Riello RS 160/E O2 BLU Quick start guide

Installation, use and maintenance instructions
20164541 (5) - 03/2021
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20166113 - 20164535 RS 160/E O2BLU 843T1
20171269 - 20166368 RS 200/E O2BLU 1106T1
GB

Translation of the original instructions

1 20164541
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories ........................................................................................................................................................ 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Maximum dimensions.................................................................................................................................................. 9
4.7 Firing rates .................................................................................................................................................................. 9
4.7.1 Firing rate on basis of air density .............................................................................................................................. 10
4.8 Test boiler.................................................................................................................................................................. 11
4.9 Burner equipment...................................................................................................................................................... 11
4.10 Burner description ..................................................................................................................................................... 12
4.11 Control box for the air/fuel ratio (LMV52...) ............................................................................................................... 13
4.12 Servomotor................................................................................................................................................................ 15
4.13 PLL52... module (Optional) ....................................................................................................................................... 16
4.13.1 Terminal ratings, cable lengths and cross-sectional areas ....................................................................................... 16
4.14 Oxygen sensor QGO20 ... (optional)........................................................................................................................ 17
4.14.1 Technical data QGO20.............................................................................................................................................. 18
4.15 Calibration of the thermal relay ................................................................................................................................. 19
5 Installation ................................................................................................................................................................................ 20
5.1 Notes on safety for the installation ............................................................................................................................ 20
5.2 Handling .................................................................................................................................................................... 20
5.3 Preliminary checks .................................................................................................................................................... 20
5.4 Operating position ..................................................................................................................................................... 21
5.5 Preparing the boiler ................................................................................................................................................... 21
5.5.1 Introduction................................................................................................................................................................ 21
5.5.2 Boring the boiler plate ............................................................................................................................................... 21
5.5.3 Blast tube length........................................................................................................................................................ 22
5.6 Positioning probe - electrode..................................................................................................................................... 22
5.7 Securing the burner to the boiler............................................................................................................................... 23
5.8 Combustion head adjustment.................................................................................................................................... 24
5.9 Gas feeding ............................................................................................................................................................... 26
5.9.1 Gas feeding line ........................................................................................................................................................ 26
5.9.2 Gas train.................................................................................................................................................................... 27
5.9.3 Gas train installation.................................................................................................................................................. 27
5.9.4 Gas pressure............................................................................................................................................................. 27
5.10 Electrical wiring ......................................................................................................................................................... 29
5.10.1 Supply cables and external connections passage .................................................................................................... 29
6 Start-up, calibration and operation of the burner ................................................................................................................. 30
6.1 Notes on safety for the first start-up .......................................................................................................................... 30
6.2 Adjustments prior to ignition ...................................................................................................................................... 30
6.3 Burner start-up .......................................................................................................................................................... 31
6.4 Burner adjustment ..................................................................................................................................................... 31
6.4.1 Firing output .............................................................................................................................................................. 31
6.4.2 Maximum output........................................................................................................................................................ 31
6.4.3 Minimum output......................................................................................................................................................... 31

20164541 2
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Contents
6.5 Final calibration of the pressure switches ..................................................................................................................32
6.5.1 Air pressure switch.....................................................................................................................................................32
6.5.2 Maximum gas pressure switch...................................................................................................................................32
6.5.3 Minimum gas pressure switch....................................................................................................................................33
6.5.4 PVP pressure switch kit .............................................................................................................................................33
6.6 Steady-state operation...............................................................................................................................................33
6.7 Ignition failure.............................................................................................................................................................33
6.8 Burner flame goes out during operation.....................................................................................................................33
6.9 Stopping of the burner ...............................................................................................................................................34
6.10 Final checks (with burner operating)..........................................................................................................................34
6.11 Description of O2 trim control (optional) ...................................................................................................................35
6.11.1 Operating principle of O2 trim control ........................................................................................................................35
7 Maintenance ..............................................................................................................................................................................36
7.1 Notes on safety for the maintenance .........................................................................................................................36
7.2 Maintenance programme ...........................................................................................................................................36
7.2.1 Maintenance frequency..............................................................................................................................................36
7.2.2 Safety test - with gas feeding closed .........................................................................................................................36
7.2.3 Checking and cleaning...............................................................................................................................................36
7.2.4 Measuring the ionisation current................................................................................................................................37
7.2.5 Checking the air and gas pressure on the combustion head .....................................................................................37
7.2.6 Safety components ....................................................................................................................................................37
7.3 Opening the burner ....................................................................................................................................................38
7.4 Closing the burner......................................................................................................................................................38
A Appendix - Accessories ...........................................................................................................................................................39
B Appendix - Electrical panel layout...........................................................................................................................................41

3 20164541
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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 and type: RS 160/E O2BLU
RS 200/E O2BLU
846T1
847T1
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 Devices Regulation
MD 2006/42/CE Machine Directive
LVD 2014/35/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
Such products are marked as follows:
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 21.04.2018 Executive General Manager
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
CE-0085BS0266 RS 160/E O2BLU
CE-0085BT0419 RS 200/E O2 BLU

20164541 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Ta b . Ta b l e
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 HOOD AND
ALL THE SAFETY AND PROTECTION DEVIC-
ES
This symbol signals the obligation to reassemble
the hood and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
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 20164541
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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.

20164541 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other 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 chamber
and the room temperature must all be within the values indicated
in the instruction manual.
Modification of the burner to alter its performance and 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 20164541
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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
R S 160 E O2TC FS1 3/400-230/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
Range : R
Size
Fuel : Natural gas
Light oil
Light oil / Natural gas
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
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
S
L
LS
N
Head : TC Standard head
TL Long head
Emission : C01 or ...
MZ
BLU
MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
3/400-230/50 3N / 400V-230V / 50Hz
E O2Electronic cam and suitable for Oxygen Control (O2)
EV O2Electronic cam and variable speed (with Inverter) and suitable for Oxygen Control O2
Designation Voltage Start-up Code
RS 160/E O2BLU TC 3~ 400V - 50Hz Direct 20166113
RS 160/E O2BLU TL 3~ 400V - 50Hz Direct 20164535
RS 200/E O2BLU TC 3~ 400V - 50Hz Direct 20171269
RS 200/E O2BLU TL 3~ 400V - 50Hz Direct 20166368

20164541 8
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Technical description of the burner
4.3 Burner categories
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m above sea level.
(2) Pressure on the pressure switch socket (Fig. 29 at page 30) 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 “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
(4) Blast tube: short-long.
4.5 Electrical data
Tab. D
Country of destination Gas category
CY, MT I3B/P
LU,PL I2E, II2E3B/P
BE I2E(R), I3
NL I2EK, II2EK3B/P
DE I2ELL, II2ELL3B/P
FR I2Er, II2Er3P
AT-BG-CH-CZ-DK-EE-ES-FI-GB-GR-HU-IE-IS-IT-LT-LV-NO
PT- RO-SE-SI-SK-TR I2H, II2H3B/P, II2H3P
Model RS 160/E O2BLU RS 200/E O2BLU
Output (1) Max. kW
Mcal/h
930 ÷ 1860
800 ÷ 1600
1380 ÷ 2400
1187 ÷ 2064
Min. kW
Mcal/h
300
258
550
473
Combustibile Natural gas: G20 (methane gas) G25 - G31
Pressione gas alla potenza max. (2)
- Gas: G20 / G25
- Gas: G31
mbar 17.7 / 26.4
19.6
28.0 / 41.8
19.6
Fuel – Intermittent (min. 1 stop in 24 hours)
– Modulating with the kit (see ACCESSORIES)
Standard applications Boilers: water. steam. diathermic oil
Ambient temperature °C 0 - 40
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 80.5 91.5
83.0
94.0
Weight (4) kg 96 - 98 101 - 103
Model RS 160/E O2BLU RS 200/E O2BLU
Main electrical supply
Control circuit power supply
3~ 400V +/-10% 50Hz
1N~ 230V +/-10% 50Hz
Fan motor IE3 Hz
rpm
V
kW
A
50
2895
230 - 400
4,5
15 - 8.7
50
2930
230 - 400
5,5
17.7 - 10.2
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 5.5 6.5
Protection level IP 44

9 20164541
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Technical description of the burner
4.6 Maximum dimensions
The dimensions of the burner are shown in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part drawn back on the guides.
The dimensions of the open burner are indicated by position I.
Tab. E
(1) Blast tube: short-long
4.7 Firing rates
The maximum output is chosen within area A of the diagram
(Fig. 2).
The minimum output must not be lower than the minimum limit
of the diagram.
Fig. 1
D1206
mm ABCDE F (1) GH I LMNO
RS 160/E O2BLU 681 366 315 650 1035 373-503 222 435 1442-1587 230 141 260 2”
RS 200/E O2BLU 742 427 315 650 1035 373-503 222 435 1442-1587 230 141 260 2”
WARNING
The firing rate (Fig. 2) was obtained considering a
room temperature of 20°C and an atmospheric
pressure of 1013 mbar (approx. 0 m above sea
level), with the combustion head adjusted as
shown at page 24.
Fig. 2
20127184
20124471
Thermal power
Combustion chamber
pressure - mbar
Thermal power
Combustion chamber
pressure - mbar
RS 160
RS 200

20164541 10
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Technical description of the burner
4.7.1 Firing rate on basis of air density
The firing rate of the burner shown in the manual is valid for a
room temperature of 20°C and an altitude of 0m above sea level
(barometric pressure around 1013 mbar).
It may be that a burner has to operate with combustive air at a
higher temperature and/or higher altitudes.
The heating of the air and the increase in altitude produce the
same effect: the expansion of the air volume (i.e. the reduction of
its density).
The delivery of the burner fan remains essentially the same, but
the oxygen per m3of air, and the thrust (discharge head) of the
fan are reduced.
It is therefore important to know if the maximum output requested
from the burner at a determinate combustion chamber pressure
remains within the firing rate of the burner even with the changed
temperature and altitude conditions.
To check it, proceed as follows:
1 find the corrective factor F (relating to the air temperature
and altitude of the system) in the Tab. F.
2 Divide the output Q required from the burner by F to obtain
the equivalent output Qe:
3 In the firing rate of the burner, mark the work point identified
by:
Qe = equivalent output
H1 = pressure in combustion chamber
point A that must remain within the firing rate.
4 Trace a vertical line from point A)(Fig. 3), and find the maxi-
mum pressure H2 of the firing rate.
5 Multiply H2 by F to obtain the maximum lowered pressure
H3 of the firing rate:
If H3 is greater than H1)(Fig. 3), the burner can produce the de-
livery requested.
If H3 is less than H1, it is necessary to reduce the output of the
burner. The reduction in output is accompanied by a reduction in
the combustion chamber pressure:
Qr = reduced output
H1r = reduced pressure
Example, 5% reduction in output:
Qr = Q x 0.95
H1r = H1 x (0.95)2
With the new values - Qr and H1r - repeat steps 2 - 5.
Tab. F
Qe = Q : F (kW)
H3 = H2 x F (mbar)
WARNING
The combustion head should be adjusted in rela-
tion to the equivalent output Qe.
H1r = H1 x ()
Qr
Q
2
Qe kg/h
mbar
Qe kW
mbar
A
H1
H2
H3
D388
Fig. 3
Altitude Average baro-
metric pressure
F
Air temperature °C
m a.s.l. mbar 0 5 10 15 20 25 30 40
0
100
200
300
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2400
2800
3200
3600
4000
1013
1000
989
978
966
955
944
932
921
910
898
878
856
836
815
794
755
714
675
635
616
1.087
1.073
1.061
1.050
1.037
1.025
1.013
1.000
0.988
0.977
0.964
0.942
0.919
0.897
0.875
0.852
0.810
0.766
0.724
0.682
0.661
1.068
1.054
1.042
1.031
1.018
1.007
0.995
0.982
0.971
0.959
0.946
0.925
0.902
0.881
0.859
0.837
0.796
0.753
0.711
0.669
0.649
1.049
1.035
1.024
1.013
1.000
0.989
0.977
0.965
0.954
0.942
0.930
0.909
0.886
0.866
0.844
0.822
0.782
0.739
0.699
0.657
0.638
1.031
1.017
1.006
0.995
0.983
0.972
0.960
0.948
0.937
0.926
0.914
0.893
0.871
0.851
0.829
0.808
0.768
0.726
0.687
0.646
0.627
1.013
1.000
0.989
0.978
0.966
0.955
0.944
0.932
0.921
0.910
0.898
0.878
0.856
0.836
0.815
0.794
0.755
0.714
0.675
0.635
0.616
0.996
0.983
0.972
0.962
0.950
0.939
0.928
0.916
0.906
0.895
0.883
0.863
0.842
0.822
0.801
0.781
0.742
0.702
0.664
0.624
0.606
0.980
0.967
0.956
0.946
0.934
0.923
0.913
0.901
0.891
0.880
0.868
0.849
0.828
0.808
0.788
0.768
0.730
0.690
0.653
0.614
0.596
0.948
0.936
0.926
0.916
0.904
0.894
0.884
0.872
0.862
0.852
0.841
0.822
0.801
0.783
0.763
0.743
0.707
0.668
0.632
0.594
0.577

11 20164541
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Technical description of the burner
4.8 Test boiler
The firing rates were obtained in special test boilers, according to
EN 676 regulations.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 756 kW (650 Mcal/h) - diameter 60 cm, length 2 m.
The coupling is ensured when the boiler is EC type-approved; for
boilers or ovens with combustion chambers of very different di-
mensions compared to those shown in the diagram of Fig. 4, pre-
liminary checks are recommended.
4.9 Burner equipment
The burner is supplied complete with:
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Gasket for gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws M10 x 40 to fix the flange . . . . . . . . . . . . . . . . . . . No. 4
Screws M16 x 50 to fix the burner flange to the boiler . . . . No. 4
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Fig. 4
Combustion chamber
length - m
D715

20164541 12
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Technical description of the burner
4.10 Burner description
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling
6 Gas servomotor
7 Plug-socket on ionisation probe cable
8 Lifting rings
9 Operation on/off switch
10 Terminal board for electrical wiring
11 Operator panel with LCD display
12 Control box for checking flame and air/fuel ratio
13 “K6” relay
14 Fuses of auxiliaries
15 Flame inspection window
16 Ignition transformer
17 Cable grommets for electrical wiring (to be carried out by the
installer)
18 Air servomotor
19 Minimum air pressure switch (differential operating type)
20 Slide bars for opening the burner and inspecting the com-
bustion head
21 Gas pressure test point and head fixing screw
22 Air pressure socket
23 Terminals for shielding cables
24 Air damper
25 Fan air inlet
26 Screws to secure fan to pipe coupling
27 Gas input pipe
28 Gas butterfly valve
29 Boiler fixing flange
30 Flame stability disk
31 “BURNER LOCK-OUT AND RESET” button
32 “EMERGENCY STOP” button
33 Hole available
34 “POWER ON” indicator light
35 “FUEL ON” indicator light
36 “K3” relay
37 Fan motor
38 Support rail for fuse holder and available for accessories
39 Transformer control box “T1”
40 Ground screws
41 Contactor + ralay
13 36
17
17
38
23 840
18
26
622
29
15
30
2
1
3
21
20
12
14
11
10
8
40
32
9
33
34
35 31
25
5
39
8
24
19
4
27
28 716
41
37
20174962
Fig. 5
Seen from A
A

13 20164541
GB
Technical description of the burner
4.11 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 analyzer).
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
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 or 6 actuators
• Optional PID temperature / pressure controller (load control-
ler)
• Optional VSD module Mechanical design
Installation notes
• Check the electric wiring inside the boiler complies with the na-
tional and local safety regulations.
• Do not confuse the powered conductors with the neutral ones.
• Make 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-
boring 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 230 V ter-
minals with dummy plugs (refer to sections Suppliers of other
accessory items).
• When wiring the unit, make sure that AC 230 V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The LMV52 control box... is a safety device! Avoid
opening or modifying it, or forcing its 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. 6
D9301

20164541 14
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Technical description of the burner
Electrical connection of ionization probe and 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.
• The ionisation probe is not protected against the risk of elec-
trocution. When connected to the electricity supply, the ionisa-
tion probe must be protected against any accidental contact.
• Position the ignition electrode and the ionisation probe so
that the ignition spark cannot form an arc on the probe
(risk of electric overcharge).
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
Classe 3K3
Classe 3M3
-20...+60°C
< 95% RH

15 20164541
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Technical description of the burner
4.12 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.
Model SQM45.295A9 SQM48.497A9
Operating voltage AC 2 x 12 V via bus cable from
the base unit or via a separate
transformer
Safety class extra low-voltage with safe isolation
from mains voltage
Power consumption 9...15 VA 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) 1.5 Nm 20 Nm
Holding torque (max) 3 Nm 20 Nm
Weight approx. 1 kg approx. 1.6 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-1
Classe 1K3
Classe 1M2
-20...+60 °C
< 95% RH
WARNING
Condensation, formation of ice and the entrance
of water are not permitted!
D8271 Fig. 7

20164541 16
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Technical description of the burner
4.13 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.
4.13.1 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. 8
S9902

17 20164541
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Technical description of the burner
4.14 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.
Otherwise, measurements might get distorted, possibly lea-
ding 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 lon-
ger 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. 9

20164541 18
GB
Technical description of the burner
4.14.1 Technical data QGO20
Tab. K
Operating voltage of measuring cell’s:
– QGO20.000D27
– QGO20.000D17
AC 230 V ±15 %
AC 120 V °15 %
(only with LMV52 ... with PLL52...)
Mains frequency: 50...60 Hz ±6 %
Power consumption: Max. 90 W, typical value 35 W (controlled)
Permissible mounting position: Refer to mounting Instructions M7842
Degree of protection: IP40, to be ensured through installation
Weight (net): approx. 0.9 kg
Signal lines
– Shielded 6-wires cable
– Shielding connected to terminal GND of the PL52...
Twisted pairs
Wire diameter LifYCY3x2x0,2 o LYCY3x2x0,2
Measuring system Zirconium dioxide measuring cell as an oxygen ion
conductor
Permissible flue gas velocity (only with AGO20...) 1...10 m/s
Fuel type Fuel oil EL or Natural gas H
Measuring range 0.2...20.9 % O2
Permissible cable length Max. 100 m
Wire diameter <10 m
Power supply lines (Net cable)
– Cable diameter
– Cable type
Min. 1 mm²
QGO20.000D27: e.g. NYM 3 x 1,5
QGO20.000D17: UL AWM Style 1015/MTW or
CSA-AWM/TEW
Required operating temperature of measuring cell 700 °C ±50 °C
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:
– Flange
– Connecting head
– Flue gases
Humidity:
Installation altitude:
DIN EN 60721-3-3
Class 3K5
Class 3M2
Max. 250 °C
Max. 70 °C
300 °C
<95% r.h.
Max. 2000 m a.s.l.