Riello RS 200/E LN Quick start guide

20008113 (7) - 10/2013
Installation, use and maintenance instructions
Forced draught gas burner
Code Model
20007528 RS 200/E LN
GB
Progressive two stage or modulating operation

1 20008113
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 Danger: live components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Owner’s 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 Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Overall dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Burner equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Control box for the air/fuel ratio (LMV37.4...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Actuators (SQM33.5...). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Notes on safety for the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Operation position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.2 Boring the boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5.3 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Electrode positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Adjustment of the combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Gas train assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.9 Gas feeding line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Gas supply pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11 Electrical wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.11.1 Calibration of the thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.12 Motor connection at 208-230 or 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.13 Motor connection at 575V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.14 Reversible direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Notes on safety for the first start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Operations before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3 Burner start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 Final calibration of the pressure switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.1 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.2 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3 Maximum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.4 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

20008113 2 GB
Contents
6.1 Notes on safety for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Maintenance programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.2 Checking and cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Opening the burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Information and general instructions
3 20008113
GB
1.1 Information about the instruction manual
1.1.1 Introduction
The instruction manual supplied with the burner:
³is 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 Service
of the area;
³is designed for use by qualified personnel;
³offers 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.
Maximum danger level!
This symbol indicates operations which, if not carried
out correctly, cause serious injury, death or long-
term health risks.
This symbol indicates operations which, if not carried
out correctly, may cause serious injury, death or
long-term health risks.
This symbol indicates operations which, if not carried
out correctly, may cause damage to the machine
and/or injury to people.
1.1.3 Danger: live components
This symbol indicates operations which, if not carried
out correctly, lead to electric shocks with lethal con-
sequences.
Other symbols
ENVIRONMENTAL PROTECTION
This symbol gives indications for the use of the
machine with respect for the environment.
³This symbol indicates a list.
Abbreviations used
Ch. Chapter
Fig. Figure
Pag. Page
Sec. Section
Tab. Table
Delivery of the system and the instruction manual
When the system is delivered, it is important that:
³The instruction manual is supplied to the user by the system
manufacturer, with the recommendation to keep it in the room
where the heat generator is to be installed.
³The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assist-
ance Centre;
³The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system
is started up,
- maintenance and the need to have the system checked at
least once a year by the manufacturer or another special-
ised technician.
To ensure a periodic check, recommends the
drawing up of a Maintenance Contract.
1 Information and general instructions
DANGER
WARNING
CAUTION
............................................................................................
...........................................................................................
...........................................................................................
...........................................................................................
DANGER

20008113 4 GB
Information and general instructions
1.2 Guarantee and responsibility
guarantees its new products from the installation date,
in accordance with the regulations in force and/or the sales con-
tract. At the moment of the first start-up, check that the burner is
integral and complete.
Failure to observe the information given in this man-
ual, operating negligence, incorrect installation and
the carrying out of non authorised modifications will
result in the annulment by of the guarantee
that it supplies with the burner.
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:
³incorrect installation, start-up, use and maintenance of the
burner;
³improper, incorrect or unreasonable use of the burner;
³intervention of unqualified personnel;
³carrying out of non authorised modifications on the equip-
ment;
³use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
³installation of untested supplementary components on the
burner;
³powering of the burner with unsuitable fuels;
³faults in the fuel power supply system;
³use of the burner even following an error and/or an irregular-
ity;
³repairs and/or overhauls incorrectly carried out;
³modification of the combustion chamber with inserts that pre-
vent the regular development of the flame, as structurally
established;
³insufficient and inappropriate surveillance and care of those
burner components most subject to wear and tear;
³use of non-original components, including spare
parts, kits, accessories and optionals;
³force majeure.
furthermore declines any and every responsibility
for the failure to observe the contents of this manual.
1.2.1 Owner’s responsibility
Please pay attention to the Safety Warnings contained within
this instruction manual. Keep this manual for your records and
provide it to your quali fi ed service agency for use in profession-
ally setting up and maintaining your burner.
Your burner will provide years of ef fi cient operation if it is pro-
fessionally installed and maintained by a qualifi ed service tech-
nician. If at any time the burner does not appear to be operating
properly, immediately contact your qualifi ed service agency for
consultation.
We recommend annual inspection/service of your gas heating
system by a qualifi ed service agency.
Failure to follow these instructions, misuse, or incorrect adjust-
ment of the burner could lead to equipment malfunction and re-
sult in asphyxiation, explosion or fire.
If you smell gas:
³Do not touch any electrical items.
³Open all windows.
³Close all gas supply valves.
³Contact your local gas authority immediately.
• Do not store flammable or hazardous materials in the vicinity of
fuel burning appliances.
• Improper installation, adjustment, alteration, service or mainte-
nance can cause property damage, personal injury or death.
• Refer to this manual for instructional or additional information.
• Consult a certified installer, service representative or the gas
supplier for further assistance.
• Burner shall be installed in accordance with manufacturers re-
quirements as outlined in this manual, local codes and authori-
ties having jurisdiction.
WARNING
WARNING

Safety and prevention
5 20008113
GB
2.1 Introduction
The burners have been designed and built in compli-
ance 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 burn-
er or other items. Inattention, thoughtlessness and excessive
confidence often cause accidents; the same applies to tiredness
and sleepiness.
It is a good idea to remember the following:
³The burner must only be used as expressly described.
Any other use should be considered improper and therefore
dangerous.
In particular:
it can be applied to boilers operating with water, steam, dia-
thermic oil, and to other users expressly named by the manu-
facturer;
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 pres-
surisation 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.
³Modification of the burner to alter its performance and desti-
nations is not allowed.
³The burner must be used in exemplary technical safety condi-
tions. Any disturbances that could compromise safety must
be quickly eliminated.
³Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
³Only 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
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people
working around it.
The user:
³Undertakes to entrust the machine exclusively to suitably
trained and qualified personnel.
³Must take all the measures necessary to prevent unauthor-
ised people gaining access to the machine.
³Undertakes 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.
³Must inform the manufacturer if faults or malfunctioning of the
accident prevention systems are noticed, along with any pre-
sumed danger situation.
³Personnel must always use the personal protective equip-
ment envisaged by legislation and follow the indications given
in this manual.
³Personnel must follow all the danger and caution indications
shown on the machine.
³Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
³Personnel are obliged to inform their superiors of every prob-
lem or dangerous situation that may arise.
³The 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 all responsibility for any damage that may
be caused by the use of non-original parts.
2 Safety and prevention

20008113 6 GB
Technical description of the burner
3.1 Technical data
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394 ”wc - Altitude 329 ft.
(2) Pressure at test point 21) (Fig. 5), with zero pressure in the combustion chamber, with open gas ring 2) (Fig. 21) at maximum burner output.
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
* Firing rate for C-ETL Canadian Listing
3.2 Electrical data
Fan motor IE1
Fan motor IE2/EPACT
3 Technical description of the burner
Model RS 200/E LN
Output (1)
maximum kW
MBtu/hr 1526 - 2664 (2422*) 5207 - 9090 (8264*)
minimum kW
MBtu/hr 615 2100
Fuel
- max. delivery
- pressure at max. delivery (2) SCFH
“ wc
Natural gas
8917
11.3
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 83.1
Model RS 200/E LN
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 460/3/60
Fan motor rpm
HP
V
A
3480
7.6
460
9.7
Ignition transformer V1 - V2
I1 - I2 120 V - 1 x 8 kV 1.6 A - 20 mA
Electrical power consumption W6550
Electrical control circuit consumption W max 750
Total electrical consumption W7300
Electrical protection NEMA 1
Model RS 200/E LN
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/- 10%) V/Ph/Hz 460/3/60
Fan motor rpm
HP
V
A
3500
7.5
460
9.3
Ignition transformer V1 - V2
I1 - I2 120 V - 1 x 8 kV 1.6 A - 20 mA
Electrical power consumption W6300
Electrical control circuit consumption W max 750
Total electrical consumption W7050
Electrical protection NEMA 1

Technical description of the burner
7 20008113
GB
3.3 Packaging
³The 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
table.
³The weight of the burner complete with its packaging is
shown in table.
3.4 Overall dimensions
The dimensions of the burner are shown in Fig. 2.
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.
inch A B C lbs
RS 200/E LN 52 3/428 1/239 3/8208 D36
Fig. 1
A B C D E
inch 28 13/16 16 13/16 12 21 27/32 34 21/64
F (1) G H I L
inch 14 11/16 8 11/16 16 15/16 56 49/64 9 21/64
M N O
inch 5 29/32 10 15/64 2
D1206 Fig. 2

20008113 8 GB
Technical description of the burner
3.5 Firing rate
The maximum output is chosen within area Aof the diagram (Fig. 3).
The minimum output must not be lower than the minimum limit of the diagram.
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.
The firing rates were obtained in special test boilers. Fig. 4 indicates the diameter and length of the test combustion chamber.
Example
Output 6400 Mbtu/hr - diameter 31.5 inch - length 10.4 ft.
WARNING
Fig. 3
D9085
A
MBtu/hr
kW
Pressure in combustion
chamber - mbar
Firing rate for C-ETL Canadian Listing
Fig. 4
Length of combustion
chamber - ft
D9086

Technical description of the burner
9 20008113
GB
3.6 Burner components
1 Combustion head
2 Burner pilot
3 Screw for combustion head adjustment
4 Maximum gas pressure switch
5 Pipe coupling
6 Gas actuator
7 Ignition electrode
8 Motor contact maker and thermal relay with reset button
9 Burner pilot attachment
10 Terminal board for electrical wiring
11 Operator panel with LCD display
12 Control box for checking flame and air/fuel ratio
13 Relay for external signal and operation
14 High voltage lead
15 UV flame sensor
16 Ignition transformer
17 Holes for cable grommets for electrical wiring (to be carried
out by the installer)
18 Air actuator
19 Air pressure switch (differential type)
20 Guides for opening the burner and inspecting the combustion
head with extensions
21 Gas pressure test point and head fixing screw
22 Air pressure socket
23 Output regulator RWF40
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 disc
31 Alarm
32 RWF40 connectors
3.7 Burner equipment
The burner is supplied complete with:
³Gas train flange
³Flange gasket
³4 screws to fix the flange: M10 x 35
³4 screws to fix the burner flange to the boiler: M 12 x 35
³Instruction manual and spare parts list
31
30
25
19 20 521 31
22
29
26
6
13
18
24
1211
10
17
2
15
4
27
28
8
16
9
7
14
32
23
17
Fig. 5
D9268
A
seen from A

20008113 10 GB
Technical description of the burner
3.8 Control box for the air/fuel ratio (LMV37.4...)
Warning notes
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.
Riello S.p.A. will not assume responsibility for
any damage resulting from unauthorized interfer-
ence!
³All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
³Before 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.
³Ensure protection against electric shock hazard by providing
adequate protection for the burner control’s connection termi-
nals.
³Each time work has been carried out (mounting, installation,
service work, etc.), check to ensure that wiring and parame-
ters is in an orderly state.
³Fall 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. 6), (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:
³flame control;
³the dosage of air and fuel via the positioning (with direct ser-
vocontrol) of the relative valves, excluding the possible play in
the mechanical cam calibration systems;
³the 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;
³the 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 observ-
ing 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.
The first start-up, like every further operation for
the internal settings of the control box, requires ac-
cess by means of a password and is only to be car-
ried out by personnel of the Technical Assistance
Service who have been specifically trained in the
internal programming of the tool.
Electrical connection of the flame detectors
It is important to achieve practically disturbance- and loss-free
signal 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 haz-
ard. It is mainspowered and must be protected against acciden-
tal 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
Fig. 6
D9300
WARNING

Technical description of the burner
11 20008113
GB
Technical data
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
cosϕ> 0.4
Alarm output
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
1 A
cosϕ> 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
cosϕ> 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
cosϕ> 0.4
Operation display
• Nominal voltage
• Nominal current
• Power factor
AC 120 V, 50 / 60 Hz
0.5 A
cosϕ> 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.

20008113 12 GB
Technical description of the burner
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. 7
D9288
Signal ON
Signal OFF
Any signal is allowed
In standby: after referencing, the actuator is driven to
the no-load position

Technical description of the burner
13 20008113
GB
3.9 Actuators (SQM33.5...)
Warning notes
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!
³All activities (mounting, installation and service work, etc.)
must be performed by qualified staff.
³Before 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.
³Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
³After any kind of activity (mounting, installation and service
work, etc.), check wiring.
Also ensure that the parameters are correctly set.
³Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not
exhibit any damage.
The actuator’s housing must not be opened.
The actuator contains an optical feedback sys-
tem.
Use
The actuators (Fig. 8) are used to drive and position the air
damper and the gas butterfly valve, without mechanical leverag-
es 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 inside the actuator.
The position (in degrees) of the actuators can be seen on the
display 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.
When servicing or replacing the actuators, take
care not to invert the connectors.
Technical data
WARNING
WARNING
WARNING
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. 8

20008113 14 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 environ-
ment, proceed with the installation operations.
All the installation, maintenance and disassembly op-
erations must be carried out with the electricity sup-
ply disconnected.
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.
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.
With regard to the transport in the obligatory passages, refer to
the overall dimensions shown in Fig. 2.
The handling operations for the burner can be highly
dangerous if not carried out with the greatest atten-
tion: 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 10” from the
ground.
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.
4.3 Preliminary checks
Checking the consignment
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 cardboard
box, nails, clips, plastic bags, etc.) must not be aban-
doned as they are potential sources of danger and
pollution; they should be collected and disposed of in
the appropriate places.
The output of the burner must be within the boiler's
firing rate;
A burner label that has been tampered with, removed
or is missing, along with anything else that prevents
the definite identification of the burner makes any in-
stallation or maintenance work difficult.
4.4 Operation position
The burner is designed to operate only in the positions 1, 2, 3
and 4(Fig. 9).
Installation 1is preferable, as it is the only one that allows the
maintenance operations as described in this manual. Installa-
tions 2, 3 and 4 permit operation but make maintenance and in-
spection of the combustion head more difficult.
Any other position could compromise the correct operation of
the appliance.
Installation 5is prohibited for safety reasons.
4Installation
DANGER
WARNING
WARNING
CAUTION
CAUTION
WARNING
WARNING
2 3 4 51
D7739
Fig. 9

Installation
15 20008113
GB
4.5 Securing the burner to the boiler
4.5.1 Introduction
The burners are suitable for working on both flame inversion
boilers and boilers with a combustion chamber with bottom run-
off (three flue gas circulations), from which the best results of
low NOx emissions are obtained.
The maximum thickness of the front hatch of the boiler, complete
with refractory, must not exceed 10” (A, Fig. 10).
• For boilers with front flue passes 13) (Fig. 12) or flame inversion
chambers, a protection in refractory material 11) must be insert-
ed between the boiler refractory 12) and the blast tube 10).
This protection must not compromise the extraction of the blast
tube.
• For boilers with a water-cooled frontal, a refractory lining is not
necessary 11)-12) (Fig. 12) unless expressly requested by the
boiler manufacturer.
4.5.2 Boring the boiler plate
Make holes in the plate shutting off the combustion chamber, as il-
lustrated in Fig. 11.
The position of the threaded holes can be marked using the ther-
mal insulation screen supplied with the burner.
4.5.3 Boiler fixing
Secure the burner to the boiler, fixing the flange 9) (Fig. 12) to
the boiler plate and interposing the insulating gasket 8).
Use the 4 screws supplied, with a tightening torque of 26-29 Lbf. ft,
after protecting their thread with anti-seize products.
The seal between burner and boiler must be airtight.
After the start-up, check there is no leakage of flue gases into
the external environment.
A
D1079
Fig. 10
inch A B C
RS 200/E LN 9 1/16 12 25/32 - 14 1/25/8W
Fig. 11
D455
15 5
3
4
2
1
3
14
9
12
11
8
10
13
13
4"
Fig. 12
D9269

20008113 16 GB
Installation
4.6 Electrode positioning
To verify the correct position of the ignition electrode (Fig. 13),
you need to separate the combustion head from the rest of the
burner.
Measures must be respected!
Proceed as follows:
³loosen the 4 screws 3) (Fig. 12) and remove the hood 1);
³remove the screws 2) from the two guides 5);
³install the extensions 15) and re-screw the screws 2);
³remove the two screws 4);
³pull back the burner on the guides 5) of about 4”;
³disconnect the electrode lead, then unthread the burner com-
pletely from the guides;
³remove the screw 1) (Fig. 14) and extract the inner part 2) of
the head;
³check the correct position of ignition electrode, as shown in
Fig. 13.
³Re-install all components with reverse procedure.
WARNING
1/ 8"
1"
1/ 20"
Fig. 13
D11978
Fig. 14
D9284

Installation
17 20008113
GB
4.7 Adjustment of the combustion head
At this point of the installation, the combustion head is fixed to
the boiler as shown in Fig. 12.
It is therefore especially easy to adjust, and this adjustment de-
pends only on the maximum output of the burner.
Two adjustments of the head are foreseen:
³external air R1
³central air R3
In the diagram of Fig. 15, find the notch at which to adjust both
air and central gas/air.
³External air adjustment (R1)
Rotate the screw 4) (Fig. 16) until the notch you have found
corresponds with the front surface 5) of the flange.
³Central air adjustment (R3)
Loosen the 2 screws 1) and rotate the ring nut 2) until the
notch you have found corresponds with the screw 1).
Block the 2 screws 1).
The burner leaves the factory with the ring nut 2) set to
notch 0.
Do not change this value.
Example:
Burner output = 7575 MBtu/hr.
The diagram of Fig. 15 shows that the adjustments for this
potential is external air R1 = notch 6.
NOTE
The diagram indicates the optimum adjustment for a type of boil-
er according to Fig. 4.
The adjustments indicated can be modified during the initial
start-up.
To facilitate adjustment, loosen the screw
6), adjust and then lock.
Fig. 15
D9088 MBtu/hr
No. notch
(R1)(R3)
CAUTION
WARNING
Fig. 16
D9270

20008113 18 GB
Installation
Once the combustion head adjustment is completed:
³reassemble the burner on the guides 3) at about 4” from the
pipe coupling 4) - burner in the position shown in Fig. 12;
³insert the electrode cable, then slide the burner as far as the
pipe coupling - burner in the position shown in Fig. 17;
³unscrew the 2 screws 2) from the extension 6) and reposition
them as previously.
³refit the screws 2) on the guides 3);
³fix the burner to the pipe coupling with the screws 1).
When fitting the burner on the two guides, it is
advisable to gently draw out the high voltage
cable until it is slightly taut.
CAUTION
Fig. 17
D9276