Riello RS 45/E LN Quick start guide

20026767 (8) - 08/2023
Installation, use and maintenance instructions
Forced draught gas burner
Progressive two stage or modulating operation
CODE MODEL
C9341400 RS 45/E LN
GB

Original instructions

1 20026767
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Delivery of the system and the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Packaging - weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Burner dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6.1 Procedure to refer burner operating condition at an altitude and/or at a combustion supporter air temperature
different to the standard values (328 ft above sea level, 68 °F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Commercial boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Control box for the air/fuel ratio (LMV37.4...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11 Actuators (SQM33.5...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Preparing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4.1 Boring the boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4.2 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Combustion head adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7.1 To open the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.8 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.8.1 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.8.2 Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.8.3 Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.8.4 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.9 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9.1 Supply cables and external connections passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.10 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10.1 Electro-mechanical thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Operations before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4 Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5 Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5.1 Adjusting gas/air delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6 Final calibration of the pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

20026767 2 GB
Contents
5.6.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6.2 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.8 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.2 Safety test - with gas ball valve closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.3 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B Appendix - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Information and general instructions
3 20026767
GB
1.1 Information about the instruction manual
1.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not be
separated from it; it must therefore be kept carefully for any
necessary consultation and must accompany the burner even
if it is transferred to another owner or user, or to another sys-
tem. If the manual is lost or damaged, another copy must be
requested from the Technical Assistance Service of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER signs.
Pay great attention to these, as they indicate a situation of potential
danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 Information and general instructions
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with lethal
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 DEVICES
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 ma-
chine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

20026767 4 GB
Information and general instructions
1.1.4 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 recommends the drawing up of a Mainte-
nance Contract.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installation
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 peo-
ple, 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, incorrectly
applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
use of the burner even following an error and/or an irregularity;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that pre-
vent the regular development of the structurally established
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 respon-
sibility for the failure to observe the contents of this manual.
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WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installation
and carrying out of non authorised modifications
will result in the annulment by the manufacturer of
the guarantee that it supplies with the burner.

Safety and prevention
5 20026767
GB
2.1 Introduction
The burners have been designed and built in compliance with cur-
rent 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, diathermic
oil, and to other uses 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 destina-
tions is not allowed.
The burner must be used in exemplary technical safety condi-
tions. Any disturbances that could compromise safety must be
quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
2.2 Personnel training
The user is the person, body or company that has acquired the ma-
chine and intends to use it for the specific purpose. He is responsi-
ble for the machine and for the training of the people working
around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
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 indications
shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel 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:
2 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 necessary
to prevent unauthorised people gaining access
to the machine;
the user must inform the manufacturer if faults
or malfunctioning of the accident prevention
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 manual.

20026767 6 GB
Technical description of the burner
3.1 Technical data
Tab. A
(*) Firing rate for C-UL Canadian Listing (CNL).
(1) Reference conditions: ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2) Pressure at test point 7)(Fig. 6, page 10) with zero pressure in the combustion chamber and maximum burner output.
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
3.2 Burner models designation
Tab. B
3 Technical description of the burner
Model RS 45/E LN
Output (1) High MBtu/hr
kW
717 - 2037 (1969*)
210 - 597 (577*)
Low MBtu/hr
kW
341
100
Fuel Natural or propane gas
• Max delivery
• Pressure at maximum delivery (2)
natural gas
SCFH
“ WC
2037
5.31
Operation Low - high-low or modulating
Standard application Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Main power supply (+/-10%) V/Ph/Hz 120/1/60
Fan motor
rpm
W - HP
V - Hz
A
3400
370 - 0.5
120 - 60
5.2
Motor capacitor µF 45
Ignition transformer V1 - V2
I1 - I2
120 V - 1 x 7 kV
1.6 A - 23 mA
Electrical power consumption W 600
Electrical control circuit cons. W max 750
Total electrical consumption W 400 + 750
Electrical protection NEMA 1
Noise levels (3) dB(A) 72
Model Code Code RBNA Voltage Flame safeguard
RS 45/E LN 20025415 C9341400 120/1/60 Burner mounted

Technical description of the burner
7 20026767
GB
3.3 Packaging - weight
The burners are skid mounted. Outer dimensions of packaging are
indicated in (Tab. C).
The weight of the burner complete with packaging is indicated in
Tab. C.
Tab. C
3.4 Burner dimensions
The maximum dimensions of the burners are given in Fig. 2.
Inspection of the combustion head requires the burner to be
opened and the rear part withdrawn on the slide bars.
The maximum dimension of the burner when open, without casing,
is give in measurement H.
Tab. D
(1) Blast tube: short - long (obtainable with the kit)
3.5 Standard equipment
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange fixing screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 4
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
inch A B C lbs
RS 45/E LN 47 1/4“ 23 5/8“ 27 31/32“ 152
Fig. 1
D36
inch A B C D(1) E F G H I L M
RS 45/E LN 25 31/32” 20 7/32” 26 3/4” 9 1/32” - 13 15/16” 6 9/32” 13 5/16” 6 7/16” 37 7/32” 4 1/4” 6 5/8” 1 1/2”
DG
C
M
L
E
F
I
A
B
H
D10233 Fig. 2
WARNING
It is recommended to tighten the screws of the gas
flange with a tightening torque of 15 Nm ±10%.
Tighten the nuts gradually (first to 30%, then to 60%
up to 100%) according to the cross pattern shown in
the figure.
S10230

20026767 8 GB
Technical description of the burner
3.6 Firing rate
The burner can work in two ways: low and high fire.
MAXIMUM OUTPUT must be selected in area A (Fig. 3).
MINIMUM OUTPUT must not be lower than the minimum limit
shown in the diagram.
3.6.1 Procedure to refer burner operating condition
at an altitude and/or at a combustion supporter
air temperature different to the standard values
(328 ft above sea level, 68 °F).
Tab. E
F - correction factor of discharge head and delivery in relation to temperature and altitude.
Reference conditions:
–Air temperature 68 °F (20 °C)
– Barometric pressure 394 ''w.c. (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.)
Example
Using the Tab. E , for an altitude of 3,000 ft and an air temperature
of 68 °F, an F factor value is obtained equal to 0.908;
if the capacity at the boiler furnace is Qfoc = 4,500 Mbtu/h, the cor-
rect output will be equal to:
Qburner = Qfoc / F = 4,500 / 0.908 = 4,956 Mbtu/h
Model MBtu/hr kW
RS 45/E LN 341 100
WARNING
The firing rate area values have been obtained con-
sidering an ambient temperature of 68 °F, and an
atmospheric pressure of 394” WC and with the
combustion head adjusted as shown at page 17.
Fig. 3
Combustion chamber pressure
“WC
Firing rate for C-UL Canadian Listing (CNL) - 1969 MBtu/hr
D2787
AIR TEMPERATURE
Altitude Altitude bar. press. bar. press. 0 5 10 15 20 25 30 40 °C
ft a.s.l. m a.s.l. "w.c. mbar 32 41 50 59 68 77 86 104 °F
00 399 1013,00 1,087 1,068 1,049 1,031 1,013 0,996 0,980 0,948
328 100 394 1000,00 1,073 1,054 1,035 1,017 1,000 0,983 0,967 0,936
1.000 305 385 977,40 1,049 1,030 1,012 0,994 0,977 0,961 0,945 0,915
2.000 610 371 942,80 1,012 0,994 0,976 0,959 0,943 0,927 0,912 0,883
3.000 915 358 908,20 0,975 0,957 0,940 0,924 0,908 0,893 0,878 0,850
4.000 1.220 345 875,80 0,940 0,923 0,907 0,891 0,876 0,861 0,847 0,820
5.000 1.525 332 843,50 0,905 0,889 0,873 0,858 0,844 0,829 0,816 0,790
6.000 1.830 320 811,85 0,871 0,856 0,841 0,826 0,812 0,798 0,785 0,760
7.000 2.135 307 779,80 0,837 0,822 0,807 0,793 0,780 0,767 0,754 0,730
8.000 2.440 294 747,80 0,803 0,788 0,774 0,761 0,748 0,735 0,723 0,700

Technical description of the burner
9 20026767
GB
3.7 Commercial boilers
The burner is suitable for operation on either flame-inversion boil-
ers or boilers with combustion chambers featuring flow from the
base (three flue passes) on which the best results are obtained in
terms of low NOx emissions.
The maximum thickness of the boiler’s front door must not ex-
ceed 8” (see Fig. 4).
3.8 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 5 indicates the diameter and length of the test combustion
chamber.
Example
Output 1388 MBtu/hr:
diameter 20 inch - length 4.9 ft
Fig. 4
8” max
D1079
D2918
Length (ft)
Furnace dimensions
Diameter (inches)
Fig. 5

20026767 10 GB
Technical description of the burner
3.9 Burner description
1 Combustion head
2 Ignition pilot
3 Screw for combustion head adjustment
4 Sleeve
5 Low air pressure switch (differential operating type)
6 Air combustion head pressure test point
7 Gas pressure test point and head fixing screw
8 Screw securing fan to sleeve
9 Slide bars for opening the burner and inspecting the combus-
tion head
10 Alarm signal lamp
11 Pilot attachment
12 Ignition transformer
13 Air actuator
14 UV flame sensor
15 Plate with four hole knock-outs for electrical cable routing
16 Air inlet to fan
17 Gas input connection
18 Boiler mounting flange
19 Flame stability disk
20 Flame inspection window
21 Alarm silence (noise)
22 Fan motor contactor and thermal overload with reset button
23 Control box for checking flame and air/fuel ratio
24 Local/remote - manual selector
25 Fan motor with capacitor
26 Ground terminals
27 Auxiliary fuse
28 Burner ON/OFF selector
29 Power ON signal
30 Call for heat lamp
31 Ignition ON lamp
32 Fuel ON lamp
33 Burner terminal board
34 RWF55 modulator (with analog output 4-20 mA)
35 Lifting rings
36 K2 relay
37 K1 relay
38 K3 min. relay
39 K5 max. relay
40 Power supply entry cable
41 Gas actuator
42 RWF55 terminal board
43 Optional holes
44 Operator panel with LCD display and lock-out reset button
45 Horn
46 Air pressure switch test point
Two types of burner failure may occur:
Flame safeguard lock-out: If the alarm signal lamp in “ON”
10)(Fig. 6) lights up, it indicates that the burner is in lock-out.
To reset, press the reset pushbutton 44).
Motor trip: release by pressing the pushbutton on thermal
overload, see “Thermal relay calibration” page 22.
824
21
18 1
31
32
10
30
29
41
2
6
2834 43
42
43
911 3
17
15
16
719
4
25
26
23
27
22
33
45
40
20
12
5
35
13
44
36
37
39
38
14 46
Fig. 6
D10435

Technical description of the burner
11 20026767
GB
3.10 Control box for the air/fuel ratio (LMV37.4...)
Warning notes
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area,
completely isolate the plant from mains supply (all-polar dis-
connection). Ensure that the plant cannot be inadvertently
switched on again and that it is indeed dead. If not observed,
there is a risk of electric shock hazard.
Ensure protection against electric shock hazard by providing
adequate protection for the burner control’s connection termi-
nals.
Each time work has been carried out (mounting, installation,
service work, etc.), check to ensure that wiring and parame-
ters is in an orderly state.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Introduction
The control box for the air/fuel ratio (Fig. 7), (hereafter referred to
simply as the control box), that equips the burners, carries out a se-
ries of integrated functions in order to optimise burner functioning,
both for single operation and together with other units (e.g. double
furnace boiler or more than one generator at the same time).
The basic functions carried out by the control box relate to:
flame control;
the dosage of air and fuel via the positioning (with direct servo-
control) of the relative valves, excluding the possible play in
the mechanical cam calibration systems;
the modulation of burner output, on the basis of the load
requested by the system, maintaining the pressure or temper-
ature of the boiler at the working values set;
the safety diagnostic of the air and fuel circuits, via which it is
possible to easily identify any causes of malfunctioning.
Mechanical design
The following system components are integrated in the LMV37.4...
basic unit:
• Burner control with gas valve proving system
• Electronic air / fuel ratio control
• Control frequency converter air fan
• Modbus interface
Installation notes
• Always run high-voltage ignition cables separately while ob-
serving the greatest possible distance to the unit and to other
cables.
• Do not mix up live and neutral conductors (fire hazard, danger-
ous failures, loss of protection against electric shock hazard,
etc.).
• Do not lay the connecting cable from the LMV37.4... to the
AZL2… together with other cables.
Electrical connection of the flame detectors
It is important to achieve practically disturbance- and loss-free sig-
nal transmission:
• Never run the detector cable together with other cables.
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the maximum permissible detector cable lengths.
• The ionization probe is not protected against electric shock
hazard. It is mainspowered and must be protected against ac-
cidental contact.
• Locate the ignition electrode and the ionization probe such that
the ignition spark cannot arc over to the ionization probe (risk
of electrical overloads).
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
must be observed!
The LMV37.4... is a safety device!
Do not open, interfere with or modify the unit.
The manufacturer will not assume responsibili-
ty for any damage resulting from unauthorized
interference!
WARNING
The first start-up, like every further operation for
the internal settings of the control box, requires
access by means of a password and is only to
be carried out by personnel of the Technical As-
sistance Service who have been specifically
trained in the internal programming of the tool.
Fig. 7
D9300

20026767 12 GB
Technical description of the burner
Technical data
Tab. F
LMV37.4... basic unit Mains voltage AC 120 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power consumption < 30 W (typically)
Safety class I, with parts according to II and III to DIN EN 60730-1
Terminal loading
‘Inputs’
Unit fuse F1 (internally) 6.3 AT
Perm. mains primary fuse (externally) Max. 16 AT
Undervoltage
• Safety shutdown from operating position
at mains voltage
• Restart on rise in mains voltage
Approx. AC 93 V
Approx. AC 96 V
Terminal loading
‘Outputs’
Total contact loading:
• Nominal voltage
• Unit input current (safety loop) from:
- Fan motor contactor
- Ignition transformer
- Valves
- Oil pump / magnetic clutch
AC 120 V, 50 / 60 Hz
Max. 5 A
Individual contact loading:
Fan motor contactor
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cos > 0.4
Alarm output
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1 A
cos > 0.4
Ignition transformer
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372 or 250 VA ignition
load declaration to UL372
cos > 0.2
Fuel valves
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1.6 A pilot duty load declaration to UL372
cos > 0.4
Operation display
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
0.5 A
cos > 0.4
Cable lengths Mains line
Display, BCI
External lockout reset button
Max. 100 m (100 pF/m)
For used outside the burner cover or the control panel:
Max. 3 m (100 pF/m)
Max. 20 m (100 pF/m)
Environmental
conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60 °C
< 95 % r.h.

Technical description of the burner
13 20026767
GB
Operation sequence of the burner
Legend to the sequence diagrams:
Valve proving takes place depending on the parameter:
2) Only with valve proving on startup
3) Parameter: with/without alarm in the event of start prevention
4) In the event of an erroneous signal on startup, followed by
phase 10, otherwise phase 70
0° Position as supplied (0°)
90° Actuator fully open (90°)
Assignment of times:
t1 Prepurge time
TSA1 Safety time 1 gas / oil
TSA2 Safety time 2 gas / oil
00 02 12 22 24 30 36 38 40 42 44 50 52 60 62 70 72 74 81 82 8380
3)
4)
2)
TSA1 TSA2
t1
90
p
a
T
P
P
T
P
10
Shutdown
Operation
Startup Valve proving
OUTPUTS INPUTS
Phase number
Fuel
Actuator 2
Air
Actuator 1
Actuators
Safety limit thermostat (STB)
Control thermostat or pressurestat (R)
Flame signal (FS)
Air pressure switch (LP)
Pressure switch-min (Pmin)
Pressure switch-max (Pmax)
Valve proving / leakage test (P LT)
POC (alternative to Pmax)
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
VSD
Motor (M)
Ignition transformer (Z)
Alarm (AL)
Safety valve (SV)
Fuel valve 1 (V1)
Fuel valve 2 (V2)
Pilot valve (PV)
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
No-load position
Ignition load
Postpurge position
Nominal load
Low-fire
90°
0°
Fig. 8
D9288
Signal ON
Signal OFF
Any signal is allowed
In standby: after referencing, the actuator is driven to the
no-load position

20026767 14 GB
Technical description of the burner
3.11 Actuators (SQM33.5...)
Warning notes
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area of
the units, completely isolate the equipment from mains supply
(all-polar disconnection). If not observed, there is a risk of
electric shock hazard.
Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
After any kind of activity (mounting, installation and service
work, etc.), check wiring.
Also ensure that the parameters are correctly set.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not exhibit
any damage.
Use
The actuators (Fig. 9) are used to drive and position the air damper
and the gas butterfly valve, without mechanical leverages but via
the interposition of an elastic coupling.
They are commanded by the control box, which constantly checks
their position by means of a return signal from the optic sensor in-
side the actuator.
The position (in degrees) of the actuators can be seen on the dis-
play of the Operator Panel.
Index “0” for fuel actuator, index “1” for air actuator.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible dis-
tance.
• The holding torque is reduced when the actuator is disconnect-
ed from power.
Technical data
Tab. G
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
should be observed!
Do not open, interfere with or modify the actua-
tors!
WARNING
The actuator’s housing must not be opened.
The actuator contains an optical feedback sys-
tem.
WARNING
When servicing or replacing the actuators, take
care not to invert the connectors.
Operating voltage AC / DC 24 V ±20 %
(load on interface)
Safety class 2 to EN 60 730 part 1 and parts 2…14
Power consumption max. 10 W
Degree of protection IP54 to EN 60 529-1
Opening time 0 - 90° min: 5s, max.: 120s
(depending on the type of control box)
Firing rate 0 - 90°
Cable connection RAST2,5 connectors
Direction of rotation Clockwise/anticlockwise
(can be selected from the control box)
Nominal output torque 3 Nm
Holding torque
(when live) 3 Nm
Holding torque
(when dead) 2.6 Nm
Weight approx. 1 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
class 3K5
class 3M4
-20...+60 ×C
< 95 % r.h.
D8271
Fig. 9

Installation
15 20026767
GB
4.1 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 environment, pro-
ceed with the installation operations.
4.2 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.
4.3 Preliminary checks
Checking the consignment
4.4 Preparing the boiler
4.4.1 Boring the boiler plate
Drill the combustion chamber mounting plate as shown in Fig. 10.
The position of the threaded holes can be marked using the head
gasket supplied with the burner.
Tab. H
4 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 regulations of
the laws in force.
WARNING
The handling operations for the burner can be high-
ly dangerous if not carried out with the greatest at-
tention: 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 quickly move
if the burner should fall).
During the handling, keep the load at not more than
20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
CAUTION
After removing all the packaging, check the integrity
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 dan-
ger and pollution; they should be collected and dis-
posed of in the appropriate places.
WARNING
The output of the burner must be within the boil-
er’s firing rate.
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
inch A B C
RS 45/E LN 6 9/32“ 8 13/16“ 3/8 W
D455
Fig. 10

20026767 16 GB
Installation
4.4.2 Blast tube length
The length of the blast tube must be selected according to the indi-
cations provided by the manufacturer of the boiler, and it must be
greater than the thickness of the boiler door complete with its insu-
lation.
The range of lengths available, L (inch), is as follows:
Tab. I
For boilers with front flue passes 6) or flame inversion cham-
bers, protective insulation 4) must be inserted between the
boiler refractory 5) and the blast tube 3).
This protective insulation must not compromise the extraction
of the blast tube.
For boilers having a water-cooled front the insulation 4)-
5)(Fig. 11) is not required unless it is required by the boiler
manufacturer.
4.5 Securing the burner to the boiler
Secure the flange 2)(Fig. 11) to the boiler plate, inserting the
gasket 1)(Fig. 11).
Use the 4 screws, after first protecting the thread with an anti-
locking product.
The seal between burner and boiler must be airtight.
4.6 Ignition pilot adjustment
Place the pilot and electrode as shown in Fig. 12.
The pilot works correctly at pressures ranging from 5 - 12” WC.
Model L (short blast tube) L (long blast tube)
RS 45/E LN 9 1/32“ 13 15/16“
3
6
5
4
6
1
2
L
Fig. 11
D10436
WARNING
Measures must be respected.
5/16"
1/8"
Fig. 12
D10437

Installation
17 20026767
GB
4.7 Combustion head adjustment
Installation operations are now at the stage where the blast tube
and sleeve are secured to the boiler as shown in Fig. 13.
It is now a very simple matter to set up the combustion head, as this
depends solely on the output developed by the burner at maximum
power.
It is therefore essential to establish this value before proceeding to
set up the combustion head.
There are three adjustments to make on the head:
• outside air R1
• central air R2
• gas deliveries R3
In diagram (Fig. 14) find the notch to use for adjusting the air and
the gas, and then proceed as follows:
Outside air adjustment R1 (Fig. 13)
Turn screw 4) until the notch identified is aligned with the front
surface 5) of the flange.
Gas adjustment R3 (Fig. 13)
Loosen screws 1)(B) and 4)(B) and turn ring 2) until the notch
identified is aligned with index 3).
Central air adjustment R2 (Fig. 13)
Turn choke 5) until the notch identified is aligned with screw
4).
Tighten the screws 1) and 4) fully down.
Example
Burner output = 1515 MBtu/hr.
If we consult diagram (Fig. 14) we find that for this output, the ad-
justments are:
• outside air R1 = 5.3
• central air R2 = 2.7
• gas R3 = 0.7
WARNING
The fan part of the burner shall be completely back-
ward using the guides.
64 (R1)
0
1
2
3
5
1
2 (R3)
4
3
5 (R2)
Fig. 13
AIR
GAS
D10450
Fig. 14
Burner max output
Notches (Air = Gas)

20026767 18 GB
Installation
4.7.1 To open the burner
To open the burner proceed sa follows:
remove screws 2)(Fig. 16) and withdraw the cover 3);
remove the screws 4) from the slide bars 5);
install the extention bars 7);
remove screw 6) and pull the burner back 13) on slide bars 5)
by about 4”;
disconnect the electrode wires and then pull the burner com-
pletely back;
unscrew the head fixing screw 11);
unscrew the pin 8)(Fig. 15) from the connection 9);
push ahed the connection to the end stop on the plug 10),
therefore extract the inner part of the combustion head 12).
WARNING
Switch off the electrical power.
8
910
Fig. 15
D10451
12
14
13
4"
11
5
4
7
3
2
6
Fig. 16
D10438