Riello RLS 300/EV FGR Quick start guide

20102963 (6) - 10/2022
Installation, use and maintenance instructions
Dual fuel light oil/ gas burners
Progressive two stage or modulating operation
CODE MODEL
20121980
C9161410
20114841
RLS 300/EV FGR
20112654
C9162410
C9162401
20114853
RLS 400/EV FGR
20144501
20143350 RLS 500/EV FGR
20101061 RLS 650/EV FGR
20121979
20075884
20101057
RLS 800/EV FGR
GB

1 20102963
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 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Danger: live components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Owner’s 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Packaging - weight - Approximate measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Burner dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6.1 Panel board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8.1 Procedure to refer burner operating condition at an altitude and/or at a combustion supporter air temperature
different to the standard values (328 ft above sea level, 68 °F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Control box for the air/fuel ratio (LMV52...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.11 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Operation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6.1 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6.2 Burner securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6.3 Accessibility to the interior of the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Electrode and ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.8 Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.8.1 Recommended nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.8.2 Nozzle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.9 Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.9.1 Adjustment at the maximum output (for gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10 FGR duct system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.10.1 Flue gas recirculation line sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.10.2 Calculating the percentage of recirculated flue gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.11 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11.1 Double-pipe circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11.2 The loop circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.12 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.12.1 Pressure variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.13 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.13.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.13.2 Priming pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.14 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.14.1 Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

20102963 2
GB
Contents
4.14.2 Gas feeding line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.14.3 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.15 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.15.1 Installation of shielded cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.16 Speed sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.16.1 Inverter connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.17 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.17.1 Electro-mechanical thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.17.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.18 Motor connection at 208-230 or 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.19 Motor connection at 575V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.20 Reversible direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Adjustments before first firing (light oil operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.2 Combustion head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.3 Pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.4 Fan air gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Fuel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 Adjustments before first firing (gas operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6 Burner start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6.1 Combustion air adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6.2 Air adjustment for maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6.3 Adjusting gas/air delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6.4 Adjusting oil/air delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6.5 Air/fuel control and power modulation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.7 Final calibration of the pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7.2 Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7.3 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7.4 Low oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.8 Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.8.1 Steady state operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.8.2 Firing failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.9 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.2 Safety test - with gas ball valve closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.3 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.4 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
B Appendix - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Information and general instructions
3 20102963
GB
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 Safety precautions
Good safety practices must be used when working on burner
equipment. The potential energy in the electrical supply, fuel and
related equipment must be handled with extreme care to prevent
equipment failures, injuries and potential death.
1.1.4 Danger: live components
Other symbols
This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
The instruction manual is supplied 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 carefully informs the user about:
– the use of the system,
– any further tests that may be necessary before the system is
started up,
– maintenance and the need to have the system checked at
least once a year by the manufacturer or another specialised
technician.
To ensure a periodic check, the manufacturer recommends
the drawing up of a Maintenance Contract.
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.
WARNING
If you smell gas, open window, extinguish any open
flames, stay away from electrical switches, evacu-
ate the building and immediately call the gas com-
pany.
If this equipment is not installed, operated, operated
and maintained in accordance with the manufactur-
ers instructions, this product could expose you to
substances in fuel or from fuel combustion which
can cause death or serious illness.
Improper servicing of this equipment may create a
potential hazard to equipment and operators.
Servicing must be done by a fully trained and
qualified personnel.
DANGER
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with lethal
consequences.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the ma-
chine with respect for the environment.
............................................................................................
...........................................................................................
...........................................................................................
...........................................................................................

20102963 4
GB
Information and general instructions
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installa-
tion 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 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 non authorised 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 power 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 flame, as structurally
established;
insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
use of non-original components, including spare parts, kits,
accessories and optionals;
force majeure.
the manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
1.2.1 Owner’s responsibility
Please pay attention to the Safety Warnings contained within
this instruction manual. Keep this manual for your records and
provide it to your qualified service agency for use in profession-
ally setting up and maintaining your burner.
Your burner will provide years of efficient operation if it is profes-
sionally installed and maintained by a qualified service techni-
cian. If at any time the burner does not appear to be operating
properly, immediately contact your qualified service agency for
consultation.
We recommend annual inspection/service of your gas heating
system by a qualified service agency.
Failure to follow these instructions, misuse, or incorrect adjust-
ment of the burner could lead to equipment malfunction and re-
sult in asphyxiation, explosion or fire.
WARNING
Failure to observe the information given in this man-
ual, operating negligence, incorrect installation and
the carrying out of non authorised modifications will
result in the annulment by the manufacturer of the
guarantee that it supplies with the burner.
WARNING
If you smell gas:
Do not touch any electrical items.
Open all windows.
Close all gas supply valves.
Contact your local gas authority immediately.
• Do not store flammable or hazardous materials
in the vicinity of fuel burning appliances.
• Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury or death.
• Refer to this manual for instructional or addition-
al information.
• Consult a certified installer, service representa-
tive or the gas supplier for further assistance.
• Burner shall be installed in accordance with
manufacturers requirements as outlined in this
manual, local codes and authorities having ju-
risdiction.

Safety and prevention
5 20102963
GB
2.1 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 burn-
er or other items. Inattention, thoughtlessness and excessive
confidence 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
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the manu-
facturer;
the type and pressure of the fuel, the voltage and frequency of
the electrical power supply, the minimum and maximum deliv-
eries for which the burner has been regulated, the pressurisa-
tion 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
machine and intends to use it for the specific purpose. He is re-
sponsible 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.
Must take all the measures necessary to prevent unauthorised
people gaining access to the machine.
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.
Must inform the manufacturer if faults or malfunctioning of the
accident prevention systems are noticed, along with any pre-
sumed danger situation.
Personnel must always use the personal protective equipment
envisaged by legislation and follow the indications given in this
manual.
Personnel must follow 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 are obliged to inform their superiors of every prob-
lem 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 all responsibility for any damage that may
be caused by the use of non-original parts.
2 Safety and prevention

20102963 6
GB
Technical description of the burner
3.1 Technical data
Tab. A
(*) Firing Rate for C-ETL Canadian Listing
(1) Reference conditions: ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2) Pressure at test point 20)(Fig. 3 at page 11) with zero pressure in the combustion chamber and maximum burner output.
(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.
(4) Equivalent Btu values based on 1 USGPH = 140,000 Btu/hr.
3 Technical description of the burner
Model RLS 300/EV FGR RLS 400/EV FGR RLS 500/EV FGR
Output (1)
Delivery (1)
High kW
MBtu/hr (4)
GPH
1387 – 4220 (3834*)
4732 – 14390 (13082*)
33.6 – 102.7 (93.4*)
1998 – 4995 (4541*)
6817 – 17042 (15494*)
47.8 – 121.7 (110.6*)
2775 – 5740 (5217*)
9468 – 19692 (17800*)
67.6 – 140.6 (127.1*)
Low kW
MBtu/hr (4)
GPH
666
2272
16.0
888
3030
21.8
1243
4241
30.4
Fuel # 2 Fuel oil - Natural gas
Gas maximum delivery
Gas pressure at maximum delivery (2)
SCFH
“WC
14,390
9.0
17,042
13.0
19,692
15.0
Operation Low-high or modulating
Nozzle number 1
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Pump delivery (at 300 PSI)
pressure range
fuel temperature
GPH
PSI
° F max
218
102 - 580
302 (150 °C)
218
102 - 580
302 (150 °C)
290
102 - 580
302 (150 °C)
Noise levels (3) dB(A) 82 85 86
Model RLS 650/EV FGR RLS 800/EV FGR
Output (1)
Delivery (1)
High kW
MBtu/hr (4)
GPH
3330 – 7270 (6543*)
11362 – 24807 (22325*)
81.1 – 177.1 (159.4*)
3885 – 8990 (8172*)
13256 – 30670 (27882*)
94.5 – 219 (199.1*)
Low kW
MBtu/hr (4)
GPH
1587
5415
38.7
1942
6626
47.1
Fuel # 2 Fuel oil - Natural gas
Gas maximum delivery
Gas pressure at maximum delivery (2)
SCFH
“WC
24,807
13.1
30,299
19.9
Operation Low-high or modulating
Nozzle number 1
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Pump delivery (at 300 PSI)
pressure range
fuel temperature
GPH
PSI
° F max
403
102 - 435
302 (150 °C)
Noise levels (3) Sound pressure
Sound power dB(A) 80 91
89.6
100.6

Technical description of the burner
7 20102963
GB
3.2 Electrical data
Model RLS 300/EV FGR
RBNA Code 20121980 C9161410 tbd
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60
Fan motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3540
10
230
24
3540
10
460
12
3540
10
575
9.6
Pump motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3515
2
230
5.6
3515
2
460
2.8
3515
2
575
2.2
Ignition transformer Oil/Gas V1 - V2
I1 - I2
120 V - 1 x 8 kV
1.6 A - 20 mA
Electrical power consumption W10050 10050 10050
Electrical control circuit consumption W max 750
Total electrical consumption W10800 10800 10800
Electrical protection NEMA 1
Model RLS 400/EV FGR
RBNA Code tbd C9162410-20112654 C9162401
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60
Fan motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3545
12.4
230
29
3545
12.4
460
14.5
3545
12.4
575
11.6
Pump motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3515
2
230
5.6
3515
2
460
2.8
3515
2
575
2.2
Ignition transformer Oil/Gas V1 - V2
I1 - I2
120 V - 1 x 8 kV
1.6 A - 20 mA
Electrical power consumption W11900
Electrical control circuit consumption W max 750
Total electrical consumption W12650
Electrical protection NEMA 1

20102963 8
GB
Technical description of the burner
Tab. B
Model RLS 500/EV FGR
RBNA Code tbd 20144501 tbd
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60
Fan motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3555
25
230
62
3555
25
460
31
3555
25
575
24.8
Pump motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3515
2
230
5.6
3515
2
460
2.8
3515
2
575
2.2
Ignition transformer Oil/Gas V1 - V2
I1 - I2
120 V - 1 x 8 kV
1.6 A - 20 mA
Electrical power consumption W22000
Electrical control circuit consumption W max 750
Total electrical consumption W22750
Electrical protection NEMA 1
Model RLS 650/EV FGR
RBNA Code tbd tbd tbd
Model RLS 800/EV FGR
RBNA Code 20121979 20075884 tbd
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 230/3/60 460/3/60 575/3/60
Fan motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3540
30
230
71.6
3540
30
460
35.8
3540
30
575
28.6
Pump motor
NEMA Premium Efficiency IE3
rpm
HP
V
A
3515
2
230
5.6
3515
2
460
2.8
3515
2
575
2.2
Ignition transformer Oil/Gas V1 - V2
I1 - I2
120 V - 1 x 8 kV
1.6 A - 20 mA
Electrical power consumption W25700 25650
Electrical control circuit consumption W max 750
Total electrical consumption W26450 26400
Electrical protection NEMA 1

Technical description of the burner
9 20102963
GB
3.3 Burner models designation
Tab. C
3.4 Packaging - weight - Approximate measurements
The packaging of the burner (Fig. 1) rests on a wooden platform
that is particularly suitable for lift trucks. The overall dimensions of
the packaging are shown in the Tab. D.
The weight of the burner complete with its packaging is shown in
Tab. D.
Tab. D
Model Code Code RBNA Voltage Fan motor starting Flame safeguard
RLS 300/EV FGR 20114841
20121980
C9161410
tbd
230/3/60
460/3/60
575/3/60
Inverter Burner mounted
RLS 400/EV FGR 20114853
tbd
C9162410-20112654
C9162401
230/3/60
460/3/60
575/3/60
Inverter Burner mounted
RLS 500/EV FGR 20143350
tbd
20144501
tbd
230/3/60
460/3/60
575/3/60
Inverter Burner mounted
RLS 650/EV FGR 20101061
tbd
tbd
tbd
230/3/60
460/3/60
575/3/60
Inverter Burner mounted
RLS 800/EV FGR 20101057
20121979
20075884
tbd
230/3/60
460/3/60
575/3/60
Inverter Burner mounted
inch ABClbs
RLS 300/EV FGR 80 7/64“ 42 29/32“ 47 3/64“ 496
RLS 400/EV FGR 80 7/64“ 42 29/32“ 47 3/64“ 520
RLS 500/EV FGR 80 7/64“ 42 29/32“ 47 3/64“ 551
RLS 650/EV FGR 80 7/64“ 42 29/32“ 47 3/64“ 661
RLS 800/EV FGR 80 7/64“ 42 29/32“ 47 3/64“ 661
Fig. 1
D36

20102963 10
GB
Technical description of the burner
3.5 Burner dimensions
The maximum dimensions of the burner are given in Fig. 2.
Bear in mind that inspection of the combustion head requires the
burner to be opened by rotating the rear part on the hinge.
The overall dimensions of the burner when open are indicated by L
and R.
Tab. E
Q
F1
P
C
F
N
E
D
BA G
H
R
SS
LS1
R
Fig. 2
20092552
inch ABCDEFF1GH
RLS 300/EV FGR 52 3/16“ 20 1/2“ 6 7/16“ 12 5/16“ 23 5/32“ ANSI 3” ANSI 4” 36 17/32“ 34 9/64“
RLS 400/EV FGR 52 3/16“ 20 1/2“ 6 7/16“ 12 5/16“ 23 5/32“ ANSI 3” ANSI 4” 39 21/64“ 34 9/64“
RLS 500/EV FGR 52 3/16“ 20 1/2“ 6 7/16“ 14 17/32“ 23 5/32“ ANSI 3” ANSI 6” 46 7/8“ 34 9/64“
RLS 650/EV FGR 52 3/16“ 22 29/32“ 6 7/16“ 16 9/64“ 23 5/32“ ANSI 3” ANSI 6” 41” 34 9/64“
RLS 800/EV FGR 52 3/16“ 22 29/32“ 6 7/16“ 16 27/32“ 23 5/32“ ANSI 3” ANSI 6” 43 13/16“ 34 9/64“
inch I L N P Q R S S1
RLS 300/EV FGR 14 1/32“ 46 1/4“ 13 7/16“ 34” 10 29/32“ 41 17/32“ 12 19/32“ 17 1/4“
RLS 400/EV FGR 14 1/32“ 46 1/4“ 13 7/16“ 34” 10 59/32“ 41 17/32“ 12 19/32“ 17 1/4“
RLS 500/EV FGR 14 46 1/4“ 13 7/16“ 34” 10 9/32“ 41 17/32“ 12 19/32“ 17 1/4“
RLS 650/EV FGR 14 3/16“ 46 1/4“ 14 29/64“ 34” 10 9/32“ 41 17/32“ 12 19/32“ 17 1/4“
RLS 800/EV FGR 16 15/32“ 46 1/4“ 14 29/64“ 34” 10 9/32“ 41 17/32“ 12 19/32“ 17 1/4“

Technical description of the burner
11 20102963
GB
3.6 Burner description
1 Lifting eyebolts
2Fan
3Fanmotor
4 Air gate valve servomotor
5 Gas pressure test point
6 Combustion head
7 Ignition pilot
8 Flame stability disk
9 Electric panel board - cover
10 Hinge for opening burner
11 Air inlet to fan
12 Manifold
13 Thermal insulation screen for securing burner to boiler
14 Gas train flange
15 Shutter
16 Lever for movement of combustion head
17 Gears for movement of air damper
18 Air pressure switch (differential operating type)
19 Air pressure test point
20 Maximum gas pressure switch with pressure test point
21 QRI flame sensor
22 Air pressure test point “+”
23 Oil modulator and gas butterfly valve servomotor
24 Pump
25 Pump motor
26 Minimum oil pressure switch
27 Oil shut-off valve
28 Nozzle delivery pressure gauge
29 Nozzle return pressure gauge
30 Oil modulator
31 Strainer
32 Check valve
33 Security relief valve
34 Inlet exhaust gas flange
35 Speed sensor
36 Flue gas butterfly valve servomotor (supplied as equipment)
37 Air pressure test point “-”
11 34 14 20 30 29
8
6
7
15
12
19
5
16
1
17
1
9
36
13 37 10 21 418 22
3
35
2
24
2623
32 31 27 33 25 27 28
OIL PIPING VIEW
Fig. 3
20092554
WARNING
The burner can be opened either on the right or left
sides, irrespective of the side from which fuel is sup-
plied. When the burner is closed, the hinge can be
re-positioned on the opposite side.

20102963 12
GB
Technical description of the burner
3.6.1 Panel board description
1 “OFF - LOCAL - REMOTE” switch
2 “POWER ON” signal
3 “CALL FOR HEAT” signal
4 “OIL - OFF - GAS” switch
5 “FUEL ON” signal
6 “ALARM SILENCE” button
7 “BURNER LOCK-OUT and RESET” push-button
8 Low air pressure switch
9 Operator panel with LCD display
10 Burner terminal board “X1”
11 Control box for checking flame and air/fuel ratio
12 Ignition transformer “TA”
13 Control box transformer
14 Step-down transformer (available)
15 Terminal strip “X2”
16 Plug/socket branch unit
17 Pump motor contactor and thermal relay with reset button
18 Bracket for shielded cables with thumbscrew
Warning: used only to avoid a break in the cable’s shielding,
hence do not overtighten.
19 “KG2” relay
20 Auxiliary fuse
21 DIN bar for: relay, fuse holder and terminal strip “XAUX”
22 Horn
23 ”KO” relay
24 “KG1” relay
25 “K5” relay
26 “K3” relay
27 Transformer, available for additional actuator or O2 control
28 “K2” relay
29 “K1”relay
30 DIN bar for “X2” terminal strip, thermal relays and contactors
31 “K7” relay
32 Holes for cables grommets for electrical wirings, accessories
and power supply (to be carried out by the installer)
33 Plug/socket for maximum pressure switch
34 Plug/socket for air actuator
35 Plug/socket for QRI flame sensor
36 Terminal strip “XAUX”
Two types of burner failure may occur:
Flame safeguard lock-out
If the flame safeguard alarm 6)(Fig. 4) lights up, it indicates
that the burner is in lock-out. To reset, press the reset push-
button.
Pump motor trip
release by pressing the push-button on thermal overload
17)(Fig. 4). See “Thermal relay calibration” on page 39.
3.7 Standard equipment
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws (M16 x 50) . . . . . . . . . . . . . . . . . . . . . . No. 4
Screws (M18 x 70) to secure the burner flange to the boiler . No. 4
Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Flue gas butterfly valve servomotor. . . . . . . . . . . . . . . . . . . . No. 1
Instruction booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
11
9
20
123
4
5
6
7
14
32
10
17
15
8
32
30
18
36
23
24
19
28
31 21 29 26 25
13 16 27
12
22
33
34
35
Fig. 4
D11449
WARNING
The connection of the inverter and O2kits must be
carried out by the client / installer following the in-
structions (electrical drawing) provided with the
burner and the kits.

Technical description of the burner
13 20102963
GB
3.8 Firing rates
Maximum output must be selected in the hatched area of the dia-
gram (Fig. 5).
Minimum output must not be lower than the minimum limit shown
in the diagram.
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 26.
Model MBtu/hr
RLS 300/EV FGR 1387
RLS 400/EV FGR 1998
RLS 500/EV FGR 2775
RLS 650/EV FGR 3300
RLS 800/EV FGR 3885
0
2
4
6
8
10
12
14
16
18
20
mbar
22
9
8
7
6
5
4
3
2
0
1
w.c.
05600
5200
4800
4400
4000
3600
32002800
2400
2000
1600
1200
800
400
0
6000 9200 8800
8400
8000
7600
72006800
6400
MBt u/ h
kW
2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000
Fig. 5
D11255
RLS 650/EV FGR RLS 800/EV FGR
0
2
4
6
8
10
12
14
16
18
20
mbar
8
7
6
5
4
3
2
0
1
w.c.
05600
5200
4800
4400
4000
3600
32002800
2400
2000
1600
1200
800
400
0
6000
MBt u/ hr
kW
2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
RLS 300/EV FGR RLS 400/EV FGR RLS 500/EV FGR
Burner power output
Combustion chamber pressure
Firing rate for C-ETL Canadian Listing
Firing rate for C-ETL Canadian Listing
Burner power output
Combustion chamber pressure
D11254

20102963 14
GB
Technical description of the burner
3.8.1 Procedure to refer burner operating condition
at an altitude and/or at a combustion supporter
air temperature different to the standard values
(328 ft above sea level, 68 °F)
Tab. F
F- correction factor of discharge head and delivery in relation to temperature and altitude.
Reference conditions:
–Air temperature 68 °F (20 °C)
– Barometric pressure 394 ''w.c. (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.)
Example
Using the Tab. F , for an altitude of 3,000 ft and an air temperature
of 68 °F, an Ffactor value is obtained equal to 0.908;
if the capacity at the boiler furnace is Qfoc = 4,500 Mbtu/h, the cor-
rect output will be equal to:
Qburner = Qfoc / F = 4,500 / 0.908 = 4,956 Mbtu/h
3.9 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 6 indicates the diameter and length of the test combustion
chamber.
Example RLS 500/EV FGR:
Output 18500 MBtu/hr: diameter 39.4 inch - length 16.5 ft.
AIR TEMPERATURE
Altitude Altitude bar. press. bar. press. 0 5 10 15 20 25 30 40 °C
ft a.s.l. m a.s.l. "w.c. mbar 32 41 50 59 68 77 86 104 °F
00399 1013,00 1,087 1,068 1,049 1,031 1,013 0,996 0,980 0,948
328 100 394 1000,00 1,073 1,054 1,035 1,017 1,000 0,983 0,967 0,936
1.000 305 385 977,40 1,049 1,030 1,012 0,994 0,977 0,961 0,945 0,915
2.000 610 371 942,80 1,012 0,994 0,976 0,959 0,943 0,927 0,912 0,883
3.000 915 358 908,20 0,975 0,957 0,940 0,924 0,908 0,893 0,878 0,850
4.000 1.220 345 875,80 0,940 0,923 0,907 0,891 0,876 0,861 0,847 0,820
5.000 1.525 332 843,50 0,905 0,889 0,873 0,858 0,844 0,829 0,816 0,790
6.000 1.830 320 811,85 0,871 0,856 0,841 0,826 0,812 0,798 0,785 0,760
7.000 2.135 307 779,80 0,837 0,822 0,807 0,793 0,780 0,767 0,754 0,730
8.000 2.440 294 747,80 0,803 0,788 0,774 0,761 0,748 0,735 0,723 0,700
15. 7 19. 7 23. 6 31. 5 39. 4 47. 2
ft
inches
ft= 0,12
MBtu/ hr 18.9
11.3
7.5
1000
1.5
760
16.5
13.2
9.9
6.6
3.3
1.6
MBtu
hr
37870
23.0
29.6
22.7
Fig. 6
Diameter (inches)
Length (ft)
Furnace dimensions
D9396

Technical description of the burner
15 20102963
GB
3.10 Control box for the air/fuel ratio (LMV52...)
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 LMV5..., completely isolate the plant from mains supply
(all-polar disconnection). Ensure that the plant cannot be inad-
vertently switched on again and that it is indeed dead. If not
observed, there is a risk of electric shock hazard.
Protection against electrical shock hazard on the LMV5... and
on all connected electrical components must be ensured
through appropriate mounting.
Each time work has been carried out (mounting, installation
and service work, etc.), check to ensure that wiring is in an
orderly state, that the parameters have been correctly set and
make the safety checks.
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.
In programming mode, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
Like in automatic operation, the actuators are still jointly driven
to their required positions. If an actuator does not reach the
required position, corrections are made until that position is
reached. However, in contrast to automatic operation, there
are no time limits to these corrective actions.
The other actuators maintain their positions until all actuators
have reached the positions currently required.
This is essential for setting fuel /air ratio control.
This means that during the time the fuel / air ratio curves are
programmed, the person making the plant settings must con-
tinuously monitor the quality of the combustion process (e.g.
by means of a flue gas analyzer).
Also, if combustion levels are poor, or in the event of danger-
ous situations, the commissioning engineer must take appro-
priate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV5... system, the fol-
lowing points must also be observed:
– Condensation and ingress of humidity must be avoided.
Should such conditions occur, make sure that the unit will be
completely dry before switching on again!
– Static charges must be avoided since they can damage the
unit’s electronic components when touched.
Mechanical design
The LMV5... is a microprocessor-based burner management sys-
tem with matching system components for the control and supervi-
sion of forced draft burners of medium to large capacity.
The following components are integrated in the basic unit of the
LMV5...:
• Burner control with gas valve proving system
• Electronic fuel / air ratio control with a maximum of 4
(LMV51…) or 6 (LMV52…) actuators
• Optional PID temperature / pressure controller (load controller)
• Optional VSD module Mechanical design
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
must be observed!
The LMV52... is a safety device! Do not open, in-
terfere with or modify the unit.
Riello S.p.A. will not assume responsibility for
any damage resulting from unauthorized inter-
ference! Risk of explosion!
Incorrect configuration can lead to excessive
fuel supply which might cause an 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 ac-
tuator positions can lead to dangerous burner
operating conditions.
Fig. 7
D9301

20102963 16
GB
Technical description of the burner
Electrical connection of ionization probe and flame detector
It is important to achieve practically disturbance- and loss-free
signal transmission:
• Never run the detector cables together with other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the permissible cable lengths.
• The ionization probe is not protected against electrical shock
hazard. The mainspowered ionization probe must be protected
against accidental 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).
Technical data
LMV52... basic unit Mains voltage AC 120 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power consumption < 30 W (typically)
Safety class I, with parts according to II and III to DIN EN 60730-1
Terminal loading
‘Inputs’
Unit fuse F1 (internally) 6.3 AT
Perm. mains primary fuse (externally) Max. 16 AT
Undervoltage
• Safety shutdown from operating position
at mains voltage
• Restart on rise in mains voltage
< AC 96 V
> AC 100 V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor
1.6A
cos> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor
0.5A
cos> 0.4
Terminal loading
‘Outputs’
Total contact loading:
• Mains voltage
• Input current of unit (safety loop) total
load on contacts resulting from:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 120 V -15 % / +10 %
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor
1 A
cos> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos> 0.2
Fuel valve gas (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos> 0.4
Fuel valve oil (nominal voltage)
• Nominal current
• Power factor
1.6 A
cos> 0.4
Cable lengths Main line Max. 100 m (100 pF/m)
Environmental
conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60 °C
< 95 % r.h.

Technical description of the burner
17 20102963
GB
Operation sequence of the burner
TSA1
k)
Gas
Gas
OR
0° / 0%
90° / 100%
TSA1
Fuel
Actuator 2, 3
Nox red.
Actuator 6
Gas+oil
Oil
Ignition (Z)
Fuel valve, SV
Fuel valve, PV
Fuel valve, V1
Fuel valve, V2
Fuel valve, V1
Fuel valve, V2
Fuel valve, V3
Fuel valve, SV
Oil
INPUTS
Timer 1
Timer 2
Fuel 1 (oil)
Fuel 2 (gas)
Controller - ON (internal + external)
Air pressure switch (LP)
Start release - oil
Fuel
selection
Fan conductor contact (GSK)
Interval 1 ti1
Operation 2 LK => K - POS
SR = ON
Pressure test
Direct start
Air, Aux, VSD
Actuator 1, 4, 5
(CPI function with LMV52...)
(alternative start signal)
Fig. 8
D9507

20102963 18
GB
Technical description of the burner
Key to the sequence diagrams:
Depending on the parameter, valve proving takes place:
between phase 62 and phase 70 or/and
between phase 30 and phase 32.
Assignment of times:
t0 Postpurge lockout position
t01 Max. time safety phase
t10 Min. time home run
t21 Min. time start release
t22 Fan runup time t30 Prepurge time part 1
t34 Prepurge time part 3
t36 Min. ON time oil pump
t38 Preignition time gas / oil
t42 Preignition time OFF
t44 Interval 1 gas / oil
t62 Max. time low-fire
t70 Afterburn time
t74 Postpurge time 1 gas / oil (tn1)
t78 Postpurge time 3 gas / oil (tn3)
t80 Valve proving evacuate time
t81 Leakage test time atmospheric pressure
t82 Leakage test filling test
t83 Leakage test time gas pressure
tmn1 Min. time extraneous light test (5 s.) after skip over of
prepurge
tmx1 Max. damper running time
tmx2 Max. time startup release
tmx3 Max. time circulation heavy oil
tn Postpurge time
TSA1 Safety time 1
TSA2 Safety time 2
tv Prepurge time gas / oil
Signal ON Signal OFF Next phase
Parameter direct start
Checking with controller on
Deviation 10
No Rep. decrement
10
70
Without VP70 with VP80
62
Stop, up to Ph – max. time 01
Stop, up to Ph – max. time 10
Input: don´t care
Output: OFF
Output: ON
00, Rep = 0
12, Rep > 0
01
0-3 s.
00, Rep = 0
12, Rep > 0
01
0-30 s.
00, Rep = 0
12, Rep > 0
01
0-3 s.
00, Rep = 0
12, Rep > 0
01
79
10
Param.