizing oil/gas burner
Modulating operation
CODE MODEL
20164347 - 20164348 RLAS 1000/EV (FGR prepared)
20164351 - 20164352 RLAS 1200/EV (FGR prepared)
GB

Original instructions

1 20146383
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Burner equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Burner capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Panel board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 AZL display... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Control box for the air/fuel ratio (LMV52...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.13 Servomotor (SQM48.4....) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Removing the shutter lockout screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Preparing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.7 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.8 Access to head internal part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9 Combustion head adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.10 Electrode position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.11 Nozzle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.12 Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.13 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.14 Gas train supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.15 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.16 Installation of shielded cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.17 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.18 Motor connection at 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Adjustments before first firing (light oil operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Fuel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Adjustments before first firing (gas operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.7 Burner ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

20146383 2
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Contents
5.8 Final calibration of the pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.9 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Faults - Possible causes - Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Information and general instructions
3 20146383
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1.1 Information about the instruction manual
1.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not be
separated from it; it must therefore be kept carefully for any
necessary consultation and must accompany the burner even
if it is transferred to another owner or user, or to another sys-
tem. If the manual is lost or damaged, another copy must be
requested from the Technical Assistance Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER signs.
Pay great attention to these, as they indicate a situation of potential
danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 Information and general instructions
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with lethal
consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to high
temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving parts:
danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in the
form of gases, vapours, mist or dust in which, after
ignition has occurred, combustion spreads to the
entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must be
worn and kept by the operator for protection against
threats against safety and/or health while at work.
OBLIGATION TO ASSEMBLE THE COVER AND
ALL THE SAFETY AND PROTECTION DEVICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the ma-
chine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20146383 4
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Information and general instructions
1.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the room
where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer or
another specialised technician.
To ensure a periodic check, the manufacturer recommends
the drawing up of a Maintenance Contract.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installation
date, in accordance with the regulations in force and/or the sales
contract. At the moment of the first start-up, check that the burner
is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to peo-
ple, if such damage/injury was due to any of the following causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incorrectly
applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregularity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that pre-
vent the regular development of the structurally established
flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and tear;
the use of non-original components, including spare parts,
kits, accessories and optional;
force majeure.
The manufacturer furthermore declines any and every respon-
sibility for the failure to observe the contents of this manual.
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WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

Safety and prevention
5 20146383
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2.1 Introduction
The burners have been designed and built in compliance with cur-
rent regulations and directives, applying the known technical rules
of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk for
the user or third parties, as well as the damaging of the burner or
other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diathermic
oil, and to other users expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion chamber
and the room temperature must all be within the values indicated in
the instruction manual.
Modification of the burner to alter its performance and destina-
tions is not allowed.
The burner must be used in exemplary technical safety condi-
tions. Any disturbances that could compromise safety must be
quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
2.2 Personnel training
The user is the person, body or company that has acquired the ma-
chine and intends to use it for the specific purpose. He is responsi-
ble for the machine and for the training of the people working
around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about the
application and observance of the safety instructions. With
that aim, he undertakes to ensure that everyone knows the
use and safety instructions for his own duties;
Personnel must observe all the danger and caution indications
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.
In addition:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
the user must take all the measures necessary
to prevent unauthorised people gaining access
to the machine
the user must inform the manufacturer if faults
or malfunctioning of the accident prevention
systems are noticed, along with any presumed
danger situation
personnel must always use the personal pro-
tective equipment envisaged by legislation and
follow the indications given in this manual

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Technical description of the burner
3.1 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394” wc - Altitude 329 ft.
(2) Related to G.C.V.
(3) Pressure at test point 13)(Fig. 5, pag. 11), with zero pressure in the combustion chamber, and maximum burner output.
(4) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated
output.
(*) Firing Rate for C-ETL Canadian Listing
3.2 Electrical data
Tab. B
3 Technical description of the burner
Model RLAS 1000/EV
(FGR prepared)
RLAS 1200/EV
(FGR prepared)
Output delivery(1)
High
Natural
Gas MBtu/hr (2) 14.000 39.780 35.800*20.500 43.000 38.700*
#2 GPH 100 284 255*146.4 307 276.4*
Low
Natural
Gas MBtu/hr (2) - - - 4.300 - -
#2 GPH - - - 30.7 - -
Fuel Oil #2
Natural gas
- Gas max. delivery SCFH 39.386 42.574
- Gas pessure at max. delivery (3) “WC 30.1 36.8
Operation Low - high or modulating
Nozzles 1
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40°C)
Combustion air temperature °F max 140 (60°C)
Noise levels (4) dBA 80 90
Model RLAS 1000/EV
(FGR prepared)
RLAS 1200/EV
(FGR prepared)
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 460/3/60
Fan motor
IE3/NEMA Premium Efficiency
rpm
HP
V
A
3540
30
460
35.8
3530
40
460
49.8
Pump motor
IE3/NEMA Premium Efficiency
rpm
HP
V
A
3500
2
460
2.8
3500
2
460
2.8
Ignition transformer (GAS) V1 - V2
I1 - I2
120 V - 1 x 8 kV
1.6 A - 20 mA
Electrical power consumption W25670 34235
Electrical control circuit consumption W max 1250 1250
Total electrical consumption W26920 35485
Electrical protection NEMA 3
Minimum Circuit Ampacity (MCA) A47 62
Maximum rating of overcurrent
protective device (MOP) A84 112

Technical description of the burner
7 20146383
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3.3 Burner models designation
Tab. C
3.4 Burner equipment
The burner is supplied complete with:
Thermal insulator screen . . . . . . . . . . . . . . . . . . . . . . .No. 1
Gas flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Head looking screw replacement . . . . . . . . . . . . . . . . .No. 2
Gas flange to burner fixing - M16x67 Screw . . . . . . . .No. 4
Gas flange to burner fixing - M16 Nut . . . . . . . . . . . . .No. 4
Gas flange to burner fixing - M16 Washer . . . . . . . . . No. 4
Burner to boiler fixing - M20x70 Screw. . . . . . . . . . . . No. 4
Burner to boiler fixing - M20 Washer . . . . . . . . . . . . . No. 4
Burner to boiler fixing - M20 Nut . . . . . . . . . . . . . . . . . No. 4
Installation, use & maintenance instruction . . . . . . . . No. 1
3.5 Packaging
The packaging of the burner (Fig. 1) rests on a wooden plat-
form that is particularly suitable for lift trucks.
The overall dimensions of the packaging are shown in the
Tab . D .
The weight of the burner complete with its packaging is shown
in Tab. D.
Tab. D
Model RIELLO
Code
RBNA
Code Voltage Fan Motor Starting Flame safeguard
RLAS 1000/EV (FGR prepared) 20141370 20164347 460/3/60 Inverter Burner Mounted
RLAS 1000/EV (FGR prepared) 20164348 230/3/60 Inverter Burner Mounted
RLAS 1200/EV (FGR prepared) 20141378 20164351 460/3/60 Inverter Burner Mounted
RLAS 1200/EV (FGR prepared) 20164352 230/3/60 Inverter Burner Mounted
inch X Y Z lbs
RLAS 1000/EV 94 31/64“61 1/32“62 63/64”1190
RLAS 1200/EV 94 31/64“61 1/32“62 63/64”1190
20158479
X
Z
Y
Fig. 1

20146383 8
GB
Technical description of the burner
3.6 Overall dimensions
The maximum dimensions of the burner are given in Fig. 2.
Bear in mind that inspection of the combustion head requires the
burner to be opened by rotating the rear part on the hinge.
The overall dimensions of the burner when open are indicated by L
and R.
Tab. E
F
C
P T
I
D
E
L
G M
H
R
AO
Fig. 2
20162816
Model A C D E F G H I L M O P R T
1000
[mm] 1500 200 413 884 ASME
150lb 674 1375 485 1360 686 299 1640 1350 658
[inch] 59 1/16 7 7/8 16 17/64 34 51/64 Ø 3" 26 17/32 59 9/64 19 3/32 53 35/64 27 1/64 11 49/64 64 9/16 53 5/32 25 29/32
1200
[mm] 1500 200 456 884 ASME
150lb 774 1375 464 1460 686 299 1640 1350 658
[inch] 59 1/16 7 7/8 17 61/64 34 51/64 Ø 3" 30 15/32 59 9/64 18 17/64 57 31/64 27 1/64 11 49/64 64 9/16 53 5/32 25 29/32

Technical description of the burner
9 20146383
GB
3.7 Burner capacity
3.7.1 Procedure to refer burner operating condition at an altitude and/or at a combustion supporter air
temperature different to the standard values (328 ft above sea level, 68 °F).
Tab. F
F - correction factor of discharge head and delivery in relation to temperature and altitude.
Reference conditions:
–Air temperature 68 °F (20 °C)
– Barometric pressure 394 ''w.c. (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.)
Example
Using the , for an altitude of 3,000 ft and an air temperature of 68
°F, an F factor value is obtained equal to 0.908;
if the capacity at the boiler furnace is Qfoc = 4,500 Mbtu/h, the cor-
rect output will be equal to:
Qburner = Qfoc / F = 4,500 / 0.908 = 4,956 Mbtu/h
Ϭ
ϭ
Ϯ
ϯ
ϰ
ϱ
ϲ
ϳ
ϴ
ϵ
ϭϬ
ϭϭ
ϭϮ
ϭϯ
ϭϰ
ϭϱ
ϭϲ
ϭϳ
ϭϴ
ϭϵ
ϮϬ
Ϯϭ
ϮϮ
Ϯϯ
Ϯϰ
Ϯϱ
Ϯϲ
Ϭ ϮϱϬϬ ϱϬϬϬ ϳϱϬϬ ϭϬϬϬϬ ϭϮϱϬϬ ϭϱϬϬϬ ϭϳϱϬϬ ϮϬϬϬϬ ϮϮϱϬϬ ϮϱϬϬϬ ϮϳϱϬϬ ϯϬϬϬϬ ϯϮϱϬϬ ϯϱϬϬϬ ϯϳϱϬϬ ϰϬϬϬϬ ϰϮϱϬϬ ϰϱϬϬϬ
;ΎͿ
;ΎͿ
Burner power output - MBtu/hr Fig. 3
20162856
Combustion chamber
pressure - “wc
(*) Firing Rate for C-ETL Canadian Listing
RLAS 1000
RLAS 1200
AIR TEMPERATURE
Altitude Altitude bar. press. bar. press. 0 5 10 15 20 25 30 40 °C
ft a.s.l. m a.s.l. "w.c. mbar 32 41 50 59 68 77 86 104 °F
00399 1013.00 1.087 1.068 1.049 1.031 1.013 0.996 0.980 0.948
328 100 394 1000.00 1.073 1.054 1.035 1.017 1.000 0.983 0.967 0.936
1.000 305 385 977.40 1.049 1.030 1.012 0.994 0.977 0.961 0.945 0.915
2.000 610 371 942.80 1.012 0.994 0.976 0.959 0.943 0.927 0.912 0.883
3.000 915 358 908.20 0.975 0.957 0.940 0.924 0.908 0.893 0.878 0.850
4.000 1.220 345 875.80 0.940 0.923 0.907 0.891 0.876 0.861 0.847 0.820
5.000 1.525 332 843.50 0.905 0.889 0.873 0.858 0.844 0.829 0.816 0.790
6.000 1.830 320 811.85 0.871 0.856 0.841 0.826 0.812 0.798 0.785 0.760
7.000 2.135 307 779.80 0.837 0.822 0.807 0.793 0.780 0.767 0.754 0.730
8.000 2.440 294 747.80 0.803 0.788 0.774 0.761 0.748 0.735 0.723 0.700

20146383 10
GB
Technical description of the burner
3.8 Minimum furnace dimensions
The firing rate was obtained in special test boilers.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 26510 Mbtu/hr: - diameter 47.7 inch - length 20 ft.
Fig. 4
1000MBt u/ hr 760 1.5 7.5 11.3 18.9 37870
1.6
3.3
6.6
9.9
13.2
16.5
29.6
23.0
15. 7 19. 7 23. 6 31. 5 39. 4 47. 2
inches
ft
ft= 0,12 MBtu
hr
22.7
D9084

Technical description of the burner
11 20146383
GB
3.9 Burner components
1 Compressed air valve
2 Air solenoid valve
3 Air inlet pressure gauge
4 Oil modulator and gas butterfly valve servomotor
5 Oil modulator
6 Nozzle delivery pressure gauge
7 Oil shut off VOG valve
8 Air inlet to fan
9 Electric panel board - cover
10 Lifting eyebolts
11 Air gate valve servomotor
12 Nozzle return pressure gauge
13 Max oil pressure switch
14 Air pressure switch
15 Manifold
16 Thermal insulation screen for securing burner to boiler
17 Shutter
18 Ignition pilot
19 Combustion head
20 Flame stability disk
21 Nozzle
22 Atomizing lance DN40
23 Gas train flange
24 Pump motor
25 Lever for movement of combustion head
26 Max gas pressure switch with pressure test point
27 QRI flame detector
28 Hinge for opening burner
29 Air pressure switch (diff.operating type)
30 Fan motor
31 Speed sensor (*only EV version)
32 Fan
33 Min oil pressure switch
34 Strainer
35 Check valve
36 Pump
37 Air pressure test point
8
9
10 11 12 13 14 15 16 17 18
19
20
21
22
23
24
29
30
*31
32
33
34
35
36
25 26 27 28
37
1234
5
6
7
7
Fig. 5
20147279

20146383 12
GB
Technical description of the burner
3.10 Panel board description
1Horn
2Relays
3 Control box transformer “T1”
4 Control box for checking flame and air/fuel ratio
5 Ignition transformer “TA”
6 Plug/socket for maximum gas pressure switch
7 “OFF - LOCAL - REMOTE” switch
8 “OIL-EXT-GAS” switch
9 “ALARM SILENCE” button
10 “POWER ON” signal
11 “CALL FOR HEAT” signal
12 “Burner lock-out and reset” push button
13 Auxiliary fuse
14 Electric joint for air pressure switch pipe
15 “X2” terminal strip
16 “X1” burner terminal board
17 Holes for cables grommets for electrical wirings, accessories
and power supply (to be carried out by the installer)
18 Low air pressure switch
19 Operator panel with LCD display
20 “XAUX” terminal strip
21 Bracket for shielded cables
Warning: used only to avoid a break in the cable’s shielding,
hence do not overtighten.
22 Electric joint for ignition cable
23 Speed sensor terminal strip “X70”
24 Addictional trasformer
25 Plug/socket for flame sensor
26 Plug/socket for air servomotor
27 Optional hole
28 Electric joint for speed sensor
29 Pump motor contactor and thermal relay
30 Touch screen display (available as kit)
31 Step-down transformer (available)
32 Plug/socket for pump motor group
33 Oil valve and motor pump electrical group
A type of burner failure may occur:
Flame safeguard lock-out
If the flame safeguard alarm 12)(Fig. 6) lights up, it indicates
that the burner is in lock-out. To reset, press the reset push-
button.
3
45
13
15
18
20
21
24
2
14
16
22
23
25
29
30
A
32
6
26
7
8
9
10 11
12
19 27 1
17
28
33
A
31
20164636
Fig. 6
WARNING
The connection of the inverter and O2 kits must be
carried out by the client / installer following the in-
structions (electrical drawing) provided with the
burner and the kits.

Technical description of the burner
13 20146383
GB
3.11 AZL display...
Warnings
The electronic cam is operated and programmed through the AZL5
interface... or with the aid of a PC.
The AZL5 has a backlit LCD display with clear reading of the menu
text and diagnostics.
The Modbus function of the AZL display integrates the electronic
cam LMV5 and through data management allows the diagnostic of
the burner.
The display shows the operating status, the types of errors and
lockouts. Used to parametrize and monitor data.
Technical data
Tab. G
WARNING
To avoid accidents, material or environmental dam-
age, observe the following instructions!
The AZL... display is a safety device! Avoid opening
or modifying it, or forcing its operation. Riello S.p.A.
cannot assume any responsibility for damage re-
sulting from unauthorised interventions!
Operating voltage AC 24 V - 15% / +10%
Power consumption < 5W (typical)
Protection level of the container
–Rear
–Front
IP00 according to IEC 529
IP54 according to IEC 529 (if
installed)
Safety class I with parts II and III accord-
ing to DIN EN 60730-1
Battery - Manufacturer: Type reference:
VARTA
DURACELL
SANYO ELECTRIC, Osaka/
Japan
RENATA AG, Itingen/CH
CR 2430 (LF-1/2 W)
DL 2430
CR 2430 (LF-1/2 W)
CR 2430
S9232 Fig. 7

20146383 14
GB
Technical description of the burner
3.12 Control box for the air/fuel ratio (LMV52...)
Warnings
All interventions (assembly and installation operations, assis-
tance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the control box connection area,
fully disconnect the system from the power supply (omnipolar
separation). Check the system is not powered and cannot be
accidentally reconnected. Failure to do this will lead to the risk
of electrocution.
Protection against electrocution from the control box and all
connected electric components is obtained with correct
assembly.
Before any intervention (assembly and installation operations,
assistance, etc.), ensure the wiring is in order and that the
parameters are correctly set, then make the safety checks.
Falls and collisions can negatively affect the safety functions.
In this case, the control box must not be operated, even if it
displays no evident damage.
In programming mode, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
As for automatic operation, the actuators are guided together
to the positions requested and, if an actuator does not reach
the position requested, adjustments are made until the posi-
tion is actually reached. However, in contrast to automatic
operation, there are no time limits to these corrective actions.
The other actuators maintain their positions until all actuators
have reached the positions currently required.
This is absolutely important to set the fuel / air ratio control
system. During the time the fuel / air ratio curves are being
programmed, the person making the plant settings must con-
tinuously monitor the quality of the combustion process (e.g.
by means of a flue gas analyser).
Also, if combustion levels are poor, or in the event of danger-
ous situations, the commissioning engineer must take appro-
priate action (e.g. switching off manually).
To ensure the safety and reliability of the control box, the follow-
ing instructions must also be followed:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again, make
sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the con-
trol box’s electronic components when touched.
Mechanical structure
The control box is a system to check the burners, based on a mi-
croprocessor and equipped with components to adjust and monitor
medium and large capacity forced draught burners.
The base control box incorporates the following components:
• Burner control with gas valve proving system
• Electronic fuel / air ratio control with a maximum of 6 actuators
• Optional PID temperature / pressure controller (load controller)
• Optional VSD module Mechanical design
WARNING
To avoid accidents, material or environmental dam-
age, observe the following instructions!
The control box is a safety device! Avoid opening or
modifying it, or forcing its operation. Riello S.p.A.
cannot assume any responsibility for damage re-
sulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the AZL5… display and operating unit and
incorrect settings of the fuel and / or air actuator po-
sitions can lead to dangerous burner operating con-
ditions.
Fig. 8
D9301

Technical description of the burner
15 20146383
GB
Electrical connection of ionization probe and flame detector
It is important to achieve practically disturbance- and loss-free
signal transmission:
• Never run the detector cables together with other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the permissible cable lengths.
Technical data
Tab. H
LMV52... basic unit Mains voltage AC 120 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power consumption < 30 W (typically)
Safety class I, with parts according to II and III to DIN EN 60730-1
Terminal loading
‘Inputs’
Unit fuse F1 (internally) 6.3 AT
Perm. mains primary fuse (externally) Max. 16 AT
Undervoltage
• Safety shut-down from operating position
at mains voltage
• Restart on rise in mains voltage
< AC 96 V
> AC 100 V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor
1.6A
cos > 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor
0.5A
cos > 0.4
Terminal loading
‘Outputs’
Total contact loading:
• Mains voltage
• Input current of unit (safety loop) total
load on contacts resulting from:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 120 V -15 % / +10 %
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor
1A
cos > 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor
1 A
cos > 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos > 0.2
Fuel valve gas (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos > 0.4
Fuel valve oil (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos > 0.4
Cable lengths Main line Max. 100 m (100 pF/m)
Environmental
conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60 °C
< 95 % r.h.

20146383 16
GB
Technical description of the burner
Operation sequence of the burner
TSA1
k)
Gas
Gas
OR
0° / 0%
90° / 100%
TSA1
Fuel
Actuator 2, 3
Nox red.
Actuator 6
Gas+oil
Oil
Ignition (Z)
Fuel valve, SV
Fuel valve, PV
Fuel valve, V1
Fuel valve, V2
Fuel valve, V1
Fuel valve, V2
Fuel valve, V3
Fuel valve, SV
Oil
INPUTS
Timer 1
Timer 2
Fuel 1 (oil)
Fuel 2 (gas)
Controller - ON (internal + external)
Air pressure switch (LP)
Start release - oil
Fuel
selection
Fan conductor contact (GSK)
Interval 1 ti1
Operation 2 LK => K - POS
SR = ON
Pressure test
Direct start
Air, Aux, VSD
Actuator 1, 4, 5
(CPI function with LMV52...)
(alternative start signal)
Fig. 9
D9507

Technical description of the burner
17 20146383
GB
Key to the sequence diagrams:
Depending on the parameter, valve proving takes place:
between phase 62 and phase 70 or/and
between phase 30 and phase 32.
Assignment of times:
t0 Postpurge lockout position
t01 Max. time safety phase
t10 Min. time home run
t21 Min. time start release
t22 Fan runup time t30 Prepurge time part 1
t34 Prepurge time part 3
t36 Min. ON time oil pump
t38 Preignition time gas / oil
t42 Preignition time OFF
t44 Interval 1 gas / oil
t62 Max. time low-fire
t70 Afterburn time
t74 Postpurge time 1 gas / oil (tn1)
t78 Postpurge time 3 gas / oil (tn3)
t80 Valve proving evacuate time
t81 Leakage test time atmospheric pressure
t82 Leakage test filling test
t83 Leakage test time gas pressure
tmn1 Min. time extraneous light test (5 s.) after skip over of
prepurge
tmx1 Max. damper running time
tmx2 Max. time startup release
tmx3 Max. time circulation heavy oil
tn Postpurge time
TSA1 Safety time 1
TSA2 Safety time 2
tv Prepurge time gas / oil
Signal ON Signal OFF Next phase
Parameter direct start
Checking with controller on
Deviation 10
No Rep. decrement
10
70
Without VP70 with VP80
62
Stop, up to Ph – max. time 01
Stop, up to Ph – max. time 10
Input: don´t care
Output: OFF
Output: ON
00, Rep = 0
12, Rep > 0
01
0-3 s.
00, Rep = 0
12, Rep > 0
01
0-30 s.
00, Rep = 0
12, Rep > 0
01
0-3 s.
00, Rep = 0
12, Rep > 0
01
79
10
Param.

20146383 18
GB
Technical description of the burner
Key to the sequence diagrams:
1) Parameter: With / without pressure switch
2) Parameter: Short / long preignition time for oil only Short /
long oil pump – ON – time
3) Delayed shutdown within TSA1 + TSA2
4) Parameter: Output as startup signal / pressure switch relief
valve
5) Parameter: Normal / direct startup
Normal startup sequential phase = 10
Direct startup sequential phase = 79
(when R = ON)
6) Sequential phase = 24
7) Only with valve proving during startup
8) Parameter: With / without alarm on prevention of startup
9) Parameter: With continuous purging the shown output sig-
nals are inverted
10) Fan controlled as before
Running time when LOCK OUT = T_FanLockout LF
11) Parameter: With / without extraneous light test in STANDBY
12) With valve proving during startup phase 10
13) Parameter: Normal / continuous purging
Normal purging: Checking for off in 10, stop to
Ph-max time 01
Continuous purging: Checking for on in 10 and
12, Stop up to phase-max time 01
14) Parameter: “OilPressureMin”, “akt_from_ts“ no check
before TSA1 (LO, HO) or TSA2 (LOgp, HOgp)
15) Parameter: “GasPressureMin“, “deakt_xOGP“ pres-
sure switch-min can be deactivated for oil pro-
grams with gas pilot
16) Parameter: “OilPumpCoupling“, “direct_coupl“ shutoff
valve oil has to be connected to output “Oil pump
/ magnetic clutch“.
Output is active when fan is on and for another
15 s after fan is switched off
17) Parameter: “Start / pressure switch valve“, “PS_Re-
li_Inv“ Output pressure switch valve will be
logically inverted
18) Parameter: “Alarm act / deact“, “deactivated“ The alarm
output can temporarily be deactivated (for cur-
rent error only)
19) Parameter: Only with LMV52...: Continuous pilot gas / oil:
Activated Pilot valve is also activated in op-
eration
20) Parameter: Only with LMV52...: Extraneous light, pilot
phase, operating phase gas / oil Separate
flame supervision possible
21) Parameter: Only with LMV52...: pressure switch valve prov-
ing / CPI or StartReleaseGas Parameter-
dependent ON / OFF test
CPI Gas: OFF test for gas trains only
CPI Oil: OFF test for oil trains only
CPI Gas+Oil: OFF test for gas and oil trains
22) Parameter: After LMV52... software version 04.50 and
AZL5... software version 04.40, dependent on
parameter StartPktOperation
0° Position as supplied (0°)
90° Actuator fully open (90°)
AGR Fuel gas recirculation
CPI Closed position indication
DP Pressure tester
PS-VP Pressure switch – valve proving
FCC Fan contactor contact
LF Air damper
APS Air pressure switch
N Postpurging
SR Safety relay
SLT Safety limit thermostat
TL Temperature limiter
Repetition counter:
k) Heavy oil
l) Restricted startup behavior
n) Restricted safety loop
Permissible positioning range
In Standby: actuator can travel within the permissible po-
sitioning range, but is always driven to the home position.
Must be in the home position before changing the phase.