Riello RLS 310/EV O2 MX Instruction Manual

Installation, use and maintenance instructions
20182250 (2) - 09/2021
Dual fuel light oil/ gas burners
Modulating operation
CODE MODEL TYPE
20182022 RLS 310/EV O2 MX 1161T2
20182023 RLS 410/EV O2 MX 1162T2
20182024 RLS 510/EV O2 MX 1163T2
20182026 RLS 610/EV O2 MX 1164T2
GB

Translation of the original instructions

1 20182250
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
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 Burner weight .............................................................................................................................................................. 9
4.7 Maximum dimensions.................................................................................................................................................. 9
4.8 Firing rates ................................................................................................................................................................ 10
4.9 Test boiler.................................................................................................................................................................. 11
4.10 Burner equipment...................................................................................................................................................... 11
4.11 Burner description ..................................................................................................................................................... 12
4.12 Electrical panel description........................................................................................................................................ 13
4.13 Control box for the air/fuel ratio (LMV52...) ............................................................................................................... 14
4.14 Servomotor................................................................................................................................................................ 16
4.15 PLL52... module (optional) ........................................................................................................................................ 17
4.16 Oxygen sensor QGO20 ... (optional)........................................................................................................................ 18
4.17 Calibration of the thermal relay ................................................................................................................................. 20
5 Installation ................................................................................................................................................................................ 21
5.1 Notes on safety for the installation ............................................................................................................................ 21
5.2 Handling .................................................................................................................................................................... 21
5.3 Preliminary checks .................................................................................................................................................... 21
5.4 Operating position ..................................................................................................................................................... 22
5.5 Preparing the boiler ................................................................................................................................................... 22
5.6 Securing the burner to the boiler............................................................................................................................... 22
5.7 Access to head internal part...................................................................................................................................... 23
5.8 Position of the electrodes and central gas nozzles ................................................................................................... 23
5.9 Gas butterfly valve..................................................................................................................................................... 24
5.10 Combustion head adjustment.................................................................................................................................... 24
5.11 Nozzle installation ..................................................................................................................................................... 25
5.12 Light oil supply........................................................................................................................................................... 26
5.13 Gas pressures ........................................................................................................................................................... 29
5.14 Electrical wiring ......................................................................................................................................................... 32
6 Start-up, calibration and operation of the burner ................................................................................................................. 34
6.1 Notes on safety for the first start-up .......................................................................................................................... 34
6.2 Adjustments prior to ignition (light oil) ....................................................................................................................... 34
6.3 Burner ignition (light oil)............................................................................................................................................. 34
6.4 Adjustments prior to ignition (gas)............................................................................................................................. 35
6.5 Burner start-up (gas) ................................................................................................................................................. 35
6.6 Burner ignition ........................................................................................................................................................... 35
6.7 Change of fuel ........................................................................................................................................................... 35

20182250 2
GB
Contents
6.8 Air / fuel adjustment ...................................................................................................................................................36
6.9 Final adjustment of the pressure switches.................................................................................................................37
6.10 Pressure switch adjustment .......................................................................................................................................38
6.11 Operation ...................................................................................................................................................................39
6.12 Ignition failure.............................................................................................................................................................40
6.13 Burner flame goes out during operation.....................................................................................................................40
6.14 Stopping of the burner ...............................................................................................................................................40
6.15 Final checks ...............................................................................................................................................................40
6.16 Pump motor lock-out..................................................................................................................................................40
6.17 Description of O2 trim control (optional) ...................................................................................................................41
7 Maintenance ..............................................................................................................................................................................42
7.1 Notes on safety for the maintenance .........................................................................................................................42
7.2 Maintenance programme ...........................................................................................................................................42
7.3 Opening the burner ....................................................................................................................................................45
7.4 Closing the burner......................................................................................................................................................45
8 Faults - Possible causes - Solutions.......................................................................................................................................46
A Appendix - Accessories ...........................................................................................................................................................47
B Appendix - Electrical panel layout...........................................................................................................................................48

3 20182250
GB
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: Forced draught gas burners
Model and type: RLS 310/EV O2 MX
RLS 410/EV O2 MX
RLS 510/EV O2 MX
RLS 610/EV O2 MX
1161T2
1162T2
1163T2
1164T2
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/CE Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
The products are marked as follows:
RLS 310/EV O2 MX (Classe 2 EN 267 - Classe 3 EN 676)
RLS 410/EV O2 MX (Classe 2 EN 267 - Classe 3 EN 676)
RLS 510/EV O2 MX (Classe 2 EN 267 - Classe 3 EN 676)
RLS 610/EV O2 MX (Classe 2 EN 267 - Classe 3 EN 676)
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard “1. BIm-
SchV revision 26.01.2010”.
Product Model Type Output
Forced draught gas burners RLS 310/EV O2 MX 1161T2 600 - 3600 kW
RLS 410/EV O2 MX 1162T2 640 - 4200 kW
RLS 510/EV O2 MX 1163T2 660 - 5170 kW
RLS 610/EV O2 MX 1164T2 1000 - 6155 kW
0085CQ0196

20182250 4
GB
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 may be present. An explosive atmos-
phere is defined as a mixture - under atmospheric
conditions - of air and flammable substances in
the form of gases, vapours, mist or dust in which,
after ignition has occurred, combustion spreads to
the entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
OBLIGATION TO ASSEMBLE THE COVER AND
ALL THE SAFETY AND PROTECTION DEVICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
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 20182250
GB
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.

20182250 6
GB
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, the user undertakes to ensure that everyone
knows the use and safety instructions for his own duties.
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
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 manufacturing company
therefore accepts no responsibility whatsoever for any which
may result from 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 20182250
GB
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: Natural gas
Light oil
Gas oil / Methane
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
RLS 310 TC FS1/FS2* 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
MX
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
S
L
LS
N
Head : TC Standard head
TL Long head
Emission: C11 o ... ...
C22 o MZ
C33 - BLU
C23 - MX
Class 1 EN 267 - EN676
Class 2 EN 267 - EN676
Class 3 EN 267 - EN676
Class 2 EN 267 - Class 3 EN676
Adjustment : E Electronic cam
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
E O2Electronic cam and suitable for Oxygen Control (O2)
EV O2Electronic cam and variable speed (with Inverter) and suitable for Oxygen Control O2
EV O2
WARNING
*The burner leaves the factory set up for FS1 op-
eration. If FS2 operation is required, refer the spe-
cific manual to LMV 5...
Designation Voltage Start-up Code
RLS 310/EV O2 MX 3/400/50 Inverter 20182022
RLS 410/EV O2 MX 3/400/50 Inverter 20182023
RLS 510/EV O2 MX 3/400/50 Inverter 20182024
RLS 610/EV O2 MX 3/400/50 Inverter 20182026

20182250 8
GB
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 - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point of the pressure switch 5)(Fig. 5) with zero pressure in the combustion chamber and at 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 accurate “Accuracy: Category 3”, as described by EN ISO
3746”.
4.5 Electrical data
Tab. D
Gas category Destination country
I2E LU - PL
I2E(R) BE
I2EK NL
I2ELL DE
I2Er FR
I2H AT-GB-CH-CZ-DK-EE-ES-FI-GB-GR-HU-IE-IS-IT-LT-LV-NO-PT-RO-SE-
SI-SK-TR
Model RLS 310/EV O2 MX RLS 410/EV O2 MX RLS 510/EV O2 MX RLS 610/EV O2 MX
Power(1)
Delivery (1)
min - max kW
Kg/h
600/1200 ÷ 3600
50/100 ÷ 305
640/1500 ÷ 4200
55/126 ÷ 352
660/1800 ÷ 5170
56/195 ÷ 435
1000/2200 ÷ 6155
110/185 ÷ 516
Fuels Natural gas: G20 (methane gas) - G25
Light oil, max. viscosity at 20 °C: 6 mm2/s (1.5°E - 6 cSt)
Gas pressure at max. output (2)
Gas: G20/G25 mbar 31,8/47,4 47,3/70,6 47,8/71,3 68,2/101,8
Operation
FS1: Intermittent (min. 1 stop in 24 hours)
FS2: Continuous (min. 1 stop in 72 hours)
The burner leaves the factory set for the intermittent operation.
Pump
Minimum output at 16.5 bar
Pressure range
kg/h
bar
TA 3
700
7/40
TA 4
930
7/40
TA 5
1270
7/30
Fuel temperature °c max 140
Nozzles number 1111
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise level (3)
Sound pressure
Sound power
dB(A) 78
89
80
91
82,5
93,5
85
96
Model RLS 310/EV O2 MX RLS 410/EV O2 MX RLS 510/EV O2 MX RLS 610/EV O2 MX
Main electrical supply 3N~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2920
220-240 / 380-415
7.5
25.2 - 14.5
2930
230/400
9.2
28.6 - 16.5
2920
400/690
12
21 - 12.2
2915
400/690
15
26.8 - 15.5
Pump motor IE3 rpm
V
kW
A
2870
220 - 380
1.5
5.9 - 3.4
Ignition transformer V1 - V2
I1 - I2
230 V - 2 x 5 kV
1.9 A - 35 mA
Absorbed electrical power
Gas
Light oil
kW max 9.1
11
10.7
12.6
13.6
15.8
17.2
19.1
Protection level IP 54

9 20182250
GB
Technical description of the burner
4.6 Burner weight
The weight of the burner complete with its packaging is shown in
Tab . E.
Tab. E
4.7 Maximum 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 and the rear part turned on the hinge.
The maximum dimensions of the open burner are indicated by
the L and R positions.
The l position is reference for the refractory thickness of the boiler
door.
Tab. F
Model kg
RLS 310/EV O2 MX 300
RLS 410/EV O2 MX 300
RLS 510/EV O2 MX 300
RLS 610/EV O2 MX 320
Fig. 1
20086678
WARNING
*The gas adaptor is set also for DN 80 bore.
Fig. 2
20086680
mm A B C D E F* G H I L M N O R
RLS 310 1270 507 176 313 520 DN65 500 790 373 1178 596 528 290 970
RLS 410 1270 507 176 313 520 DN65 541 790 373 1178 596 528 290 970
RLS 510 1270 507 176 313 520 DN65 541 790 373 1178 596 528 290 970
RLS 610 1270 512 176 336 520 DN65 543 790 360 1178 596 528 290 970

20182250 10
GB
Technical description of the burner
4.8 Firing rates
The MAXIMUM OUTPUT is chosen from within the diagram area
(Fig. 3).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
Model kW
RLS 310 600
RLS 410 640
RLS 510 660
RLS 610 Gas 1000
RLS 610 Light oil 1300
WARNING
The firing rate value (Fig. 3) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 24.
WARNING
Pre-calibration of the combustion head only for
the burner model RLS 310/M MX:
If the maximum burner output of the burner falls
within:
- area A of the firing rate, it is necessary to replace
the gas nozzles with those supplied (No. 8 gas
nozzles Ø 5,3), Fig. 17 on page 23.
- area B of the firing rate, no modifications are re-
quired.
Fig. 3
Pressure in
combustion head - mbar
20096600
Pressure in
combustion head - mbar
Thermal power – kW
Thermal power – kW
RLS 310/M MX
RLS 410/M MX
RLS510/MMX
Firing rate light oil - RLS 610/M MX
RLS 610/M MX

11 20182250
GB
Technical description of the burner
4.9 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. 4).
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, consult the manufac-
turer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 4 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 3000 kW - diameter 100 cm - length 3.5 m
4.10 Burner equipment
Gasket for gas train adaptor. . . . . . . . . . . . . . . . . . . . . . . . No. 1
Adaptor for gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws for fixing the gas train adaptor: M 16 x 70 . . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M 18 x 60 screws to secure the burner flange
to the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Hydraulic fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Cable grommets kit for optional electrical wiring input . . . . No. 1
M16 nuts to fix the gas elbow to the pipe coupling. . . . . . . No. 4
Stud bolts M16X70 to fix the gas elbow
to the pipe coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 4
Gas nozzles (only for RLS 310 model). . . . . . . . . . . . . . . . No. 8
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
20057548 Fig. 4
Combustion chamber
m

20182250 12
GB
Technical description of the burner
4.11 Burner description
1 Lifting rings
2Fan
3Fanmotor
4 Air damper servomotor
5 Combustion head gas pressure test point
6 Combustion head
7 Ignition electrodes
8 Flame stability disk
9 Electrical panel casing
10 Gas butterfly valve and oil modulator servomotor
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas butterfly valve
15 Shutter
16 Combustion head movement screw
17 Lever for controlling the dampers with graduated scale
18 Air pressure switch
19 Oil modulator
20 Maximum gas pressure switch with pressure test point
21 Valve group
22 Hinge for opening the burner
23 Pressure test point for air pressure switch “+”
24 Combustion head air pressure test point
25 Gas train adapter
26 Indication for checking the rotation direction of the purging
motor
27 Flame inspection window
28 Flame sensor
29 Motor revolution sensor
30 Transparent protection
31 Pump
32 Pump motor
33 Minimum oil pressure switch
34 Maximum oil pressure switch
35 Nozzle return pressure gauge
36 Nozzle delivery pressure gauge
116
15
16
21 27
33
34 36
19
4
11
17 20
30 32
35
87
1431
59
12
13 18
22 23
24 28
2
326
10
25
29
20177891
Fig. 5
ASSEMBLY VIEW
The burner can be opened to the right or to the left
without links to the fuel supply side.
WARNING
To open the burner see section “Access to head
internal part” on page 23.

13 20182250
GB
Technical description of the burner
4.12 Electrical panel description
1 Electronic cam
2 ON/OFF selector
3 Emergency button
4 Earth terminal
5 Supply cables and external connections passage.
See section “Electrical wiring” on page 32
6 “POWER ON” light signalling
7 Main terminal supply board
8 Relay with clean contacts for signalling the burner is in lock-
out
9 Relay with clean contacts for signalling the burner is in GAS
operation
10 Auxiliary circuits fuse
11 Air pressure switch
12 Ignition transformer
13 Valve group terminal board
14 Operator panel with LCD display
15 Light signalling burner lockout and reset button
16 “OVERLOAD FAN MOTOR” light signalling
17 Electronic cam transformer
18 Relay with clean contacts for signalling the burner is in oper-
ation
19 Thermal relay of pump motor (with RESET button)
20 Pump motor contactor
21 Sheath for pump motor cables
22 Change of fuel selector
23 Sheath for motor revolution sensor
24 Flame sensor
25 Fuel servomotor
26 Sheath for maximum gas pressure switch
27 Air servomotor
28 Safety valve sheath (VS1)
29 Return line valve sheath (VR)
30 Working valve sheath (VF)
31 Safety valve sheath (VS)
32 Sheath for minimum oil pressure switch
33 Sheath for maximum oil pressure switch
34 Relay with clean contacts for signalling the inverter is in
lockout
4
4
5
4
4
5
18
98
23
24
25
26
27
28
29
30
34
33
21
32
31
11
10
7
4
3
2
6
16
15
13
22
12
1
14
4
17
19
20
Fig. 6
20178766

20182250 14
GB
Technical description of the burner
4.13 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 LMV5... control box
and all connected electric components is obtained with cor-
rect 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, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
As for automatic operation, the actuators are guided
together to the positions requested and, if an actuator does
not reach the position requested, adjustments are made until
the 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 continu-
ously 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 LMV5... system, the fol-
lowing instructions must also be followed:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
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 LMV5... 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.
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 operation. Ri-
ello 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. 7
D9301

15 20182250
GB
Technical description of the burner
Electrical connection of flame sensor
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.
Technical data
Tab. G
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
Main fuse of perm. network (external) Max. 16 AT
Undervoltage
• Safety switch-off from operating position
to mains voltage
• Restart when mains voltage picks up
< AC 186 V
> AC 188 V
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 230 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
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 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% RH
WARNING
Condensation, the formation of ice and the entry
of water are prohibited!

20182250 16
GB
Technical description of the burner
4.14 Servomotor
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. H
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 trans-
former
Safety class extra low-voltage with safe isolation
from mains voltage
Power absorption
– SQM45...
– SQM48...
9...15 VA
26...34 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)
Nominal torque (max)
– SQM45...
– SQM48...
3 Nm
20 Nm
Holding torque (max)
– SQM45...
– SQM48...
1.5 Nm
20 Nm
Running time (min.)
for 90°
– SQM45...
– SQM48...
10 s.
30 s.
Weight
– SQM45...
– SQM48...
1 kg approx.
1.6 kg approx.
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
D8271 Fig. 8

17 20182250
GB
Technical description of the burner
4.15 PLL52... module (optional)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
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.
4.15.1 Terminal ratings, cable lengths and cross-
sectional areas
Tab. I
Technical data
Tab. J
NOTE:
For detailed information, refer to the specific manual of
PLL52 module.
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the de-
vice.
Cable lengths / cross-sectional areas
Electrical connection “X89” Screw terminals up to max. 2.5
mm2
Cable lengths 10 m fino a QGO20...
Cross-sectional areas Refer to description of QGO20...
Analog inputs
Air temperature detector Pt1000 / LG-Ni1000
Flue gas temperature Pt1000 / LG-Ni1000
QGO20... Refer to data sheet N7842
Interface Communication bus for LMV52...
Model PLL52...
Mains voltage “X89-01” AC 230 V -15%/10%
Safety class I class with parts according to II
class (DIN EN 60730-1)
Mains frequency 50 / 60 Hz ±6 %
Power consumption Ca. 4 VA
Degree protection IP54, housing closed
Transformer AGG5.220
- Primary side AC 230V
- Secondary side AC 12 V (3x)
Environmental conditions:
Storage
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60 °C
<95% r.h.
Transport
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60721-3-2
Class 2K2
Class 2M2
-25...+70 °C
<95% r.h.
Operation
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60 721-3-1
Class 3K5
Class 3M2
-20...+60 °C
< 95% r.h.
WARNING
Condensation, formation of ice and the entrance
of water are not permitted!
Fig. 9
S9902

20182250 18
GB
Technical description of the burner
4.16 Oxygen sensor QGO20 ... (optional)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the sensor connection area,
fully disconnect the burner control device from the power
supply (omnipolar separation).
Ensure that the sensor cannot be inadvertently switched on
again and check this by making a voltage test.
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
During operation, the flange of the sensor connection must
be kept closed; all screws must be tightened securely.
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.
Ensure that the device does not get into contact with explo-
sive or inflammable gases.
There is a risk of burning since the measuring cell works at
an operating temperature of 700 °C and other accessible
parts can get very hot too (> 60 °C).
To prevent injury caused by the hot immersion tube, remove
the device only after the equipment has cooled down.
Make certain that the sensor’s inlet and outlet are always
kept free from dirt.
Before cleaning the inlet and outlet, allow the sensor to cool
down for at least 1 hour.
Mount the sensor such that the connecting part (head to
flange) is free so that the exchange of air is ensured. Other-
wise, measurements might get distorted, possibly leading to
dangerous situations.
Ensure that there are no chemicals, such as solvent vapors,
near the sensor.
Installation notes
The flue gas flow passing the measuring cell must be homo-
geneous, with no or only little turbulence. When mounted too
close to air dampers or pipe bends, faulty measurements
can occur.
A number of faults can distort the measurements (this can
lead to dangerous situations in connection with oxygen trim
control):
– If the stack is not tight, false air can join the flue gases.
– In that case, the residual oxygen content indicated by the
sensor is higher than it actually is.
– If the flue gas velocity is low, the sensor’s response is
slower, since the flue gases take more time to pass the
measuring cell. In that case, it is recommended to mount
the sensor in an inclined position (refer to the manual).
– The greater the sensor’s distance from the flame, the
longer the dead time.
NOTE:
For further explanations about the wiring connetions, please
refer to the manual supplied with the accessory code
20045187.
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the oxy-
gen sensor.
WARNING
Condensation, formation of ice and the entrance
of water are not permitted!
S9895
Fig. 10