Riello RS 1200/E BIOGAS/GPL C01 FS2 Quick start guide

20049577 (2) - 07/2012
Installation, use and maintenance instructions
Forced draught gas burner
Modulating operation
Code Model
20048377 RS 1200/E BIOGAS/GPL C01 FS2
GB

1 20049577
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 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6.1 Procedure to refer burner operating condition in high altitude plants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.9 Panel board description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.10 Burner equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Control box for the air/fuel ratio (LMV51...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Servomotor (SQM48.4....) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5.1 Boring the boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Burner securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.8 Accessibility to the interior of the combustion head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.9.1 Gas feeding line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.9.2 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.10 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.10.1 Notes on safety for the electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.11 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.11.1 Electro-mechanical thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.11.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.12 Reversible direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2 Adjustments before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Burner start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Burner ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4.1 Air / gas adjustment and output modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

20049577 2
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Contents
5.5 Final calibration of the pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5.2 Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5.3 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.6 Final checks (with burner operating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Faults - Probable causes - Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B Appendix - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Information and general instructions
3 20049577
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 COVER AND
ALL THE SAFETY AND PROTECTION DEVICES
This symbol signals the obligation to reassemble
the cover and all the safety and protection devices
of the burner after any maintenance, cleaning or
checking operations.
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the 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.

20049577 4
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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 Assist-
ance 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 Maintenance 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 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.

Safety and prevention
5 20049577
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 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 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

20049577 6
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Technical description of the burner
3.1 Technical data
Tab. A
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394” wc - Altitude 329 ft.
(2) Pressure at test point 5) (Fig. 5), 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 Electrical data
Tab. B
3.3 Burner models designation
Tab. C
3 Technical description of the burner
Model RS 1200/E BIOGAS/GPL C01 FS2
Output (1) max. kW
MBtu/hr 5500 - 12000 18766 - 40944
min. kW
MBtu/hr 1500 5118
Fuel
- max. delivery
- pressure at max. delivery (2)
SCFH
“ wc
Natural gas
29973
17.9
Operation Low - high or modulating
Standard applications Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Noise levels (3) dBA 99
Fan motor IE2
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 575/3/60
Fan motor rpm
V
HP
A
3520
575/795
34
30.8
Ignition transformer V1 - V2
I1 - I2 120 V - 1 x 8 kV 1.6 A - 20 mA
Electrical power consumption A max 33
Electrical control circuit consumption W max
Total electrical consumption kW 26
Electrical protection NEMA 1
Model Code Voltage Flame safeguard
RS 1200/E C01 20048377 575/3/60 Burner mounted

Technical description of the burner
7 20049577
GB
3.4 Packaging
The packaging of the burner (Fig. 1) rests on a wooden plat-
form that is particularly suitable for lift trucks.
The overall dimensions of the packaging are shown in the
Tab. D.
The weight of the burner complete with its packaging is shown
in Tab. D.
Tab. D
3.5 Overall dimensions
The maximum dimensions of the burner are given in Fig. 2.
Bear in mind that inspection of the combustion head requires the
burner to be opened by rotating the rear part on the hinge.
The overall dimensions of the burner when open are indicated by L
and R.
Tab. E
inch A B C lbs
RS 1200/E C01 96 1/16“63 37/64“56 11/16“1100
D36 Fig. 1
inch ABCDEFGH I LRS
RS 1200/E C01 61 21/32“20 61/64“ 7 7/8“17 61/64“34 51/64“DN80 49 7/32“51 37/64“18 3/16“56“ 52 23/64“13 5/32“
I
E
C
F
D
A B G
H
SL
R
R
Fig. 2
20050803

20049577 8
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Technical description of the burner
3.6 Firing rate
Maximum output must be selected in the hatched area of the dia-
gram.
Minimum output must not be lower than the minimum limit shown
in the diagram.
WARNING
The firing rate was obtained considering a room
temperature of 68 °F and an atmospheric pressure
of 394 “wc (approx. 0 ft above sea level), with the
combustion head adjusted.
" wc
Burner power output
Combustion chamber pressure
Fig. 3
20050769

Technical description of the burner
9 20049577
GB
3.6.1 Procedure to refer burner operating condition
in high altitude plants
Find the CORRECTED BURNER CAPACITY for the plant’s alti-
tude in chart 1 and the CORRECTED PRESSURE in chart 2.
Check in the firing rate graph of the burner (Fig. 4), if the working
point defined by the values above is within the range limits.
If not, higher burner size is needed.
Note
Charts are based only on altitude variation (reference temper-
ature = 68°F, 20°C)
To get the combined correction in case of different air temper-
ature, a compensation of 1000 ft each 20°F (305 m each
11°C) is applicable (100 ft = 2°F).
Example
Rated capacity = 3000 MBtu/hr - Rated air pressure = 1.5” WC
Real altitude = 5000 ft - Real temperature = 108°F
= 108°F - 68°F (reference temp.) = 40°F
(equivalent 2000 ft variation)
40 : 2 = 20 x 100 = 2000 ft
Proceeding as descripted above and considering a “virtual altitude”
of (5000 + 2000) ft:
– 3000 MBtu/hr at 7000 ft, the corrected capacity is 3847 MBtu/hr
– 1.5” WC at 7000 ft, the corrected burner air pressure is 1.92
Reference conditions:
– Ambient temperature 68 °F (20 °C)
– Barometric pressure 394” WC (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.).
CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE
Altitude
Rated Capacity m a.s.l. 0100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0328 1000 2000 3000 4000 5000 6000 7000 8000
500 494 500 512 530 551 571 593 616 641 669
1000 987 1000 1023 1061 1101 1142 1186 1232 1282 1337
1500 1481 1500 1535 1591 1652 1713 1778 1848 1924 2006
2000 1974 2000 2046 2121 2202 2284 2371 2464 2565 2675
2500 2468 2500 2558 2652 2753 2855 2964 3079 3206 3343
3000 2962 3000 3069 3182 3303 3425 3557 3695 3847 4012
3500 3455 3500 3581 3712 3854 3996 4149 4311 4488 4680
4000 3949 4000 4092 4243 4404 4567 4742 4927 5130 5349
4500 4442 4500 4604 4773 4955 5138 5335 5543 5771 6018
5000 4936 5000 5116 5303 5505 5709 5928 6159 6412 6686
5500 5429 5500 5627 5834 6056 6280 6520 6775 7053 7355
6000 5923 6000 6139 6364 6606 6851 7113 7391 7694 8024
6500 6417 6500 6650 6894 7157 7422 7706 8006 8335 8692
7000 6910 7000 7162 7425 7708 7993 8299 8622 8977 9361
7500 7404 7500 7673 7955 8258 8564 8892 9238 9618 10029
8000 7897 8000 8185 8485 8809 9135 9484 9854 10259 10698
8500 8391 8500 8697 9016 9359 9705 10077 10470 10900 11367
9000 8885 9000 9208 9546 9910 10276 10670 11086 11541 12035
9500 9378 9500 9720 10076 10460 10847 11263 11702 12183 12704
10000 9872 10000 10231 10607 11011 11418 11855 12318 12824 13373
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
1

20049577 10
GB
Technical description of the burner
3.7 Minimum furnace dimensions
The firing rate was obtained in special test boilers.
Fig. 4 indicates the diameter and length of the test combustion
chamber.
Example:
Output 26510 Mbtu/hr: - diameter 47.7 inch - length 20 ft.
CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE
Altitude
Rated Pressure m a.s.l. 0100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0328 1000 2000 3000 4000 5000 6000 7000 8000
0.50 0.49 0.50 0.51 0.53 0.55 0.57 0.59 0.62 0.64 0.67
1.00 0.99 1.00 1.02 1.06 1.10 1.14 1.19 1.23 1.28 1.34
1.50 1.48 1.50 1.53 1.59 1.65 1.71 1.78 1.85 1.92 2.01
2.00 1.97 2.00 2.05 2.12 2.20 2.28 2.37 2.46 2.56 2.67
2.50 2.47 2.50 2.56 2.65 2.75 2.85 2.96 3.08 3.21 3.34
3.00 2.96 3.00 3.07 3.18 3.30 3.43 3.56 3.70 3.85 4.01
3.50 3.46 3.50 3.58 3.71 3.85 4.00 4.15 4.31 4.49 4.68
4.00 3.95 4.00 4.09 4.24 4.40 4.57 4.74 4.93 5.13 5.35
4.50 4.44 4.50 4.60 4.77 4.95 5.14 5.33 5.54 5.77 6.02
5.00 4.94 5.00 5.12 5.30 5.51 5.71 5.93 6.16 6.41 6.69
5.50 5.43 5.50 5.63 5.83 6.06 6.28 6.52 6.77 7.05 7.35
6.00 5.92 6.00 6.14 6.36 6.61 6.85 7.11 7.39 7.69 8.02
6.50 6.42 6.50 6.65 6.89 7.16 7.42 7.71 8.01 8.34 8.69
7.00 6.91 7.00 7.16 7.42 7.71 7.99 8.30 8.62 8.98 9.36
7.50 7.40 7.50 7.67 7.96 8.26 8.56 8.89 9.24 9.62 10.03
8.00 7.90 8.00 8.18 8.49 8.81 9.13 9.48 9.85 10.26 10.70
8.50 8.39 8.50 8.70 9.02 9.36 9.71 10.08 10.47 10.90 11.37
9.00 8.88 9.00 9.21 9.55 9.91 10.28 10.67 11.09 11.54 12.04
9.50 9.38 9.50 9.72 10.08 10.46 10.85 11.26 11.70 12.18 12.70
10.00 9.87 10.00 10.23 10.61 11.01 11.42 11.86 12.32 12.82 13.37
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
2
Fig. 4
1000MBtu/hr760 1.5 7.5 11.3 18.9 37870
1.6
3.3
6.6
9.9
13.2
16.5
29.6
23.0
15. 7 19. 7 23. 6 31. 5 39. 4 47. 2
inches
ft
ft= 0,12 MBtu
hr
22.7
D9084

Technical description of the burner
11 20049577
GB
3.8 Burner components
1 Lifting eyebolts
2Fan
3Fanmotor
4 Air gate valve servomotor
5 Maximum gas pressure switch with pressure test point
6 Combustion head
7 Ignition pilot
8 Flame stability disk
9 Electric panel board - cover
10 Servomotor for gas butterlfy valve
11 Air inlet to fan
12 Manifold
13 Thermal insulation screen for securing burner to boiler
14 Gas butterfly valve
15 Shutter
16 Lever for movement of combustion head
17 Tie rods for air damper movement
18 Air pressure switch
19 Air pressure test point
20 Ignition pilot attachment
21 UV fotocell holder
22 Hinge for opening burner
23 Air pressure test point pressure test point “+”
24 Electric board protection
9
18 1
10 6
14
4
11
12 20 16 21 24 23
15
7
8
13
19
522 17 2
Fig. 5
20050804
WARNING
The burner can be opened either on the right or left
sides,irrespectiveof the side from which fuelissup-
plied. When the burner is closed, the hinge can be
re-positioned on the opposite side.

20049577 12
GB
Technical description of the burner
3.9 Panel board description
1 “OFF - LOCAL - REMOTE” switch
2 “POWER ON” signal
3 “CALL FOR HEAT” signal
4 Contactor with auxiliary contact for star/delta start “KT1”
5 “FUEL ON” signal
6 “ALARM SILENCE” button
7 “BURNER LOCK-OUT and RESET” pushbutton
8 Low air pressure switch
9 Operator panel with LCD display
10 Burner terminal board “X1”
11 Control box for checking flame and air/fuel ratio
12 Ignition transformer “TA”
13 Control box trasformer “T1”
14 Step-down trasformer (available)
15 Terminal strip “X2”
16 Fan motor thermal relay with reset button “F1”
17 Contactor with auxiliary contact for star/delta start “KS1”
18 Bracket for shielded cables with thumbscrew
Warning: used only to avoid a break in the cable’s shielding,
hence do not overtighten.
19 “KST1” timer
20 Auxiliary fuse
21 “IGNITION ON” signal
22 Horn
23 Relay
24 Electric joint for ignition cable
25 Electric joint for air pressure switch pipe
26 Free entrance for pilot gas train valves
27 Hole for fan motor cable
28 Plug/socket for QRI flame sensor
29 Plug/socket for air actuator
30 Plug/socket for maximum pressure switch
31 Contactor with auxiliary contact for star/delta start “KL1”
32 Holes for cables grommets for electrical wirings, accessories
and power supply (to be carried out by the installer)
Two types of burner failure may occur:
Flame safeguard lock-out
If the flame safeguard alarm 6)(Fig. 6) lights up, it indicates
that the burner is in lock-out. To reset, press the reset push-
button.
Fan motor trip
Release by pressing the pushbutton on thermal overload
16)(Fig. 6). See “Thermal relay calibration” on page 22.
3.10 Burner equipment
The burner is supplied complete with:
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Flange fixing screws M 16 x 50 . . . . . . . . . . . . . . . . . . . . . . .No. 4
Screws to secure the burner flange to the boiler: M 20 x 70.No. 4
Instruction manual and spare parts list . . . . . . . . . . . . . . . . .No. 1
819 31 417
16
11
5
21
23
9
6
7
1
32
24 25
26
28
30
22
29
27
12
13
18
15 23
Fig. 6
20050806

Technical description of the burner
13 20049577
GB
3.11 Control box for the air/fuel ratio (LMV51...)
Warning notes
All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
Before making any wiring changes in the connection area of
the LMV5..., completely isolate the plant from mains supply
(all-polar disconnection). Ensure that the plant cannot be
inadvertently switched on again and that it is indeed dead. If
not observed, there is a risk of electric shock hazard.
Protection against electrical shock hazard on the LMV5... and
on all connected electrical components must be ensured
through appropriate mounting.
Each time work has been carried out (mounting, installation
and service work, etc.), check to ensure that wiring is in an
orderly state, that the parameters have been correctly set and
make the safety checks.
Fall or shock can adversely affect the safety functions.
Such units must not be put into operation even if they do not
exhibit any damage.
In programming mode, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
Like in automatic operation, the actuators are still jointly
driven to their required positions. If an actuator does not
reach the required position, corrections are made until that
position is reached. However, in contrast to automatic opera-
tion, there are no time limits to these corrective actions.
The other actuators maintain their positions until all actuators
have reached the positions currently required.
This is essential for setting fuel /air ratio control.
This means that during the time the fuel / air ratio curves are
programmed, the person making the plant settings must con-
tinuously monitor the quality of the combustion process (e.g.
by means of a flue gas analyzer).
Also, if combustion levels are poor, or in the event of danger-
ous situations, the commissioning engineer must take appro-
priate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV5... system, the
following points must also be observed:
– Condensation and ingress of humidity must be avoided. Should
such conditions occur, make sure that the unit will be completely
dry before switching on again!
– Static charges must be avoided since they can damage the
unit’s electronic components when touched.
Mechanical design
The LMV5... is a microprocessor-based burner management sys-
tem with matching system components for the control and supervi-
sion of forced draft burners of medium to large capacity.
The following components are integrated in the basic unit of the
LMV5...:
• Burner control with gas valve proving system
• Electronic fuel / air ratio control with a maximum of 4 (LMV51…)
or 6 (LMV52…) actuators
• Optional PID temperature / pressure controller (load controller)
• Optional VSD moduleMechanical design
Installation notes
• Ensure that the electrical wiring inside the boiler is in compliance
with national and local safety regulations.
• Do not mix up live and neutral conductors.
• Make certain that strain relief of the connected cables is in com-
pliance 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 neighbor-
ing terminals. Use adequate ferrules.
• Always run high-voltage ignition cables separately while observ-
ing the greatest possible distance to the unit and to other cables
• The burner manufacturer must protect unused AC 120 V termi-
nals with dummy plugs (refer to sections Suppliers of other ac-
cessory items).
• When wiring the unit, ensure that AC 120 V mains voltage ca-
bles are run strictly separate from extra low-voltage cables to
warrant protection against electrical shock hazard.
WARNING
To avoid injury to persons, damage to property
or the environment, the following warning notes
must be observed!
The LMV51... is a safety device! Do not open, in-
terfere with or modify the unit.
Riello S.p.A. will not assume responsibility for
any damage resulting from unauthorized inter-
ference! Risk of explosion!
Incorrect configuration can lead to excessive
fuel supply which might cause an explosion!
Operators must be aware that incorrect settings
made on the AZL5… display and operating unit
and incorrect settings of the fuel and / or air ac-
tuator positions can lead to dangerous burner
operating conditions.
Fig. 7
D9301

20049577 14
GB
Technical description of the burner
Electrical connection of ionization probe and flame detector
It is important to achieve practically disturbance- and loss-free
signal transmission:
• Never run the detector cables together with other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Observe the permissible cable lengths.
• The ionization probe is not protected against electrical shock
hazard. The mainspowered ionization probe must be protected
against accidental contact.
• Locate the ignition electrode and the ionization probe such
that the ignition spark cannot arc over to the ionization
probe (risk of electrical overloads).
Technical data
LMV51... basic unit Mains voltage AC 120 V -15 % / +10 %
Mains frequency 50 / 60 Hz ±6 %
Power consumption < 30 W (typically)
Safety class I, with parts according to II and III to DIN EN 60730-1
Terminal loading
‘Inputs’ Unit fuse F1 (internally) 6.3 AT
Perm. mains primary fuse (externally) Max. 16 AT
Undervoltage
• Safety shutdown from operating position
at mains voltage
• Restart on rise in mains voltage
< AC 96 V
> AC 100 V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor 1.6A cos> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor 0.5A cos> 0.4
Terminal loading
‘Outputs’ Total contact loading: • Mains voltage
• Input current of unit (safety loop) total
load on contacts resulting from:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 120 V -15 % / +10 %
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor 1A cos> 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor 1 A cos> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor 1.6 A cos> 0.2
Fuel valve gas (nominal voltage)
• Nominal current
• Power factor 1.6 A cos> 0.4
Fuel valve oil (nominal voltage)
• Nominal current
• Power factor 1.6 A cos> 0.4
Cable lengths Main line Max. 100 m (100 pF/m)
Environmental
conditions Operation Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60 °C
< 95 % r.h.

Technical description of the burner
15 20049577
GB
3.12 Servomotor (SQM48.4....)
Warnings
All interventions (assembly and installation operations, assist-
ance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the SQM4... system connection
area, fully disconnect the burner control device from the power
supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection termi-
nals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety functions.
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 functional
low-voltage section.
• The static torque is reduced when the electrical supply of the ac-
tuator is switched off.
• The housing cover may only be removed for short periods of
time for wiring or when making the addressing. In similar cases,
make sure that dust or dirt does not penetrate inside the actu-
ator.
• The actuator comprises a PCB with ESD-sensitive compo-
nents.
• The top side of the board carries a cover which affords protec-
tion against direct contact. This protective cover must not be re-
moved! The underside side of the board must not be touched.
Technical data
Tab. F
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
Avoid opening, modifying or forcing the actu-
ators.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
Operating voltage AC 2 x 12V via bus cable from the
baseunitorviaaseparatetransformer
Safety class extra low-voltage with safe isolation
from mains voltage
Power absorption 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) 20 Nm
Holding torque (max) 20 Nm
Running time (min.)
for 90° 30 s.
Weight approx. 1.6kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95% RH
D8271 Fig. 8

20049577 16
GB
Installation
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
Checking the characteristics of the burner
Check the identification label of the burner (Fig. 9), showing:
A the burner model
B the burner type
C the cryptographic year of manufacture
D the serial number
E the data for electrical supply and the protection level
F the electrical power consumption
G the types of gas used and the relative supply pressures
H the data of the burner's minimum and maximum output possi-
bilities (see Firing rate)
Warning. The burner output must be within the boiler's firing
rate
I the category of the appliance/countries of destination
4Installation
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.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halogen);
if present, it is highly recommended to carry out
cleaning and maintenance more frequently.
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).
When handling, keep the load at not more than 20-
25 cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the 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
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS- KAASU
GAZ-AEPIO X
RIELLOS.p.A.
I-37045Legnago(VR)
A
DEBC
F
I
G H
G H
D10411 Fig. 9

Installation
17 20049577
GB
4.4 Operating position
4.5 Securing the burner to the boiler
4.5.1 Boring the boiler plate
Drill the combustion chamber locking plate as shown in (Fig. 11).
Tab. G
4.6 Blast tube length
The length of the blast tube must be selected according to the
indications provided by the manufacturer of the boiler, and in
any case it must be greater than the thickness of the boiler door
complete with its fettling.
For boilers with front flue passes 1)(Fig. 12) or flame inversion
chambers, protective fettling in refractory material 5) must be in-
serted between the boiler fettling 2) and the blast tube 4).
This protective fettling must not compromise the extraction of
the blast tube.
For boilers having a water-cooled front the refractory fettling 2)-
5)(Fig. 10) is not required unless it is expressly requested by the
boiler manufacturer.
WARNING
The burner is designed to operate only in
positions 1, 2, 3 and 4 (Fig. 10).
Installation 1is preferable, as it is the only
one that allows the maintenance operations
as described in this manual.
Installations 2, 3 and 4permit operation but
make maintenance and inspection of the
combustion head more difficult.
DANGER
Any other position could compromise the cor-
rect operation of the appliance.
Installation 5is prohibited for safety reasons.
2 3 4 51
D7739 Fig. 10
mm ABC
RS 1200/E C01 19 11/16“ 23 15/16“51/64W
Fig. 11
D455
5
2
1
1
33
8
7
20050807 Fig. 12

20049577 18
GB
Installation
4.7 Burner securing
Create a suitable hoisting system by hooking onto the rings
3)(Fig. 10), removing the fastening screws 7) securing the
cover 8) first.
Slip the thermal protection onto the blast tube 4) (Fig. 10).
Place entire burner on the boiler hole (arranged previously,
see Fig. 9), and fasten with the screws given as standard
equipment.
The coupling of the burner-boiler must be airtight.
4.8 Accessibility to the interior of the combustion head
Open burner at hinge as illustrated in Fig. 11 after releasing
the tie rod of the head movement lever 1) and removing the 4
fastening screws 2).
Disconnect the wire 3) from the electrode.
Disconnect the tube of ignition pilot 4).
Unscrew the screw 5) after removing the gas pressure switch
(5 Fig. 5).
Extract the internal part 6) of the combustion head.
In case of replacement of biogas combustion head 6) with
LPG combustion head, use the nut and ogive from the con-
nector 59) (page 31) supplied with the burner and install them
on the new pilot tube. After assembling the same combustion
head on the burner; provide to tighten on the other side of the
elbow, already present on the pipe coupling.
4.9 Electrode positioning
Make sure that the electrode and the ignition pilot are positioned
as shown in figure (Fig. 13).
Prepare a suitable lifting system.
WARNING
The seal between burner and boiler must be air-
tight.
Be careful as some drops of fuel may leak out dur-
ing this phase.
2
2
1
5346
20050808 Fig. 13
15/64"
Fig. 14
20050809