Riello RS 410/EV FGR Quick start guide

Installation, use and maintenance instructions
20162733 (2) - 08/2021
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20162652 RS 410/EV FGR S029T2
20162653 RS 510/EV FGR S030T2
20162655 RS 610/EV FGR S031T2
GB

Translation of the original instructions

1 20162733
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Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 8
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 9
4.6 Maximum dimensions................................................................................................................................................ 10
4.7 Firing rates ................................................................................................................................................................ 11
4.8 Test boiler.................................................................................................................................................................. 12
4.9 Burner equipment...................................................................................................................................................... 12
4.10 Burner description ..................................................................................................................................................... 13
4.11 Electrical panel description........................................................................................................................................ 14
4.12 Control box for the air/fuel ratio (LMV51...) ............................................................................................................... 15
4.13 Servomotor................................................................................................................................................................ 17
5 Installation ................................................................................................................................................................................ 18
5.1 Notes on safety for the installation ............................................................................................................................ 18
5.2 Handling .................................................................................................................................................................... 18
5.3 Preliminary checks .................................................................................................................................................... 18
5.4 Operating position ..................................................................................................................................................... 19
5.5 Preparing the boiler ................................................................................................................................................... 19
5.5.1 Boring the boiler plate ............................................................................................................................................... 19
5.5.2 Blast tube length........................................................................................................................................................ 19
5.6 Securing the burner to the boiler............................................................................................................................... 19
5.7 Access to head internal part...................................................................................................................................... 20
5.8 Probe-electrode position ........................................................................................................................................... 21
5.9 Gas butterfly valve..................................................................................................................................................... 21
5.10 Combustion head adjustment.................................................................................................................................... 22
5.11 FGR duct system....................................................................................................................................................... 23
5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 24
5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 24
5.12 Gas pressures ........................................................................................................................................................... 25
5.12.1 Gas feeding line ........................................................................................................................................................ 25
5.12.2 Gas train.................................................................................................................................................................... 26
5.12.3 Gas train installation.................................................................................................................................................. 26
5.12.4 Gas pressure............................................................................................................................................................. 27
5.13 Electrical wiring ......................................................................................................................................................... 28
5.13.1 Supply cables and external connections passage .................................................................................................... 29
6 Start-up, calibration and operation of the burner ................................................................................................................. 30
6.1 Notes on safety for the first start-up .......................................................................................................................... 30
6.2 Adjustments prior to ignition ...................................................................................................................................... 30

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Contents
6.3 Burner start-up ...........................................................................................................................................................31
6.4 FGR commissioning...................................................................................................................................................32
6.5 Air / fuel adjustment ...................................................................................................................................................33
6.5.1 Air adjustment for maximum output ...........................................................................................................................33
6.5.2 Air/fuel adjustment and output modulation system ....................................................................................................33
6.5.3 Burner adjustment......................................................................................................................................................33
6.5.4 Output upon ignition...................................................................................................................................................33
6.5.5 Maximum output ........................................................................................................................................................33
6.5.6 Minimum output .........................................................................................................................................................33
6.6 Final adjustment of the pressure switches.................................................................................................................34
6.6.1 Air pressure switch.....................................................................................................................................................34
6.7 Final checks (with burner operating)..........................................................................................................................34
7 Maintenance ..............................................................................................................................................................................35
7.1 Notes on safety for the maintenance .........................................................................................................................35
7.2 Maintenance programme ...........................................................................................................................................35
7.2.1 Maintenance frequency..............................................................................................................................................35
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................35
7.2.3 Checking and cleaning...............................................................................................................................................35
7.2.4 Safety components ....................................................................................................................................................36
7.2.5 Voltage on the QRI sensor.........................................................................................................................................37
7.2.6 Checking the air and gas pressure on the combustion head .....................................................................................37
7.2.7 Checking the air and gas pressure on the combustion head .....................................................................................37
7.3 Checking the position of the rpm sensor....................................................................................................................37
7.4 Opening the burner ....................................................................................................................................................38
7.5 Closing the burner......................................................................................................................................................38
8 Faults - Probable causes - Solutions ......................................................................................................................................39
A Appendix - Accessories ...........................................................................................................................................................40
B Appendix - Electrical panel layout...........................................................................................................................................41

3 20162733
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Declarations
1 Declarations
Declaration of conformity in accordance with ISO / IEC 17050-1
Manufacturer: RIELLO S.p.A.
Address: Via Pilade Riello, 7
37045 Legnago (VR)
Product: Forced draught gas burners
Model and type: RS 410/EV FGR
RS 510/EV FGR
RS 610/EV FGR
S029T2
S030T2
S031T2
These products are in compliance with the following Technical Standards:
EN 676
EN 12100
and according to the European Directives:
GAR 2016/426/EU Gas Appliances Regulation
MD 2006/42/EC Machine Directive
LVD 2014/35/UE Low Voltage Directive
EMC 2014/30/UE Electromagnetic Compatibility
Such products are marked as follows:
CE- 0123CU1034 (Class 4 prEN 676:2016)
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Legnago, 03.05.2021 Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. F. Maltempi
0085

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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
2 Information and general warnings
DANGER
Maximum danger level!
This symbol indicates operations which, if not car-
ried out correctly, cause serious injury, death or
long-term health risks.
WARNING
This symbol indicates operations which, if not car-
ried out correctly, may cause serious injury, death
or long-term health risks.
CAUTION
This symbol indicates operations which, if not car-
ried out correctly, may cause damage to the ma-
chine and/or injury to people.
DANGER
DANGER: LIVE COMPONENTS
This symbol indicates operations which, if not car-
ried out correctly, lead to electric shocks with le-
thal consequences.
DANGER: FLAMMABLE MATERIAL
This symbol indicates the presence of flammable
materials.
DANGER: BURNING
This symbol indicates the risks of burns due to
high temperatures.
DANGER: CRUSHING OF LIMBS
This symbol indicates the presence of moving
parts: danger of crushing of limbs.
WARNING: MOVING PARTS
This symbol indicates that you must keep limbs
away from moving mechanical parts; danger of
crushing.
DANGER: EXPLOSION
This symbol signals places where an explosive at-
mosphere 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 DE-
VICES
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
machine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
IMPORTANT
This symbol indicates important information that
you must bear in mind.
This symbol indicates a list.

5 20162733
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Information and general warnings
2.1.4 Delivery of the system and the instruction
manual
When the system is delivered, it is important that:
the instruction manual is delivered to the user by the system
manufacturer, with the recommendation to keep it in the
room where the heat generator is to be installed.
The instruction manual shows:
– the serial number of the burner;
– the address and telephone number of the nearest Assis-
tance Centre.
The system supplier must carefully inform the user about:
– the use of the system;
– any further tests that may be required before activating the
system;
– maintenance, and the need to have the system checked at
least once a year by a representative of the manufacturer
or another specialised technician.
To ensure a periodic check, the manufacturer recom-
mends the drawing up of a Maintenance Contract.
2.2 Guarantee and responsibility
The manufacturer guarantees its new products from the date of
installation, in accordance with the regulations in force and/or the
sales contract. At the moment of the first start-up, check that the
burner is integral and complete.
In particular, the rights to the guarantee and the responsibility will
no longer be valid, in the event of damage to things or injury to
people, if such damage/injury was due to any of the following
causes:
incorrect installation, start-up, use and maintenance of the
burner;
improper, incorrect or unreasonable use of the burner;
intervention of unqualified personnel;
carrying out of unauthorised modifications on the equipment;
use of the burner with safety devices that are faulty, incor-
rectly applied and/or not working;
installation of untested supplementary components on the
burner;
powering of the burner with unsuitable fuels;
faults in the fuel supply system;
continuation of use of the burner when a fault has occurred;
repairs and/or overhauls incorrectly carried out;
modification of the combustion chamber with inserts that
prevent the regular development of the structurally estab-
lished flame;
insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and
tear;
use of non-original components, including spare parts, kits,
accessories and optional;
force majeure.
The manufacturer furthermore declines any and every re-
sponsibility for the failure to observe the contents of this
manual.
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installa-
tion and carrying out of non authorised modifica-
tions will result in the annulment by the
manufacturer of the guarantee that it supplies with
the burner.

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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other uses expressly foreseen by the manufactur-
er;
the type and pressure of the fuel, the voltage and frequency of the
electrical power supply, the minimum and maximum deliveries for
which the burner has been regulated, the pressurisation of the
combustion chamber, the dimensions of the combustion cham-
ber and the room temperature must all be within the values indi-
cated in the instruction manual.
Modification of the burner to alter its performance and desti-
nations is not allowed.
The burner must be used in exemplary technical safety con-
ditions. Any disturbances that could compromise safety must
be quickly eliminated.
Opening or tampering with the burner components is not
allowed, apart from the parts requiring maintenance.
Only those parts envisaged by the manufacturer can be
replaced.
3.2 Personnel training
The user is the person, body or company that has acquired the
machine and intends to use it for the specific purpose. He is re-
sponsible for the machine and for the training of the people work-
ing around it.
The user:
undertakes to entrust the machine exclusively to suitably
trained and qualified personnel;
undertakes to inform his personnel in a suitable way about
the application and observance of the safety instructions.
With that aim, he undertakes to ensure that everyone knows
the use and safety instructions for his own duties;
Personnel must observe all the danger and caution indica-
tions shown on the machine.
Personnel must not carry out, on their own initiative, opera-
tions or interventions that are not within their province.
Personnel must inform their superiors of every problem or
dangerous situation that may arise.
The assembly of parts of other makes, or any modifications,
can alter the characteristics of the machine and hence com-
promise operating safety. The manufacturer therefore
declines any and every responsibility for any damage that
may be caused by the use of non-original parts.
In addition:
3 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
must take all the measures necessary to pre-
vent unauthorised people gaining access to
the machine;
the user must inform the manufacturer if
faults or malfunctioning of the accident pre-
vention systems are noticed, along with any
presumed danger situation;
personnel must always use the personal pro-
tective equipment envisaged by legislation
and follow the indications given in this man-
ual.

7 20162733
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Technical description of the burner
4.1 Burner designation
4 Technical description of the burner
Range: R
Size
Fuel: Natural gas
Gas oil
Gas oil / Methane
Adjustment:
Flame control system:
FS1
FS2
Standard (1 stop every 24 h)
Continuous working (1 stop every 72 h)
Electrical supply of the system:
3/400/50
3/230/50
Voltage of auxiliaries:
230/50/60
110/50/60
R S 410 EV TC 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
E Electronic cam
EV Electronic cam with variable speed (with Inverter)
P Proportional air/gas valve
BP Two stage (light oil) / Proportional valve (gas)
M Mechanical cam
S
L
LS
N
Head: TC Standard head
TL Long head
Emission: C01 - ...
C02 - MZ
C03 - BLU
C03 - MX
Class 1 EN676
Class 2 EN676
Class 3 EN676
Class 3 EN676
FGR: Induced Flue Gas Recirculation
FGR FS1/FS2*
WARNING
*The burner leaves the factory set up for FS1 op-
eration. If FS2 operation is required, see the man-
ual of the electronic cam.

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Technical description of the burner
4.2 Models available
Tab. A
4.3 Burner categories - Countries of destination
Tab. B
4.4 Technical data
Tab. C
(1) Reference conditions: Ambient temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.
(2) Pressure at the test point of the pressure switch 5)(Fig. 4 on page 13) with zero pressure in the combustion chamber and at maximum burner
output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
Designation Voltage Start-up Code
RS 410/EV FGR FS1/FS2 3/400/50 Inverter 20162652
RS 510/EV FGR FS1/FS2 3/400/50 Inverter 20162653
RS 610/EV FGR FS1/FS2 3/400/50 Inverter 20162655
Gas category Destination country
I2H SE - FI - AT - GR - DK - ES - GB - IT - IE - PT - IS - CH - NO
I2ELL DE
I2E - I2(43,46 ÷ 45,3 MJ/m3(0°C)) NL
I2Er FR
I2E(R)B BE
I2E LU - PL
Model RS 410/EV FGR RS 510/EV FGR RS 610/EV FGR
Power(1)
Delivery (1)
min - max kW 595/1210 ÷ 3820 660/1800 ÷ 4800 912/2220 ÷ 5850
Fuels Natural gas: G20 (methane gas)
Gas pressure at max. output (2)
Gas: G20 mbar 45 70 61
Operation
FS1: Intermittent (min. 1 stop in 24 hours)
FS2: Continuous (min 1 stop 72 hours)
The burner leaves the factory set for the intermittent operation
Standard applications Boilers: water, steam, diathermic oil
Ambient temperature °C 0 - 50
Combustion air temperature °C max 60
Noise levels (3) Sound pressure
Sound power dB(A) 80 91
82.5
93.5
85
96
Weight of the burner complete with
its packaging kg 265 265 295
WARNING
In order to reduce the nitrogen oxides NOx in case
of FGR system, the maximum burner capacity ob-
tained, changes within the limits agreed with the
Riello Technical Dept. for the specific application.

9 20162733
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Technical description of the burner
4.5 Electrical data
Tab. D
Model RS 510/EV FGR RS 510/EV FGR RS 610/EV FGR
Main electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE3
rpm
V
kW
A
2930
230/400
9.2
28.6 - 16.5
2920
400/690
12
21 - 12.2
2920
400/690
15
27 - 15.6
Ignition transformer V1 - V2
I1 - I2
230 V - 1 x 8 kV
1 A - 20 mA
Absorbed electrical power kW max 10,8 14 17
Protection level IP 54

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Technical description of the burner
4.6 Maximum dimensions
The maximum dimensions of the burner are given in Fig. 1.
Bear in mind that inspection of the combustion head requires the
burner to be opened and the rear part turned on the hinge.
The maximum dimensions of the open burner are indicated by
the L and R positions.
The l position is reference for the refractory thickness of the boiler
door.
Tab. E
** Maximum position for the extraction of the servomotor cover.
WARNING
*The gas adaptor is set also for DN 80 bore.
Fig. 1
20131490
mm A B C D E F* G H I L M N O P** R
RS 410/EV BLU 1178 517 178 313 520 DN65 908 790 340 1015 400 528 290 177 890
RS 510/EV BLU 1178 517 178 313 520 DN65 908 790 340 1015 400 528 290 177 890
RS 610/EV BLU 1178 517 178 334 520 DN65 980 790 365 1015 400 528 290 177 890

11 20162733
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Technical description of the burner
4.7 Firing rates
The MAXIMUM OUTPUT is chosen from within the diagram area
(Fig. 2).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
Tab. F
Model kW
RS 410/EV FGR 595
RS 510/EV FGR 660
RS 610/EV FGR 912
WARNING
The firing rate value (Fig. 2) has been obtained
considering an ambient temperature of 20 °C, an
atmospheric pressure of 1013 mbar (approx. 0 m
a.s.l.), and with the combustion head adjusted as
shown on page 22.
WARNING
Pre-calibration of the combustion head only for
the burner model RS 410/EV FGR:
If the maximum burner output of the burner falls
within:
- area A of the firing rate, it is necessary to replace
the internal shutter with that one supplied (no. 8
holes 4,7 mm), Fig. 13 on page 21.
- area B of the firing rate, no modifications are re-
quired.
Fig. 2
Pressure in
combustion chamber - mbar
Thermal power – kW
Pressure in
combustion chamber - mbar
Limit with active flue gas recirculation system
20164284
RS 410/EV
RS 510/EV
RS 610/EV
Thermal power – kW

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Technical description of the burner
4.8 Test boiler
The burner/boiler combination does not pose any problems if the
boiler is EC approved and its combustion chamber dimensions
are similar to those indicated in the diagram (Fig. 3).
If the burner must be combined with a boiler that has not been EC
approved and/or its combustion chamber dimensions are clearly
smaller than those indicated in the diagram, consult the manufac-
turer.
The firing rates were set in relation to special test boilers, accord-
ing to EN 676 regulations.
In Fig. 3 you can see the diameter and length of the test combus-
tion chamber.
Example:
Output 7000 kW - diameter 120 cm - length 6m
4.9 Burner equipment
Gasket for gas train adaptor. . . . . . . . . . . . . . . . . . . . . . . . No. 1
Adaptor for gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws for fixing the gas train adaptor: M 16 x 70 . . . . . . No. 4
Thermal insulation screen . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
M 18 x 60 screws to secure the burner flange to the boiler . No. 4
Cable grommets kit for optional electrical wiring input . . . . No. 1
M16 nuts to fix the gas elbow to the pipe coupling . . . . . . No. 8
Stud bolts M16X60 to fix the gas elbow to the pipe coupling . .No. 1
Internal shutter (RS 410/EV FGR) . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
20057548 Fig. 3
Combustion chamber
m

13 20162733
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Technical description of the burner
4.10 Burner description
1 Lifting rings
2Fan
3Fanmotor
4 Air damper servomotor
5 Combustion head gas pressure test point
6 Combustion head
7 Ignition electrode
8 Flame stability disk
9 Electrical panel casing
10 Gas butterfly valve servomotor
11 Fan air inlet
12 Pipe coupling
13 Gasket for boiler fixing
14 Gas butterfly valve
15 Shutter
16 Combustion head movement screw
17 Lever for controlling the dampers with graduated scale
18 Probe for flue gas temperature
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 Flange inlet for flue gas
22 Hinge for opening the burner
23 Pressure test point for air pressure switch "+"
24 Combustion head air pressure test points
25 Gas train adapter
26 Indication for checking the rotation direction of the purging
motor
27 Flame inspection window
28 UV sensor
29 Servomotor for flue gas
30 Air cooling intake
31 Rpm sensor
20165354
Fig. 4
ASSEMBLY VIEW
Wait for the components in contact with heat
sources to cool down completely.
The burner can be opened to the right or to the left
without links to the fuel supply side.
WARNING
To open the burner see section “Access to head
internal part” on page 20.

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Technical description of the burner
4.11 Electrical panel description
1 Earth terminal
2 Supply cables and external connections passage
3 Main terminal supply board
4 Auxiliary circuits fuse (includes a spare fuse)
5 Air pressure switch
6 Ignition transformer
7 Free contact relay
8 Electronic cam
9 “0/AUTO” selector
10 Operator panel with LCD display
11 Control box power supply
12 Emergency button
13 Light signalling “POWER ON”
14 Light signalling burner lock-out and reset button
15 Light signalling “OVERLOAD FAN MOTOR”
Fig. 5
20165363

15 20162733
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Technical description of the burner
4.12 Control box for the air/fuel ratio (LMV51...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the LMV52 control box con-
nection area, fully disconnect the system from the power
supply (omnipolar separation). Check the system is not
powered and cannot be accidentally reconnected. Failure to
do this will lead to the risk of electrocution.
Protection against electrocution from the LMV5... control box
and all connected electric components is obtained with cor-
rect assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
In programming mode, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
As for automatic operation, the actuators are guided
together to the positions requested and, if an actuator does
not reach the position requested, adjustments are made
until the position is actually reached. However, in contrast to
automatic operation, there are no time limits to these cor-
rective actions.
The other actuators maintain their positions until all actua-
tors have reached the positions currently required.
This is absolutely important to set the fuel / air ratio control
system.
During the time the fuel / air ratio curves are being pro-
grammed, the person making the plant settings must contin-
uously monitor the quality of the combustion process (e.g. by
means of a flue gas analyser).
Also, if combustion levels are poor, or in the event of dan-
gerous situations, the commissioning engineer must take
appropriate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV5... system, the
following instructions must also be followed:
– avoid conditions that can favour the development of conden-
sate and humidity. Otherwise, before switching on again,
make sure that the entire control box is perfectly dry!
– Static charges must be avoided since they can damage the
control box’s electronic components when touched.
Mechanical structure
The LMV5... control box is a system to check the burners, based
on a microprocessor and equipped with components to adjust
and monitor medium and large capacity forced draught burners.
The base control box of the LMV5... system incorporates the fol-
lowing components:
• Burner control with gas valve proving system
• Electronic fuel / air ratio control with a maximum of 4 actuators
• Optional PID temperature / pressure controller (load control-
ler)
• Optional VSD module Mechanical design
Installation notes
• Check the electric wiring inside the boiler complies with the na-
tional and local safety regulations.
• Do not confuse the powered conductors with the neutral ones.
• Make certain that strain relief of the connected cables is in
compliance with the relevant standards (e.g. as per DIN EN
60730 and DIN EN 60 335).
• Ensure that spliced wires cannot get into contact with neigh-
bouring terminals. Use adequate ferrules.
• Arrange the HV ignition cables separately, as far as possible
from the control box and the other cables.
• The burner manufacturer must protect unused AC 230V termi-
nals with dummy plugs (refer to sections Suppliers of other ac-
cessory items).
• When wiring the unit, make sure that AC 230V mains voltage
cables are run strictly separate from extra low-voltage cables
to avoid risks of electrical shock hazard.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The LMV51... is a safety device! Avoid opening or
modifying it, or forcing its operation. Riello S.p.A.
cannot assume any responsibility for damage re-
sulting from unauthorised interventions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the AZL5… display and operating unit
and incorrect settings of the fuel and / or air actu-
ator positions can lead to dangerous burner oper-
ating conditions.
Fig. 6
D9301

20162733 16
GB
Technical description of the burner
Electrical connection of flame detector
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• always separate the detector cables from the other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
Technical data
Tab. G
LMV51... basic unit Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ± 6%
Power absorption < 30W (normal)
Safety class I, with components in compliance with II and III, according to
DIN EN 60730-1
Load on
‘input’ terminals
F1 unit fuse (internal) 6.3 AT
Primary perm. mains fuse (external) Max. 16 AT
Undervoltage
• Safety switch-off from operating position to
mains voltage
• Restart when mains voltage picks up
< AC 186V
> AC 188V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor
0.5A
cos> 0.4
Load on
‘output’ terminals
Total load on the contacts:
• Mains voltage
• Total unit input current (safety circuit)
load on contacts due to:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 230V -15 % / +10%
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.2
Fuel gas valve (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Fuel oil valve (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Cable lengths Main line Max. 100m (100 pF/m)
Environmental
conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95% RH

17 20162733
GB
Technical description of the burner
4.13 Servomotor
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the SQM4... system connec-
tion area, fully disconnect the burner control device from the
power supply (omnipolar separation).
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit must not be operated, even if it
displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
• The connection between the actuator command shaft and the
control element must be rigid, without any mechanical play.
• To avoid an excessive load on the bearings due to rigid hubs,
the use of compensation clutches without any mechanical play
is recommended (e.g. metal bellows-type clutches).
Installation notes
• Arrange the H.V. ignition cables separately, as far as possible
from the control box and the other cables.
• To avoid the risk of electrocution, make sure that the 230V AC
section of the SQM4... unit is fully separated from the function-
al low-voltage section.
• The static torque is reduced when the electrical supply of the
actuator is switched off.
• The housing cover may only be removed for short periods of
time for wiring or when making the addressing. In similar cas-
es, make sure that dust or dirt does not penetrate inside the
actuator.
• The actuator comprises a PCB with ESD-sensitive compo-
nents.
• The top side of the board carries a cover which affords protec-
tion against direct contact. This protective cover must not be
removed! The underside side of the board must not be
touched.
Technical data
Tab. H
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the ac-
tuators.
WARNING
During the maintenance or replacement of the
actuators, be careful not to invert the connec-
tors.
Operating voltage AC 2 x 12V via bus cable from the
base unit or via a separate trans-
former
Safety class extra low-voltage with safe isolation
from mains voltage
Power absorption
– SQM45...
– SQM48...
9...15 VA
26...34 VA
Degree of protection to EN 60 529, IP 54, provided ade-
quate cable entries are used
Cable connection RAST3,5 connectors
Rotation direction - Anticlockwise (standard)
- Clockwise (inverted rotation)
Nominal torque (max)
– SQM45...
– SQM48...
3 Nm
20 Nm
Holding torque (max)
– SQM45...
– SQM48...
1.5 Nm
20 Nm
Running time (min.)
for 90°
– SQM45...
– SQM48...
10 s.
30 s.
Weight
– SQM45...
– SQM48...
1 kg approx.
1.6 kg approx.
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60 721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95% RH
D8271 Fig. 7

20162733 18
GB
Installation
5.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner is to
be installed, and arranging for the environment to be illuminated
correctly, proceed with the installation operations.
5.2 Handling
The burner packaging includes a wooden platform, it is therefore
possible to move the burner (still packaged) with a transpallet
truck or fork lift truck.
5.3 Preliminary checks
Checking the consignment
Checking the characteristics of the burner
Check the identification label of the burner, showing:
the model (A)(Fig. 8) and type of burner (B);
the year of manufacture, in cryptographic form (C);
the serial number (D);
the data for electrical supply and the protection level (E);
the absorbed electrical power (F);
the types of gas used and the relative supply pressures (G);
the data of the burner's minimum and maximum output pos-
sibilities (H) (see Firing rate).
Warning. The burner output must be within the boiler's firing
rate;
the category of the appliance/countries of destination (I).
5Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out
by qualified personnel, as indicated in this manual
and in compliance with the standards and regula-
tions of the laws in force.
DANGER
Combustion air inside the boiler must be free from
hazardous mixes (e.g.: chloride, fluoride, halo-
gen); if present, it is highly recommended to carry
out cleaning and maintenance more frequently.
WARNING
The handling operations for the burner can be
highly dangerous if not carried out with the great-
est attention: keep any unauthorised people at a
distance; check the integrity and suitableness of
the available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape
area (i.e. a free, safe area to which you can quick-
ly move if the burner should fall).
When handling, keep the load at not more than
20-25cm from the ground.
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
CAUTION
Before proceeding with the installation operations,
carefully clean all around the area where the burn-
er will be installed.
CAUTION
After removing all the packaging, check the integ-
rity of the contents. In the event of doubt, do not
use the burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of
danger and pollution; but should be collected and
disposed of in the appropriate places.
WARNING
A burner label, or any other component, that has
been tampered with, removed or is missing, pre-
vents the definite identification of the burner and
makes any installation or maintenance work diffi-
cult.
R.B.L.
GAS- KAASU
GAZ- AEPI O
X
RIELLOS.p. A.
I-37045 Legnago ( VR)
A
DE
BC
F
I
G H
G H
Fig. 8
D10411