Riello RLS 120/EV MX TC FS2 User manual

20093097 (2) - 05/2015
Installation, use and maintenance instructions
Dual fuel gas oil/gas burner
Progressive two-stage or modulating operation gas side/two-stage light oil side
CODE MODEL TYPE
20092413 RLS 120/EV MX TC FS2 780T2
GB

Translation of the original instructions

1 20093097
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Maximum dimensions - approximate measurements.................................................................................................. 9
4.7 Firing rate .................................................................................................................................................................... 9
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Commercial boilers.................................................................................................................................................... 10
4.10 Burner equipment...................................................................................................................................................... 10
4.11 Burner description ..................................................................................................................................................... 11
4.12 Control box for the air/fuel ratio (LMV52...) ............................................................................................................... 12
4.13 Servomotor (SQM45.2....) ......................................................................................................................................... 14
5 Installation ................................................................................................................................................................................ 15
5.1 Notes on safety for the installation ............................................................................................................................ 15
5.2 Handling .................................................................................................................................................................... 15
5.3 Preliminary checks .................................................................................................................................................... 15
5.4 Operating position ..................................................................................................................................................... 16
5.5 Preparing the boiler................................................................................................................................................... 16
5.5.1 Boring the boiler plate ............................................................................................................................................... 16
5.5.2 Blast tube length........................................................................................................................................................ 16
5.6 Lifting the burner ....................................................................................................................................................... 16
5.7 Securing the burner to the boiler............................................................................................................................... 17
5.8 Electrodes positioning ............................................................................................................................................... 17
5.9 Nozzle installation ..................................................................................................................................................... 18
5.9.1 Choice of nozzles for 1st and 2nd stage ................................................................................................................... 18
5.9.2 Nozzle assembly ....................................................................................................................................................... 19
5.10 Combustion head adjustment.................................................................................................................................... 19
5.11 Burner closing ........................................................................................................................................................... 20
5.12 Light oil supply........................................................................................................................................................... 21
5.12.1 Double-pipe circuit..................................................................................................................................................... 21
5.12.2 The loop circuit.......................................................................................................................................................... 21
5.12.3 Hydraulic connections ............................................................................................................................................... 22
5.13 Pump......................................................................................................................................................................... 22
5.13.1 Priming pump ............................................................................................................................................................ 23
5.14 Operating cycle (light oil).......................................................................................................................................... 23
5.14.1 Operation................................................................................................................................................................... 23
5.14.2 Ignition failure ............................................................................................................................................................ 23
5.15 Gas feeding............................................................................................................................................................... 24
5.15.1 Gas feeding line ........................................................................................................................................................ 24
5.15.2 Gas train.................................................................................................................................................................... 25

20093097 2
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Contents
5.15.3 Gas train installation ..................................................................................................................................................25
5.15.4 Gas pressure .............................................................................................................................................................25
5.16 Electrical wiring ..........................................................................................................................................................27
5.16.1 Supply cables and external connections passage .....................................................................................................27
5.16.2 Shielding the connections ..........................................................................................................................................28
5.16.3 Inverter connection ....................................................................................................................................................28
5.16.4 Adjusting the speed sensor........................................................................................................................................28
6 Start-up, calibration and operation of the burner..................................................................................................................29
6.1 Notes on safety for the first start-up...........................................................................................................................29
6.2 Adjustments prior to ignition (light oil) ........................................................................................................................29
6.2.1 Nozzle ........................................................................................................................................................................29
6.2.2 Combustion head.......................................................................................................................................................29
6.2.3 Pump adjustment .......................................................................................................................................................29
6.3 Adjustments prior to ignition (gas) .............................................................................................................................29
6.4 Operations before start-up .........................................................................................................................................30
6.5 Burner start-up ...........................................................................................................................................................30
6.6 Stopping of the burner ...............................................................................................................................................30
6.7 Change of fuel............................................................................................................................................................31
6.8 Gas/air delivery adjustment .......................................................................................................................................31
6.9 Light oil/air delivery adjustment..................................................................................................................................31
6.10 Checking the air and gas pressure on the combustion head.....................................................................................31
6.11 Burner adjustment......................................................................................................................................................32
6.11.1 Firing output ...............................................................................................................................................................32
6.11.2 Maximum output ........................................................................................................................................................32
6.11.3 Minimum output .........................................................................................................................................................32
6.12 Final calibration of the pressure switches ..................................................................................................................33
6.12.1 Air pressure switch.....................................................................................................................................................33
6.12.2 Maximum gas pressure switch...................................................................................................................................33
6.12.3 Minimum gas pressure switch....................................................................................................................................33
6.12.4 Minimum oil pressure switch......................................................................................................................................34
6.13 Final checks (with burner operating)..........................................................................................................................34
7 Maintenance ..............................................................................................................................................................................35
7.1 Notes on safety for the maintenance .........................................................................................................................35
7.2 Maintenance programme ...........................................................................................................................................35
7.2.1 Maintenance frequency..............................................................................................................................................35
7.2.2 Checking and cleaning...............................................................................................................................................35
7.3 Opening the burner ....................................................................................................................................................36
7.4 Closing the burner......................................................................................................................................................36
8 Faults - Possible causes - Solutions.......................................................................................................................................37
A Appendix - Accessories ...........................................................................................................................................................38
B Appendix - Electrical panel layout...........................................................................................................................................39

3 20093097
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Dual fuel gas oil/gas burner
Model: RLS 120/EV MX TC FS2
These products are in compliance with the following Technical Standards:
EN 676
EN 267
EN 12100
and according to the European Directives:
GAD 90/396/EEC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
Legnago, 21.05.2015 Executive General Manager
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
CE- in progress

20093097 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 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 system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice 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.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
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 le-
thal 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 is present. An explosive atmosphere is
defined as a mixture of dangerous substances
with air, under atmospheric conditions, in the form
of gases, vapours, mist or dust in which, after ig-
nition 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.
MOUNT CASING
This symbol indicates that it is mandatory to
mount casing again after maintenance, cleaning
or checks.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20093097
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Information and general warnings
2.1.4 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 recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, 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
people, 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, incor-
rectly 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;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
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.

20093097 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current 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, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
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 cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. 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.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing 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 indica-
tions 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:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention 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 man-
ual.

7 20093097
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Range: R
Size
Fuel: S
L
LS
Natural gas
Gas oil
Gas oil / Methane
Adjustment: E Electronic cam
EV Electronic cam with variable speed (with Inverter)
Head: TC Standard head
TL Long head
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous working (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
N Heavy oil
M Mechanical cam
3/400-230/50 3N / 400V-230V / 50Hz
P Proportional air/gas valve
R LS 120 EV TL FS2 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
MX
Class 3 EN267 - Class 3 EN676
C11 or... Class 1 EN267 - EN676
Class 2 EN267 - EN676
C33 or BLU Class 3 EN267 - EN676
C23 or MX
C13 Class 1 EN267 - Class 3 EN676
Emission:
C22 or MZ
Designation Voltage Code
RLS 120/EV MX TC FS2 3 ~ 400V - 50Hz 20092413

20093097 8
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Technical description of the burner
4.3 Burner categories - Countries of destination
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.
(2) Gas pressure test point 4)(Fig. 5 on page 11) with 0 mbar in the combustion chamber and burner at maximum output.
(3) Sound pressure measured in the manufacturer's combustion lab, with burner operating on a test boiler, at maximum output. The sound power is
evaluated, in line with the regulations, on a spherical surface centred on the burner and with a radius of 1 metre.
4.5 Electrical data
Tab. D
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I2H
DE I2ELL
NL I2L
FR I2Er
BE I2E(R)B
LU - PL I2E
Model RLS 120/EV MX TC FS2
Power(1)
Delivery (1)
min - max kW
kg/h
300/600 - 1200
25/50 - 101
Fuel - Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5 °E - 6 cSt)
- Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2) Gas: G20 mbar 20
Operation
- Continuous (min. 1 stop in 72 hours)
- Oil: two-stage
- Gas: progressive two-stage or modulating (see accessories)
Nozzle number 2
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Pump Output (at 12 bar)
Pressure range
Fuel temperature
kg/h
bar
° C max
220
10 - 20
60
Noise levels (3) Sound pressure
Sound power dBA 76 87
Weight kg 70
Model RLS 120/EV MX TC FS2
Main electrical supply
Control circuit power supply
3 ~ 400V - 50Hz
1N ~ 230V - 50 Hz
Fan motor IE2 rpm
V
W
A
2900
230/400
2200
9.95/4.6
Pump motor IE2 rpm
V
W
A
μF
2700
220/240
550
3.6
25
Ignition transformer V1 - V2
I1 - I2
230V - 2x5 kV
1.9 A - 35 mA
Electrical power consumption Light oil
Gas kW max 3.3 2.6
Protection level IP 44

9 20093097
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Technical description of the burner
4.6 Maximum dimensions - approximate measurements
The maximum dimensions of the burner are shown in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the slide
bars.
The dimensions of the open burner are indicated by position I.
Tab. E
4.7 Firing rate
During operation, burner output varies between:
MAXIMUM OUTPUT selected from within area A (Fig. 2).
MINIMUM OUTPUT, which should not be lower than the
minimum limit of the diagram: 300 kW.
Fig. 1
D2300
mm ABCDEFGH I LMNO
RLS 120/EV MX TC FS2 850 425 425 640 1039 245 218 425 1520 223 143 221 Rp2
WARNING
The firing rate was obtained at an ambient tem-
perature of 20°C and an atmospheric pressure of
1000 mbar (approx. 100 m above sea level), and
with the combustion head adjusted as shown on
page 19.
Fig. 2
Thermal power
A
9
-1
1
3
5
7
11
mbar
12
10
8
6
4
2
0
10496877971
62
54
4637
29
2112
kg/h
kW
100
1000 1100 1200 1300500 600 700 900
200
300 400 800
20094439
Combustion chamber
pressure - mbar

20093097 10
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Technical description of the burner
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram (Fig. 3), consult the
manufacturer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In (Fig. 3) you can see the diameter and length of the test com-
bustion chamber.
Example:
Output 1000 kW - diameter 60 cm - length 2.5 m
MODULATING RATIO
The modulating ratio, obtained in the test boilers, according to
standard (EN 676 for gas, EN 267 for light oil), is of:
–3:1(gas)
–2:1(lightoil)
4.9 Commercial boilers
The burner is suitable for operating in boilers with combustion
chamber with runoff from the bottom (three smoke turns) on
which the best results are obtained according to NOxemissions.
The boiler front door maximum thickness must not exceed 250
mm (Fig. 4).
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of (Fig. 3)
preliminary checks are recommended.
4.10 Burner equipment
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M10x35. . . . . . . . . . . . . . . . . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M12x35 to secure the burner flange to the boiler . No. 4
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Nipples for flexible hoses with gasket . . . . . . . . . . . . . . . . No. 2
Pressure switch (for leak detection control) . . . . . . . . . . . No. 1
Technical instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 3
D715
Fig. 4
250 mm MAX
D1079

11 20093097
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Technical description of the burner
4.11 Burner description
1 Flame stability disk
2 Ignition electrodes
3 Combustion head
4 Gas pressure test point and head fixing screw
5 Screws to secure fan to pipe coupling
6 Slide bars for opening the burner and inspecting the com-
bustion head
7 Control box for checking flame and air/fuel ratio
8 Minimum oil pressure switch
9Fanairinlet
10 Gas input pipe
11 Gas butterfly valve
12 Screw for combustion head adjustment
13 Pipe coupling with flange for boiler fixing
14 Maximum gas pressure switch
15 Flame sensor QRI
16 Fuel servomotor
17 Fan motor
18 Extensions for slide bars 6)
19 Air servomotor
20 “BURNER ON” selector
21 Reset button
22 “POWER ON” indicator light
23 “OIL-EXT-GAS” selector
24 Main terminal board
25 Cable grommets for electrical wiring (to be carried out by the
installer)
26 Flame inspection window
27 Minimum air pressure switch (differential type)
28 Pump motor
29 Pump
30 1st and 2nd valve
31 Operation valves
32 Air pressure test point
33 Relay “K1-K2-K3-K4-K5”
34 “EMERGENCY STOP” button
35 “FAN MOTOR OVERLOAD” indicator light
36 Ignition transformer
37 Electronic cam transformer
38 Clamp for cable shielding
39 Support rail for fuse holder and available for accessories
40 Rpm sensor
41 Ground screws
42 Fuse holder
43 Operator panel with LCD display
44 Terminal strip for oil valve unit
45 Lifting rings
46 Motor-pump relay
9
303 1
12
4
45
636
7
39
41
24
45
18 38 28
8
5
16
32
13
2
25
34
19
20
21
22
23
26
29
30
33
35 37
4342
44
31
14 11
10
15
17 27
25
40 46
Fig. 5
20093978

20093097 12
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Technical description of the burner
4.12 Control box for the air/fuel ratio (LMV52...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the LMV52...control box con-
nection area, fully disconnect the system from the power
supply (omnipolar separation). Check the system is not pow-
ered and cannot be accidentally reconnected. Failure to do
this will lead to the risk of electrocution.
Protection against electrocution from the LMV52... control
box and all connected electric components is obtained with
correct assembly.
Before any intervention (assembly and installation opera-
tions, 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 func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
In programming mode, checking the position of the actuators
and the VSD (which controls the electronic device for check-
ing the fuel / air ratio) is different from the check in automatic
operating mode.
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 position is actually reached. However, in contrast to
automatic operation, there are no time limits to these correc-
tive actions.
The other actuators maintain their positions until all actua-
tors 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 pro-
grammed, the person making the plant settings must contin-
uously 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
appropriate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV52... system, the
following instructions must also be followed:
– Avoid conditions which may promote condensation and hu-
midity. 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
control box’s electronic components when touched.
Mechanical structure
The LMV5... control box is a system to check the burners, based
on a microprocessor and equipped with components to adjust
and monitor medium and large capacity forced draught burners.
The base control box of the LMV52... system incorporates the fol-
lowing components:
• Burner adjustment device with system for checking the seal of
the gas valves
• Electronic fuel/air ratio monitoring device with a maximum of 6
(LMV52…) actuators
• Optional PID temperature / pressure controller (load control-
ler)
• Optional VSD module Mechanical design
Installation notes
• Check the electric wiring inside the boiler complies with the na-
tional and local safety regulations.
• Do not confuse the powered conductors with the neutral ones.
• Make sure the cable grommets of the connected cables com-
ply with the relevant standards (e.g. DIN EN 60730 and DIN
EN 60 335).
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
• The burner manufacturer must protect unused AC 230V termi-
nals with dummy plugs (refer to sections Suppliers of other ac-
cessory items).
• When wiring the unit, make sure that AC 230V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The LMV52 control box... is a safety device!
Avoid opening or modifying it, or forcing its opera-
tion.
Riello S.p.A. cannot assume any responsibility for
damage resulting from unauthorised interven-
tions!
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 actu-
ator positions can lead to dangerous burner oper-
ating conditions.
Fig. 6
D9301

13 20093097
GB
Technical description of the burner
Electrical connection of ionisation probe and flame detector
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• always separate the detector cables from the other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
• The ionisation probe is not protected against the risk of elec-
trocution. When connected to the electricity supply, the ionisa-
tion probe must be protected against any accidental contact.
• Position the ignition electrode and the ionisation probe so that
the ignition spark cannot form an arc on the probe (risk of elec-
tric overcharge).
Technical data
Tab. F
LMV52...
base control box
Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ±6%
Power absorption < 30W (normal)
Safety class I, with components in compliance with II and III, according to
DIN EN 60730-1
Load on
‘input’ terminals
F1 unit fuse (internal) 6.3 AT
Primary perm. mains fuse (external) Max. 16 AT
Undervoltage
• Safety switch-off from operating position
to mains voltage
• Restart when mains voltage picks up
< AC 186V
> AC 188V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor
0.5A
cos> 0.4
Load on
‘output’ terminals Total load on the contacts: • Mains voltage
• Total unit input current (safety circuit)
load on contacts due to:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 230V -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
1A
cos> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.2
Fuel gas valve (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Fuel oil valve (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Cable length 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% RH

20093097 14
GB
Technical description of the burner
4.13 Servomotor (SQM45.2....)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the SQM4... system connec-
tion area, fully disconnect the burner control device from the
power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit must not be operated, even if it
displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• The connection between the actuator command shaft and the
control element must be rigid, without any mechanical play.
• To avoid an excessive load on the bearings due to rigid hubs,
the use of compensation clutches without any mechanical
play is recommended (e.g. metal bellows-type clutches).
Installation notes
• Arrange the H.V. ignition cables separately, as far as possible
from the control box and the other cables.
• To avoid the risk of electrocution, make sure that the 230V AC
section of the SQM4... unit is fully separated from the function-
al low-voltage section.
• The static torque is reduced when the electrical supply of the
actuator is switched off.
• The housing cover may only be removed for short periods of
time for wiring or when making the addressing. In similar cas-
es, make sure that dust or dirt does not penetrate inside the
actuator.
• The actuator comprises a PCB with ESD-sensitive compo-
nents.
• The top side of the board carries a cover which affords pro-
tection against direct contact. This protective cover must not
be removed! The underside side of the board must not be
touched.
Technical data
Tab. G
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the ac-
tuators.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
Operating voltage AC 2 x 12V via bus cable from the
base unit or via a separate transformer
Safety class extra low-voltage with safe isolation
from mains voltage
Power consumption 9...15 VA
Degree of protection to EN 60 529, IP 54, provided ade-
quate cable entries are used
Cable connection RAST3,5 connectors
Rotation direction - Anticlockwise (standard)
- Clockwise (inverted rotation)
Rated torque (max.) 1.5 Nm
Static torque (max.) 3 Nm
Running time (min.)
for 90° 10 s.
Weight approx. 1 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95% RH
Fig. 7
D8271

15 20093097
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Installation
5.1 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.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model A)(Fig. 8) and type of burner B);
the year of manufacture, in cryptographic form C);
the serial number D);
the data for electrical supply and the protection level E);
the absorbed electrical power F);
the types of gas used and the relative supply pressures G);
the data of the burner’s possible minimum and maximum
output H) (see Firing rate).
Warning. The burner output must be within the boiler's firing
rate;
the category of the appliance/countries of destination I);
light oil maximum viscosity L).
5 Installation
DANGER
All the installation, maintenance and disassembly
operations MUST be carried out with the electric-
ity supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this man-
ual and in compliance with the standards and
regulations of the laws in force.
DANGER
Combustion air inside the boiler must be free
from hazardous mixes (e.g.: chloride, fluoride,
halogen); if present, it is highly recommended to
carry out cleaning and maintenance more fre-
quently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: 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 work-
ing 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 left-over packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation opera-
tions, 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
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult
R.B.L.
GAS- KAASU
GAZ- AEPIO
0085
RIELLOS.p.A.
I-37045 Legnago (VR)
CE
HEIZÖLFUEL
Fig. 8
D9243
ABC
EDF
HG
GH
I
L

20093097 16
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Installation
5.4 Operating position
5.5 Preparing the boiler
5.5.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in
(Fig. 10). The position of the threaded holes can be marked using
the thermal insulation screen supplied with the burner.
Tab. H
5.5.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its fettling.
For boilers with a front flue gas passes 13)(Fig. 12) or flame in-
version chamber, a protection device in refractory material 11)
must be inserted between the boiler fettling 12) and the blast tube
10).
This protective fettling must not compromise the extraction of the
blast tube.
For boilers with a water-cooled front piece, a refractory lining 11)-
12)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
5.6 Lifting the burner
To lift the burner, proceed as follows:
screw down the two slide bars 1) on the pins 2)(Fig. 11);
position the two plates 3) fixing them on the relative ring nuts
4).
The four lifting points are shown in Fig. 11.
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 9).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
Fig. 9
2 3 4 51
D7739
mm ABC
RLS 120/EV MX TC FS2 230 325 - 368 M16
Fig. 10
D455
WARNING
The manufacturer declines any responsibility for
any lifting action other than that indicated in this
manual.
Fig. 11
20079041

17 20093097
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Installation
5.7 Securing the burner to the boiler
Separate the combustion head from the rest of the burner. To do
this, proceed as follows:
loosen the 4 screws 3) and remove the hood 1);
remove screws 2) from the two slide bars 5);
disconnect the socket from the maximum gas pressure
switch;
disconnect the light oil pipes unscrewing the two fittings 7);
remove the two screws 4);
pull back the burner on the slide bars 5) by about 100 mm;
disconnect the electrode cables, then completely unthread
the burner from the slide bars.
Fix the flange 9)(Fig. 12) to the plate of the boiler interposing
the insulating gasket 8) supplied.
Use the 4 screws supplied, and tighten with a torque of 35 ÷
40 Nm, after protecting their thread with anti-seizing prod-
ucts.
5.8 Electrodes positioning
WARNING
The seal between burner and boiler must be air-
tight: after the start-up, check there is no leakage
of flue gases into the external environment.
12
11
8
L
13
13
10
9
100mm
16
1
3
3
5
2
7
4
Fig. 12
20093526
WARNING
Make sure that the electrodes are positioned as
shown in Fig. 13.
Fig. 13
D2995

20093097 18
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Installation
5.9 Nozzle installation
The burner complies with the emission requirements of the EN
267 standard. In order to guarantee that emissions do not vary,
recommended and/or alternative nozzles specified by Riello in
the Instruction and warning booklet should be used.
5.9.1 Choice of nozzles for 1st and 2nd stage
Both nozzles must be chosen from among those listed in Tab. I.
The first nozzle determines the delivery of the burner in the 1st
stage.
The second nozzle works together with the 1st nozzle to deter-
mine the delivery of the burner in the 2nd stage.
The deliveries of the 1st and 2nd stages must be contained within
the value range indicated on page 8.
Use nozzles with a 60° spray angle at the recommended pres-
sure of 12 bar.
As a rule the two nozzles have equal deliveries but the 1st stage
nozzle may have a delivery less than 50% of the total delivery
when a reduction of the counter-pressure peak is desired at the
moment of starting (the burner allows good combustion rates
also with a 40 - 100% ratio between the 1st and 2nd stage).
Example
Boiler output = 900 kW - efficiency 90%
Output required by the burner =
900 : 0,9 = 1000 kW;
1000 : 2 = 500 KW per nozzle;
therefore, two equal, 60°, 12 bar nozzles are required:
1° = 10 GPH - 2° = 10 GPH,
or the following two different nozzles:
1° = 12 GPH - 2° = 8 GPH.
Tab. I
WARNING
It is advisable to replace the nozzle once a year
during periodical maintenance.
CAUTION
The use of nozzles other than those specified by
Riello S.p.A. 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 non observance of
the requirements contained in this manual.
GPH kg/h kW
12 bar
10 bar 12 bar 14 bar
519,2 21,2 23,1 251,4
5,5 21,1 23,3 25,4 276,3
623,1 25,5 27,7 302,4
6,5 25 27,6 30 327,3
726,9 29,7 32,3 352,3
7,5 28,8 31,8 34,6 377,2
830,8 33,9 36,9 402,1
8,3 31,9 35,2 38,3 417,5
8,5 32,7 36,1 39,2 428,2
934,6 38,2 41,5 453,1
9,5 36,5 40,3 43,8 478
10 38,4 42,4 46,1 502,9
10,5 40,4 44,6 48,4 529
11 42,3 46,7 50,7 553,9
12 46,1 50,9 55,3 603,7
12,3 47,3 52,2 56,7 619,1
13 50 55,1 59,9 653,5
13,8 53,1 58,5 63,3 693,8
14 53,8 59,4 64,5 704,5
15 57,7 63,6 69,2 754,3
15,3 58,8 64,9 70,5 769,7
16 61,5 67,9 73,8 805,3
17 65,4 72,1 78,4 855,1
17,5 67,3 74,2 80,7 880
18 69,2 76,4 83 906,1
19 73 80,6 87,6 956
19,5 75 82,7 89,9 980,9
20 76,9 84,8 92,2 1005,8
21,5 82,7 91,2 99,1 1081,7
22 84,6 93,3 101,4 1106,6
22,5 86,5 95,5 103,7 1132,6
23 88,4 97,6 106 1157,5
23,5 90,4 99,7 108,3 1182,4
24 92,2 101,8 110,6 1207,3