Riello RS 1000/E C01 Quick start guide

Installation, use and maintenance instructions
20061994 (5) - 12/2014
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20062014 RS 1000/E C01 1139 T1
20061950 RS 1200/E C01 1140 T1
GB

Translation of the original instructions

1
20061994
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual.................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner......................................................................................................................................... 7
4.1 Burner designation...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Technical data............................................................................................................................................................. 8
4.4 Electrical data.............................................................................................................................................................. 8
4.5 Burner categories - Countries of destination............................................................................................................... 9
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rates ................................................................................................................................................................ 10
4.8 Test boiler.................................................................................................................................................................. 10
4.9 Burner description ..................................................................................................................................................... 11
4.10 Electrical panel description........................................................................................................................................ 12
4.11 Burner equipment...................................................................................................................................................... 12
4.12 Control box for the air/fuel ratio (LMV51...)............................................................................................................... 13
4.13 Servomotor................................................................................................................................................................ 15
5 Installation ................................................................................................................................................................................ 16
5.1 Notes on safety for the installation............................................................................................................................ 16
5.2 Handling.................................................................................................................................................................... 16
5.3 Preliminary checks.................................................................................................................................................... 16
5.4 Operating position ..................................................................................................................................................... 17
5.5 Removal of the locking screws from the shutter........................................................................................................ 17
5.6 Preparing the boiler................................................................................................................................................... 17
5.6.1 Boring the boiler plate ............................................................................................................................................... 17
5.6.2 Blast tube length........................................................................................................................................................ 17
5.7 Securing the burner to the boiler............................................................................................................................... 18
5.8 Access to head internal part...................................................................................................................................... 18
5.9 Electrode position...................................................................................................................................................... 19
5.10 Combustion head adjustment.................................................................................................................................... 19
5.11 Gas feeding............................................................................................................................................................... 20
5.11.1 Gas feeding line ........................................................................................................................................................ 20
5.11.2 Gas train.................................................................................................................................................................... 21
5.11.3 Gas train installation.................................................................................................................................................. 21
5.11.4 Gas pressure............................................................................................................................................................. 21
5.11.5 Pilot - gas train connection........................................................................................................................................ 22
5.11.6 Ignition pilot burner.................................................................................................................................................... 22
5.12 Electrical wiring ......................................................................................................................................................... 23
5.12.1 Supply cables and external connections passage .................................................................................................... 23
5.13 Calibration of the thermal relay ................................................................................................................................. 24
5.14 Motor rotation............................................................................................................................................................ 24
6 Start-up, calibration and operation of the burner ................................................................................................................. 25
6.1 Notes on safety for the first start-up.......................................................................................................................... 25

20061994
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Contents
6.2 Adjustments prior to ignition.......................................................................................................................................25
6.3 Burner start-up...........................................................................................................................................................25
6.4 Burner ignition............................................................................................................................................................26
6.5 Combustion air adjustment ........................................................................................................................................26
6.5.1 Air / gas adjustment and output modulation...............................................................................................................26
6.6 Pressure switch adjustment.......................................................................................................................................27
6.6.1 Air pressure switch - check CO..................................................................................................................................27
6.6.2 Maximum gas pressure switch...................................................................................................................................27
6.6.3 Minimum gas pressure switch....................................................................................................................................27
6.6.4 PVP pressure switch kit .............................................................................................................................................27
6.7 Final checks (with burner operating)..........................................................................................................................28
7 Maintenance ..............................................................................................................................................................................29
7.1 Notes on safety for the maintenance.........................................................................................................................29
7.2 Maintenance programme...........................................................................................................................................29
7.2.1 Maintenance frequency..............................................................................................................................................29
7.2.2 Checking and cleaning...............................................................................................................................................29
7.3 Opening the burner....................................................................................................................................................30
7.4 Closing the burner......................................................................................................................................................30
8 Faults - Probable causes - Solutions......................................................................................................................................31
A Appendix - Accessories ...........................................................................................................................................................32
B Appendix - Electrical panel layout...........................................................................................................................................33

3
20061994
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burners
Model: RS 1000/E C01
RS 1200/E C01
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAD 2009/142/EC Gas Devices Directive
MD 2006/42/EC Machine Directive
LVD 2006/95/EC Low Voltage Directive
EMC 2004/108/EC Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with UNI EN ISO 9001.
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 Type Model Output
Forced draught gas burners 1139 T1 RS 1000/E C01 1100 - 10100 kW
1140 T1 RS 1200/E C01 1500 - 11100 kW
Legnago, 03.09.2014 Executive General Manager
RIELLO S.p.A. - Burner Department Research & Development Director RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. R. Cattaneo
CE- in progress Class 1 (EN 676)

20061994
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
➤is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
➤is designed for use by qualified personnel;
➤offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere is present. An explosive atmosphere is
defined as a mixture of dangerous substances
with air, under atmospheric conditions, in the form
of gases, vapours, mist or dust in which, after ig-
nition has occurred, combustion spreads to the
entire unburned mixture.
PERSONAL PROTECTION EQUIPMENT
These symbols indicate the equipment that must
be worn and kept by the operator for protection
against threats against safety and/or health while
at work.
MOUNT CASING
This symbol indicates that it is mandatory to
mount casing again after maintenance, cleaning
or checks.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤
This symbol indicates a list.

5
20061994
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Information and general warnings
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
➤the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
➤The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
➤The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the 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 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;
➤use of the burner even following an error and/or an irregular-
ity;
➤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;
➤the 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.

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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
➤The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other users expressly named by the manufacturer;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
➤Modification of the burner to alter its performance and desti-
nations is not allowed.
➤The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
➤Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
➤Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
➤undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
➤undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
➤Personnel must observe all the danger and caution indica-
tions shown on the machine.
➤Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
➤Personnel must inform their superiors of every problem or
dangerous situation that may arise.
➤The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
➤the user must take all the measures neces-
sary to prevent 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
20061994
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Designation Voltage Start-up Code
RS 1000/E C01 TC 3/400/50 Star/Delta 20062014
RS 1200/E C01 TC 3/400/50 Star/Delta 20061950
Range: R
Size
Fuel: Natural gas
Light oil
Light oil / Methane
Adjustment:
Flame control system:
FS1
FS2 Standard (1 stop every 24h) Continuous operation (1 stop every 72h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R S 1000 E TC
Emission: C01 or... Class 1 EN676
BLU or BLU Class 3 EN676
FS1 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
C01
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Long head
C02 or MZ Class 2 EN676

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Technical description of the burner
4.3 Technical data
Tab. B
(1)
Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2)
Pressure on the socket 5)(Fig. 4) with zero pressure in the combustion chamber and at maximum burner output.
(3)
Noise emission tests carried out as per Directive EN 15036-1, with measurement accuracy σ = ±1.5 dB, in the manufacturer's combustion lab with
burner operating on test boiler at maximum output.
4.4 Electrical data
Tab. C
Tab. D
Model RS 1000/E C01 RS 1200/E C01
Type 1139 T1 1140 T1
Output
(1)
Output
(1)
min - max kW 1100/4000 - 10100 1500/5500 - 11100
Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output
(2)
-
Gas: G20/G25 mbar 64.5/92.7 80.5/114
Operation – Intermittent (min. 1 stop in 24 hours)
– Modulating
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise levels
(3)
Sound pressure
Sound power dB(A) 85 99 89.3 99.7
Weight Kg 460 500
Model RS 1000/E C01 RS 1200/E C01
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE2
rpm
V
kW
A
2935
400/690
22
38.6/22.3
2920
400/690
25
44.1/25.5
Ignition transformer V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
Absorbed electrical power kW max 24 27
Protection level IP 55
Model RS 1000/E C01 RS 1200/E C01
Electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2880
400/690
22
38.2/22.3
2880
400/690
25
43.4/25.1
Ignition transformer V1 - V2
I1 - I2 230 V - 1 x 8 kV 1 A - 20 mA
Absorbed electrical power kW max 24 27.2
Protection level IP 55

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20061994
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Technical description of the burner
4.5 Burner categories - Countries of destination
Tab. E
4.6 Maximum dimensions
The maximum dimensions of the burner are shown in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part 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
Country of destination Gas category
SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO I
2H
DE I
2ELL
NL I
2L
FR I
2Er
BE I
2E(R)B
LU - PL I
2E
I
BA
E
D
C
F
H
G
R
L
R
20089867
Fig. 1
mm A B C D E F G H I L R
RS 1000/E C01 1637 538 200 413 885 DN80 1206 1338 485 1493 1350
RS 1200/E C01 1637 539 200 456 885 DN80 1250 1338 485 1493 1350

20061994
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Technical description of the burner
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the continuous
diagram area (Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
RS 1000/E C01 = 4000 kW
RS 1200/E C01 = 5500 kW
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the manufac-
turer.
The firing rates were obtained in special test boilers, according to
EN 676 regulations.
In Fig. 3 you can see the diameter and length ofthe test combus-
tion chamber.
Example:
Output 7000 kW - diameter 120cm - length 6m.
MODULATING RATIO
The modulating ratio, obtained in test boilers in accordance with
standard EN 676, is 7:1.
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 19.
Combustion chamber
pressure - mbar
Thermal power – kW Fig. 2
1000 1800 2600 3400 4200 5000 5800 6600 7400 8200 9000 10600
0
2
4
6
8
10
12
14
16
18
20
22
24
26
9800 1140012200
RS 1000/E C01
D11991
RS 1200/E C01
Fig. 3
Combustion chamber
m
D2448

11
20061994
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Technical description of the burner
4.9 Burner description
1 Lifting rings
2 Fan
3 Fan motor
4 Air damper servomotor
5 Ignition pilot
6 Combustion head
7 Combustion head gas pressure test point
8 Flame stability disc
9 Electrical panel casing
10 Hinge for opening the burner
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas regulator
15 Shutter
16 Combustion head movement lever
17 Air damper movement lever
18 Air pressure switch (differential operating type)
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 QRI cell
22 Pressure test point for air pressure switch “+”
23 Gas butterfly valve servomotor
24 Locking screws of the shutter during the transport (replace
them with the screws M12x25 supplied with the burner)
25 Pilot gas train
91412 13 515
8
23 14
25
11
619 24 16 20 721 17 1
24 10
2
3
22
18
Fig. 4
20089868
CAUTION
The burner can be opened to the right or to the left
without links to the fuel supply side.
When the burner is closed, the hinge can be refit-
ted on the opposite side.

20061994
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Technical description of the burner
4.10 Electrical panel description
1 Terminal board for kits
2 Clean contacts relay
3 Electronic cam transformer
4 Electronic control box
5 Ignition transformer
6 Shielding terminals
7 Stop push-button
8 Off-automatic selector
9 Light signalling of main fuel valve open
10 AZL display
11 Light signalling of mains live state
12 Fan motor lockout warning lamp
13 Light signalling of burner lockout and reset switch
14 Call for heat signal
15 Fan motor contactor and thermal relay, star-triangle starter
16 Timer
17 Flame sensor plug/sensor socket
18 Main terminal supply board
19 Air pressure switch
20 Supply cables, external connections and kits
21 Auxiliary circuits fuse
22 Plug/socket servomotor
NOTE
Two types of burner lockout may occur:
➤Control box lockout: if the pushbutton 13)(Fig. 5) (red led)
lights up, it indicates that the burner is in lockout. release by
pressing the pushbutton 13)(Fig. 5).
➤Motor lockout: release by pressing the button on the rele-
vant thermal relay.
4.11 Burner equipment
Gasket for gas train flange. . . . . . . . . . . . . . . . . . . . . . . . . No.1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No.1
Screws M12x25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2
Gas flange fixing screws M16x70 . . . . . . . . . . . . . . . . . . . No.8
Screws M20x70 to secure the burner flange to the boiler . No.4
Pressure switch (for leak detection control). . . . . . . . . . . . No.1
Technical instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.1
Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No.1
Fig. 5
20062901

13
20061994
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Technical description of the burner
4.12 Control box for the air/fuel ratio (LMV51...)
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
powered 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 cor-
rective actions.
The other actuators maintain their positions until all actua-
tors have reached the positions currently required.
This is absolutely important to set the fuel / air ratio control
system.
During the time the fuel / air ratio curves are being pro-
grammed, the person making the plant settings must contin-
uously monitor the quality of the combustion process (e.g. by
means of a flue gas analyser).
Also, if combustion levels are poor, or in the event of dan-
gerous situations, the commissioning engineer must take
appropriate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV5... system, the
following 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 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 control-
ler)
• Optional VSD module Mechanical design
Installation notes
• Check the electric wiringinside the boiler complies withthe na-
tional and local safety regulations.
• Do not confuse the powered conductors with the neutral ones.
• Make certain that strain relief of the connected cables is in
compliance with the relevant standards (e.g. as per DIN EN
60730 and DIN EN 60 335).
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
• The burner manufacturer must protect unused AC 230V termi-
nals with dummy plugs (refer to sections Suppliers of other ac-
cessory items).
• When wiring the unit, make sure that AC 230V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The LMV51... is a safety device! Avoid opening or
modifying it, or forcing its operation. Riello S.p.A.
cannot assume any responsibility for damage re-
sulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the AZL5… display and operating unit
and incorrect settings of the fuel and / or air actu-
ator positions can lead to dangerous burner oper-
ating conditions.
Fig. 6
D9301

20061994
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Technical description of the burner
Electrical connection of flame detector
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• always separate the detector cables from the other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
Technical data
Tab. G
LMV51... basic unit Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ± 6%
Power absorption < 30W (normal)
Safety class I, with components in compliance with II and III, according to
DIN EN 60730-1
Load on
‘input’ terminals F1 unit fuse (internal) 6.3 AT
Primary perm. mains fuse (external) Max. 16 AT
Undervoltage
• Safety switch-off from operating position to
mains voltage
• Restart when mains voltage picks up
< AC 186V
> AC 188V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor 2A cosϕ> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor 0.5A cosϕ> 0.4
Load on
‘output’ terminals Total load on the contacts: • Mains voltage
• Total unit input current (safety circuit)
load on contacts due to:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 230V -15 % / +10%
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor 1A cosϕ> 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor 1A cosϕ> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor 2A cosϕ> 0.2
Fuel gas valve (nominal voltage)
• Nominal current
• Power factor 2A cosϕ> 0.4
Fuel oil valve (nominal voltage)
• Nominal current
• Power factor 1A cosϕ> 0.4
Cable lengths Main line Max. 100m (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

15
20061994
GB
Technical description of the burner
4.13 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. 7

20061994
16
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will
be installed, and arranging the correct lighting of the environ-
ment, proceed with the installation operations.
5.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 8), showing:
A the burner model
B the burner type
C the cryptographic year of manufacture
D the serial number
E the data for electrical supply and the protection level
F the electrical power consumption
G the types of gas used and the relative supply pressures
H the data of the burner's minimum and maximum output pos-
sibilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate
I the category of the appliance/countries of destination
5 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; they should be collected and
disposed of in the appropriate places.
WARNING
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS-KAASU
GAZ-AEPIO X
RIELLOS.p.A.
I-37045Legnago(VR)
A
D E BC
F
I
G H
G H
Fig. 8
D10411

17
20061994
GB
Installation
5.4 Operating position
5.5 Removal of the locking screws from the shutter
5.6 Preparing the boiler
5.6.1 Boring the boiler plate
Pierce the closing plate of the combustion chamber, as in Fig. 11.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
5.6.2 Blast tube length
The length of the blast tube must be selected according to the in-
dications provided by the manufacturer of the boiler, and in any
case it must be greater than the thickness of the boiler door com-
plete with its refractory.
For boilers with front flue passes 1)(Fig. 12) or flame inversion
chamber, a protection in refractory material 5) must be inserted
between the boiler fettling 2) and the blast tube 4).
This protection must not compromise the extraction of the blast
tube.
For boilers with a water-cooled frontpiece, a refractory lining 2)-
5)(Fig. 12) is not necessary, unless expressly requested by the
boiler manufacturer.
Tab. I
WARNING
➤ The burner is designed to operate only in
positions 1 , 2 , 3 and 4 (Fig. 9).
➤ Installation 1 is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
➤ Installations 2 , 3 and 4 permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
➤ Any other position could compromise the cor-
rect operation of the appliance.
➤ Installation 5 is prohibited for safety reasons.
2 3 4 51
20062309
Fig. 9
WARNING
Remove the screws and the nuts 1)- 2)(Fig. 10),
before installing the burner on the boiler.
Replace them with the screws 3) M12x25 sup-
plied with the burner.
Fig. 10
20061924
mm A B C
RS 1000/E C01 460 608 M 20
RS 1200/E C01 500 608 M 20
Fig. 11
D455

20061994
18
GB
Installation
5.7 Securing the burner to the boiler
➤ Insert the thermal protection supplied with the blast tube 4).
➤ Insert the entire burner on the boiler hole, previously fitted,
as in Fig. 11, and fix it with the screws supplied.
5.8 Access to head internal part
In order to reach inside the combustion head (Fig. 13) proceed as
follows:
➤ disconnect the gas servomotor socket 1);
➤ disconnect the head movement leverage 2);
➤ remove the 4 fixing screws 3);
➤ open the burner on the hinge;
➤ disconnect the electrode cables 4);
➤ remove the screw/gas pressure socket 5) of the head;
➤ pull out the inner part of the head 6).
Prepare a suitable lifting system using rings
3)(Fig. 12).
WARNING
The seal between burner and boiler must be
airtight.
1
1
2
5
4
3
7
8
Fig. 12
20089869
Be careful as some drops of fuel may leak out dur-
ing this phase.
2
4
5
13
6
20089870
Fig. 13