Riello RL/E Series Quick start guide

20109674 (3) - 02/2022
Installation, use and maintenance instructions
Light oil burner
Modulating operation
CODE MODEL
20074606 RL 190/E
GB

Original instructions

1 20109674
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Delivery of the system and the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Packaging - weight (Approximate measurements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.9 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.10 Panel board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.11 Control box for the air/fuel ratio (LMV37.4...). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.12 Actuators (SQM33.5...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Operation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5 Burner raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Preparing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6.1 Commercial boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6.2 Boring the boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6.3 Length of the blast tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Electrode adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9 Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9.1 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9.2 Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9.3 Choice of nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9.4 Adjusting the nozzle flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.9.5 Eccentric setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11 Burner refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.12 Light oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.12.1 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.12.2 Hydraulic system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.13 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.13.1 Pump priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.14 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.14.1 Supply cables and external connections passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.15 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.15.1 Electro-mechanical thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.15.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.16 Motor connection at 208-230 or 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

20109674 2
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Contents
4.17 Motor connection at 575V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.18 Reversible direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.1 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.2 Nozzle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.3 Electrode position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.4 Pump adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Burner start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Final calibration of the pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4.2 Maximum oil pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.3 Fuel pump and/or couplings replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.4 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B Appendix - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Information and general instructions
3 20109674
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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 hood 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.

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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.
.........................................................................................
...........................................................................................
...........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this man-
ual, operating negligence, incorrect installation and
carrying out of non authorised modifications will re-
sult in the annulment by the manufacturer of the
guarantee that it supplies with the burner.

Safety and prevention
5 20109674
GB
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 uses 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.

20109674 6
GB
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 a.s.l.
(2) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output.
The sound power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring
accuracy, as set out in EN ISO 3746.
3.2 Electrical data
Fan motor IE3 NEMA Premium Efficiency
Tab. B
3.3 Burner models designations
Tab. C
3 Technical description of the burner
Model RL 190/E
Output (1)
Delivery (1)
High MBtu/hr(2)
GPH
5376 - 9184
38.4 - 65.6
Low MBtu/hr(2)
GPH
1792 - 5376
12.8 - 38.4
Fuel #2 Fuel oil
Operation Low-high or modulating
Nozzle number 1 (return flow nozzle)
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Pump TA2 delivery (at 290 PSI)
pressure range
fuel temperature
GPH
PSI
° F max
146
101.5 - 580
194
Noise levels (3) Sound pressure
Sound power
dB(A) 78.5
89.5
Model RL 190/E
Control circuit power supply V/Ph/Hz 120/1/60
Fan motor rpm
HP-kW
V
A
3530
7.5 - 5.5
230/460
17.8 - 8.9
Ignition transformer V1 - V2
I1 - I2
120 V - 2 X 5 kV
2.7 A - 30 mA
Electrical power consumption W max 6400
Electrical control circuit consumption W750
Total electrical consumption W7150
Electrical protection NEMA 1
Model Code Voltage Flame safeguard
RL 190/E 20074606 208-230/3/60
460/3/60 Burner mounted

Technical description of the burner
7 20109674
GB
3.4 Packaging - weight (Approximate measurements)
The burners is supplied skid mounted. Outer dimensions of
packaging are indicated in Fig. 1.
The weight of the burner complete with packaging is indicated
in Tab. D.
Tab. D
3.5 Overall dimensions
The maximum dimensions of the burner are given in Fig. 2.
Keep in mind that inspection of the combustion head requires the
burner to be opened and the rear part withdrawn on the slide bars.
The maximum dimension of the burner when open, without casing,
is given in measurement I.
Tab. E
(1) Blast tube: short - long (obtainable with kit).
3.6 Standard equipment
The burner is supplied complete with:
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Adaptor G 1/4” / 1/4” NPT . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Instruction booklet and spare parts list . . . . . . . . . . . . . . . . . .No. 1
inch A B C lbs
RL 190/E 59” 31 19/64” 33 1/2” 273
D36
Fig. 1
G
I
H
FE
D
A
B C
Fig. 2
20058874
inch ABCDE
F(1) GH I(1)
RL 190/E 35 16 47/64” 18 3/16” 23 9/16” 33 31/32” 14 9/16” 8 3/4” 16 15/16” 46 17/32”

20109674 8
GB
Technical description of the burner
3.7 Firing rate
The burner can work in two ways: low and high fire (Fig. 3).
MAXIMUM OUTPUT must be selected in area A.
MINIMUM OUTPUT must be selected in area B.
Note:
The firing rate areas given in Fig. 3 have been reduced by 10%
with respect to the maximum range that can be reached.
3.8 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example
Output 2579 MBtu/hr: diameter 24 inch - length 6.6 ft.
WARNING
The firing rate area values have been obtained con-
sidering an ambient temperature of 68 °F, and an
atmospheric pressure of 394” WC and with the
combustion head adjusted as shown on page 20.
Fig. 3
D2422
Comb. chamber - “ WC
Burner power output
Fig. 4
Diameter (inches)
length (ft)
Furnace dimensions
D2919

Technical description of the burner
9 20109674
GB
3.9 Burner description
1 Ignition electrodes
2 Combustion head
3 Screw for combustion head adjustment
4 Screw for fixing fan to flange
5 Pressure gauge for pressure on nozzle return
6Pump
7 Nozzle holder
8 Air inlet to fan
9 Fan pressure test point
10 Boiler mounting flange
11 Flame stability disk
12 Servomotor, provides adjustment of fuel delivery regulator
13 Slide bars for opening the burner and inspecting the combus-
tion head
14 HT lead
15 High oil pressure switch
16 Fan air inlet
17 Servomotor controlling the air damper
18 Valve assembly with pressure regulator on nozzle return
19 Pressure gauge for pressure on nozzle delivery
11
7
10
17
8
6
18
19 16 515 43921
14
12
13
16
Fig. 5
20111930

20109674 10
GB
Technical description of the burner
3.10 Panel board description
1 “OFF - ON” switch
2 “ALARM SILENCE” button
3 Low air pressure switch (differential operation type)
4 Operator panel with LCD display
5 Burner terminal board “X1”
6 Control box for checking flame and air/fuel ratio
7 Ignition transformer “TA”
8 Terminal strip “X2” for oil valve
9 Fan motor contactor and thermal relay with reset button
10 Horn
11 “K2” relay
12 “K3" relay
13 “K5” relay
14 “K1” relay
15 Optional hole
16 Ground terminals
17 RWF55 modulator (with analog output 4-20 mA)
18 UV flame sensor
19 Holes for cables grommets for electrical wirings, accessories
and power supply (to be carried out by the installer)
20 “LOCAL-REMOTE” switch
21 “POWER ON” signal
22 “CALL FOR HEAT” signal
23 “ALARM” signal
24 “IGNITION ON” signal
25 “FUEL ON” signal
26 Auxiliary fuse
27 Din bar available for accessories
28 Din bar for fuse holder step-down transformer and OCI 412.10
(available)
Two types of burner failure may occur:
Flame safeguard lock-out:
if the flame safeguard alarm 23)(Fig. 6) lights up, it indicates
that the burner is in lock-out. To reset, press the reset push-
button.
Motor trip:
release by pressing the push-button on thermal overload
9)(Fig. 6). See “Thermal relay calibration” on page 26.
18
14
13
12
11
4
6
16
7
8
16
19
5
16
2
15
20
1
28
26
27
22
23
21
25
24
10
17
19
16
9
3
Fig. 6
20111932

Technical description of the burner
11 20109674
GB
3.11 Control box for the air/fuel ratio (LMV37.4...)
Warning notes
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area,
completely isolate the plant from mains supply (all-polar dis-
connection). Ensure that the plant cannot be inadvertently
switched on again and that it is indeed dead. If not observed,
there is a risk of electric shock hazard.
Ensure protection against electric shock hazard by providing
adequate protection for the burner control’s connection termi-
nals.
Each time work has been carried out (mounting, installation,
service work, etc.), check to ensure that wiring and parame-
ters is in an orderly state.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Introduction
The control box for the air/fuel ratio (Fig. 7), (hereafter referred to
simply as the control box), that equips the burners, carries out a se-
ries of integrated functions in order to optimise burner functioning,
both for single operation and together with other units (e.g. double
furnace boiler or more than one generator at the same time).
The basic functions carried out by the control box relate to:
flame control;
the dosage of air and fuel via the positioning (with direct servo-
control) of the relative valves, excluding the possible play in
the mechanical cam calibration systems;
the modulation of burner output, on the basis of the load
requested by the system, maintaining the pressure or temper-
ature of the boiler at the working values set;
the safety diagnostic of the air and fuel circuits, via which it is
possible to easily identify any causes of malfunctioning.
Mechanical design
The following system components are integrated in the LMV37.4...
basic unit:
• Electronic air / fuel ratio control
• Control frequency converter air fan
• Modbus interface
Installation notes
• Always run high-voltage ignition cables separately while ob-
serving the greatest possible distance to the unit and to other
cables.
• Do not mix up live and neutral conductors (fire hazard, danger-
ous failures, loss of protection against electric shock hazard,
etc.).
• Do not lay the connecting cable from the LMV37.4... to the
AZL2… together with other cables.
Electrical connection of the flame detectors
It is important to achieve practically disturbance- and loss-free sig-
nal transmission:
• Never run the detector cable together with other cables.
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the maximum permissible detector cable lengths.
• The ionization probe is not protected against electric shock
hazard. It is mainspowered and must be protected against ac-
cidental contact.
• Locate the ignition electrode and the ionization probe such that
the ignition spark cannot arc over to the ionization probe (risk
of electrical overloads).
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
must be observed!
The LMV37.4... is a safety device!
Do not open, interfere with or modify the unit.
Riello S.p.A. will not assume responsibility for
any damage resulting from unauthorized inter-
ference!
WARNING
The first start-up, like every further operation
for the internal settings of the control box, re-
quires access by means of a password and is
only to be carried out by personnel of the Tech-
nical Assistance Service who have been specif-
ically trained in the internal programming of the
tool.
Fig. 7
D9300

20109674 12
GB
Technical description of the burner
Technical data
Tab. F
LMV37.4... 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
Approx. AC 93 V
Approx. AC 96 V
Terminal loading
‘Outputs’
Total contact loading:
• Nominal voltage
• Unit input current (safety loop) from:
- Fan motor contactor
- Ignition transformer
- Valves
- Oil pump / magnetic clutch
AC 120 V, 50 / 60 Hz
Max. 5 A
Individual contact loading:
Fan motor contactor
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cos> 0.4
Alarm output
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1 A
cos> 0.4
Ignition transformer
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372 or 250 VA ignition
load declaration to UL372
cos> 0.2
Fuel valves
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cos> 0.4
Operation display
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
0.5 A
cos> 0.4
Cable lengths Mains line
Display, BCI
External lockout reset button
Max. 100 m (100 pF/m)
For used outside the burner cover or the control panel:
Max. 3 m (100 pF/m)
Max. 20 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.

Technical description of the burner
13 20109674
GB
Operation sequence of the burner
Legend to the sequence diagrams:
Valve proving takes place depending on the parameter:
1) Parameter: short / long pre-ignition time
short / long oil pump switch - switch-on time -
time
3) Parameter: with/without alarm in the event of start prevention
5) 28 s = maximum time safety phase, followed by lockout
6) 5 s = time between occurrence of start prevention and
signalling
0° Position as supplied (0°)
90° Actuator fully open (90°)
Assignment of times:
t1 Prepurge time
TSA1 Safety time 1
00 02 12 22 24 30 36 38 40 42 44 60 62 70 72 74
3)
TSA1
t1
pa
T
P
P
T
1)
10
217 211
214 264
265 266 267
269 268
270
212
273 274
217
28 s 5 s
5) 6)
Shutdown
Operation
Startup
LK => Z - POS
Preignition Z = ON
BV = ON
Z = OFF
Interval 1 t44 Operation 1 (stationary)
Operation 2 LK => K - POS
Combine
Postburn time t13 Safety phase Standby (stationary)
M = ON, SV= IN
LK => BV - POS
Postpurge time t8 LK => N - POS
Lockout phase
Homerun
Prepurge
OUTPUTS INPUTS
Phase number
Fuel
Actuator 2
Air
Actuator 1
Actuators
Parameter number
Parameter number
Safety limit thermostat (STB)
Control thermostat or pressurestat (R)
Flame signal (FS)
Air pressure switch (LP)
Pressure switch-min (Pmin)
Pressure switch-max (Pmax)
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
VSD
Motor (M)
Ignition transformer (Z)
Alarm (AL)
Safety valve (SV)
Fuel valve 1 (V1)
Fuel valve 2 (V2)
Fuel valve 3 (V3)
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
Fig. 8
S8470
Signal ON
Signal OFF
Any signal is allowed
In standby: after referencing, the actuator is driven to
the no-load position

20109674 14
GB
Technical description of the burner
3.12 Actuators (SQM33.5...)
Warning notes
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area of
the units, completely isolate the equipment from mains supply
(all-polar disconnection). If not observed, there is a risk of
electric shock hazard.
Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
After any kind of activity (mounting, installation and service
work, etc.), check wiring.
Also ensure that the parameters are correctly set.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Use
The actuators (Fig. 9) are used to drive and position the air
damper and oil modulator, without mechanical leverages but via
the interposition of an elastic coupling.
They are commanded by the control box, which constantly
checks their position by means of a return signal from the optic
sensor inside the actuator.
The position (in degrees) of the actuators can be seen on the
display of the Operator Panel.
Index “0” for fuel actuator, index “1” for air actuator.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible dis-
tance.
• The holding torque is reduced when the actuator is disconnect-
ed from power.
Technical data
Tab. G
WARNING
To avoid injury to persons, damage to proper-
ty or the environment, the following warning
notes should be observed!
Do not open, interfere with or modify the actu-
ators!
WARNING
The actuator’s housing must not be opened.
The actuator contains an optical feedback
system.
WARNING
When servicing or replacing the actuators, take
care not to invert the connectors.
Operating voltage AC / DC 24 V ±20%
(load on interface)
Safety class 2 to EN 60 730 part 1 and parts 2…14
Power consumption max. 10 W
Degree of protection IP54 to EN 60 529-1
Opening time 0 - 90° min: 5s, max.: 120s
(depending on the type of control box)
Firing rate 0 - 90°
Cable connection RAST2,5 connectors
Direction of rotation Clockwise/anticlockwise
(can be selected from the control box)
Nominal output torque 3 Nm
Holding torque
(when live) 3 Nm
Holding torque
(when dead) 2.6 Nm
Weight approx. 1 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
class 3K5
class 3M4
-20...+60 ×C
< 95 % r.h.
D8271 Fig. 9

Installation
15 20109674
GB
4.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet truck
or fork lift truck.
4.3 Preliminary checks
Checking the consignment
4.4 Operation position
The burner is designed to operate only in the positions 1, 2, 3 and
4(Fig. 10).
Installation 1is preferable, as it is the only one that allows the main-
tenance operations as described in this manual. Installations 2, 3
and 4 permit operation but make maintenance and inspection of
the combustion head more difficult.
Any other position could compromise the correct operation of the
appliance.
Installation 5is prohibited for safety reasons.
4 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manu-
al and in compliance with the standards and reg-
ulations of the laws in force.
WARNING
The handling operations for the burner can be highly
dangerous if not carried out with the greatest atten-
tion: keep any unauthorised people at a distance;
check the integrity and suitableness of the available
means of handling.
Check also that the area in which you are working is
empty and that there is an adequate escape area
(i.e. a free, safe area to which you can quickly move
if the burner should fall).
When handling, keep the load at not more than 20-
25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must
not be abandoned as they are potential sources
of danger and pollution; they should be collected
and disposed of in the appropriate places.
WARNING
The output of the burner must be within the boil-
er's firing rate.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
2 3 4 51
D7739
Fig. 10

20109674 16
GB
Installation
4.5 Burner raising
In order to lift the burner, proceed as follows:
screw the two extension bars 1) on the pins 2)(Fig. 11);
place the two plates 3) fix them on the relevant ring nuts 4);
The four burner lifting points are indicated in Fig. 11.
4.6 Preparing the boiler
4.6.1 Commercial boilers
The burner is suitable for operation on two or three flue passes
commercial boilers.
The length of the blast tube must be selected according to the indi-
cations provided by the manufacturer of the boiler, and in any case
it must be greater than the thickness of the boiler door complete
with its refractory.
This protection must not compromise the extraction of the blast
tube.
For boilers having a water-cooled front the refractory fettling is not
required unless it is expressly requested by the boiler manufactur-
er. The maximum thickness of the boiler’s front door must not ex-
ceed 16” (Fig. 12).
4.6.2 Boring the boiler plate
Drill the combustion chamber mounting plate as shown in Fig. 13.
The position of the threaded holes can be marked using the head
gasket supplied with the burner.
Tab. H
WARNING
The manufacturer declines any and every respon-
sibility for any possible lifting movements, different
from those indicated in this manual.
Fig. 11
3
4
21
20097588
inch A B C
RL 190/E 9 1/16“ 12 25/32” - 14 15/32” 5/8 W
Fig. 12
14” max
D1079
Fig. 13
D455

Installation
17 20109674
GB
4.6.3 Length of the blast tube
The length of the blast tube must be selected according to the indi-
cations provided by the manufacturer of the boiler, and in any case
it must be greater than the thickness of the boiler door complete
with its refractory.
The available lengths L are those indicated in the Tab. I.
Tab. I
For boilers with front flue passes 12)(Fig. 14) or flame inversion
chambers, protective insulation material 10) must be inserted be-
tween the boiler refractory 11) and the blast tube 9).
This protective insulation must not compromise the extraction of
the blast tube (Fig. 14).
For boilers having a water-cooled front the insulation 10)-
11)(Fig. 14) is not required unless it is required by the boiler man-
ufacturer.
4.7 Securing the burner to the boiler
Disassemble the blast tube 9) from the burner 6) by proceeding as
follows (Fig. 14):
loosen the four screws 3) and remove the cover 1).
Remove the screws 2) from the two slide bars 5).
Remove the two screws 4) fixing the burner 6) to the flange 7).
Withdraw the blast tube 9) complete with flange 7) and slide
bars 5).
Secure flange 7) to the boiler plate inserting the supplied gas-
ket 8).
Use the 4 screws provided after having protected the thread
with an anti-seizing product.
4.8 Electrode adjustment
Model Short blast tube
RL 190/E 14 9/16”
WARNING
The burner-boiler seal must be airtight.
L
9
10
11
12
12
5
7 8
6
3
2
34
1
Fig. 14
20111941
WARNING
Make sure that the electrodes are positioned as
shown in Fig. 15.
Fig. 15
D2528

20109674 18
GB
Installation
4.9 Nozzle
The burner complies with the emission requirements of the UL 296
Standard.
In order to guarantee that emissions do not vary, recommended
and/or alternative nozzles specified by the manufacturer in the In-
struction and warning booklet should be used.
4.9.1 Recommended nozzles
Type A4 return flow nozzles - 45° angle.
4.9.2 Nozzle assembly
At this stage of installation the burner is still disassembled from the
blast tube; it is therefore possible to fit the nozzle with the box
wrench 1)(Fig. 16), inserting the wrench through the central hole in
the flame stability disk.
Finally remount the burner 3)(Fig. 18) on the slide bars 2) and
slide it up to the flange 5), keeping it slightly raised to prevent
the flame stability disk from pressing against the blast tube.
Tighten the screws 1) on the slide bars 2) and screws 4) fixing
the burner to the flange.
If it proves necessary to change a nozzle with the burner already
fitted to the boiler, proceed as outlined below:
pull back the burner on its slide bars as shown in Fig. 14 at
page 17.
Remove the nuts 1)(Fig. 17) and the disk 2).
Use wrench 3)(Fig. 17) to change the nozzles.
4.9.3 Choice of nozzle
In case an intermediate delivery between the two values indicated
in the diagrams (Fig. 19 at page 19) is required, a nozzle with high-
er delivery must be chosen.
Delivery reduction will be obtained by means of the pressure regu-
lator.
WARNING
It is advisable to replace nozzles every year during
regular maintenance operations.
CAUTION
The use of nozzles other than those specified by the
manufacturer and inadequate regular maintenance
may result into emission limits non-conforming to
the values set forth by the regulations in force, and
in extremely serious cases, into potential hazards to
people and objects.
The manufacturing company shall not be liable for
any such damage arising from nonobservance of
the requirements contained in this manual.
WARNING
Do not use any sealing products such as gaskets,
sealing compound, or tape.
Be careful to avoid damaging the nozzle sealing
seat.
Fig. 16
D1220
D1222
Fig. 17
1234
5
20111969 Fig. 18