Riello RS310/EVO2 BLU Quick start guide

Installation, use and maintenance instructions
20175134 (3) - 09/2020
Forced draught gas burners
Modulating operation
CODE MODEL TYPE
20166004 RS 310/EV O2 BLU 1138T2
20180649 RS 310/EV O2 BLU 1138T2
20174935 RS 410/EV O2 BLU 1135T2
20174936 RS 510/EV O2 BLU 1136T2
20174937 RS 610/EV O2 BLU 1137T2
GB

Translation of the original instructions

1 20175134
GB
Contents
1 Declarations................................................................................................................................................................................ 3
2 Information and general warnings............................................................................................................................................ 4
2.1 Information about the instruction manual .................................................................................................................... 4
2.1.1 Introduction.................................................................................................................................................................. 4
2.1.2 General dangers.......................................................................................................................................................... 4
2.1.3 Other symbols ............................................................................................................................................................. 4
2.1.4 Delivery of the system and the instruction manual...................................................................................................... 5
2.2 Guarantee and responsibility....................................................................................................................................... 5
3 Safety and prevention................................................................................................................................................................ 6
3.1 Introduction.................................................................................................................................................................. 6
3.2 Personnel training ....................................................................................................................................................... 6
4 Technical description of the burner ......................................................................................................................................... 7
4.1 Burner designation ...................................................................................................................................................... 7
4.2 Models available.......................................................................................................................................................... 7
4.3 Burner categories - Countries of destination ............................................................................................................... 8
4.4 Technical data ............................................................................................................................................................. 8
4.5 Electrical data.............................................................................................................................................................. 8
4.6 Burner weight .............................................................................................................................................................. 9
4.7 Maximum dimensions.................................................................................................................................................. 9
4.8 Firing rates ................................................................................................................................................................ 10
4.9 Test boiler.................................................................................................................................................................. 11
4.10 Burner equipment...................................................................................................................................................... 11
4.11 Burner description ..................................................................................................................................................... 12
4.12 Electrical panel description........................................................................................................................................ 13
4.13 Control box for the air/fuel ratio (LMV52...) ............................................................................................................... 14
4.14 Actuator ..................................................................................................................................................................... 16
4.15 PLL52... module (optional) ........................................................................................................................................ 17
4.15.1 Terminal ratings, cable lengths and cross-sectional areas ....................................................................................... 17
4.16 Oxygen sensor QGO20 ... (optional)........................................................................................................................ 18
4.16.1 Technical data QGO20.............................................................................................................................................. 19
5 Installation ................................................................................................................................................................................ 20
5.1 Notes on safety for the installation ............................................................................................................................ 20
5.2 Handling .................................................................................................................................................................... 20
5.3 Preliminary checks .................................................................................................................................................... 20
5.4 Operating position ..................................................................................................................................................... 21
5.5 Preparing the boiler ................................................................................................................................................... 21
5.5.1 Boring the boiler plate ............................................................................................................................................... 21
5.5.2 Blast tube length........................................................................................................................................................ 21
5.6 Securing the burner to the boiler............................................................................................................................... 21
5.7 Access to head internal part...................................................................................................................................... 22
5.8 Probe-electrode position ........................................................................................................................................... 23
5.9 Gas butterfly valve..................................................................................................................................................... 23
5.10 Combustion head adjustment.................................................................................................................................... 24
5.11 Gas pressures ........................................................................................................................................................... 25
5.11.1 Gas feeding line ........................................................................................................................................................ 25
5.11.2 Gas train.................................................................................................................................................................... 26
5.11.3 Gas train installation.................................................................................................................................................. 26
5.11.4 Gas pressure............................................................................................................................................................. 27
5.12 Electrical wiring ......................................................................................................................................................... 28
5.12.1 Supply cables and external connections passage .................................................................................................... 29
6 Start-up, calibration and operation of the burner ................................................................................................................. 30

20175134 2
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Contents
6.1 Notes on safety for the first start-up...........................................................................................................................30
6.2 Adjustments prior to ignition.......................................................................................................................................30
6.3 Burner start-up ...........................................................................................................................................................31
6.4 Air / fuel adjustment ...................................................................................................................................................32
6.4.1 Air adjustment for maximum output ...........................................................................................................................32
6.4.2 Air/fuel adjustment and output modulation system ....................................................................................................32
6.4.3 Burner adjustment......................................................................................................................................................32
6.4.4 Output upon ignition...................................................................................................................................................32
6.4.5 Maximum output ........................................................................................................................................................32
6.4.6 Minimum output .........................................................................................................................................................32
6.5 Final adjustment of the pressure switches.................................................................................................................33
6.5.1 Air pressure switch.....................................................................................................................................................33
6.6 Pressure switch adjustment .......................................................................................................................................34
6.6.1 Maximum gas pressure switch...................................................................................................................................34
6.6.2 Minimum gas pressure switch....................................................................................................................................34
6.6.3 PVP pressure switch kit .............................................................................................................................................34
6.7 Operation ...................................................................................................................................................................35
6.8 Ignition failure.............................................................................................................................................................35
6.9 Burner flame goes out during operation.....................................................................................................................35
6.10 Stopping of the burner ...............................................................................................................................................35
6.11 Final checks (with burner operating)..........................................................................................................................35
6.12 Description of O2 trim control (optional) ...................................................................................................................36
6.12.1 Operating principle of O2 trim control ........................................................................................................................36
7 Maintenance ..............................................................................................................................................................................37
7.1 Notes on safety for the maintenance .........................................................................................................................37
7.2 Maintenance programme ...........................................................................................................................................37
7.2.1 Maintenance frequency..............................................................................................................................................37
7.2.2 Safety test - with gas ball valve closed ......................................................................................................................37
7.2.3 Checking and cleaning...............................................................................................................................................37
7.2.4 Safety components ....................................................................................................................................................38
7.2.5 Measuring the ionisation current................................................................................................................................38
7.2.6 Checking the air and gas pressure on the combustion head .....................................................................................38
7.3 Checking the position of the rpm sensor....................................................................................................................39
7.4 Opening the burner ....................................................................................................................................................39
7.5 Closing the burner......................................................................................................................................................39
A Appendix - Accessories ...........................................................................................................................................................40
B Appendix - Electrical panel layout...........................................................................................................................................42

3 20175134
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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 310/EV O2 BLU
RS 410/EV O2 BLU
RS 510/EV O2 BLU
RS 610/EV O2 BLU
1138T2
1135T2
1136T2
1137T2
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/EU Low Voltage Directive
EMC 2014/30/EU Electromagnetic Compatibility
Such products are marked as follows:
RS 310/EV O2 BLU (Class 3 EN 676)
RS 410/EV O2 BLU (Class 3 EN 676)
RS 510/EV O2 BLU (Class 3 EN 676)
RS 610/EV O2 BLU (Class 3 EN 676)
The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.
Manufacturer's Declaration
RIELLO S.p.A. declares that the following products comply with the NOx emission limits specified by German standard "1. BIm-
SchV revision 26.01.2010".
Product Model Type Output
Forced draught gas burners RS 310/EV O2 BLU 1138T2 400 - 3630 kW
RS 410/EV O2 BLU 1135T2 500 - 4450 kW
RS 510/EV O2 BLU 1136T2 680 - 5250 kW
RS 610/EV O2 BLU 1137T2 1000 - 6250 kW
Legnago, 21.04.2018 Executive General Manager
RIELLO S.p.A. - Burner Department
Research & Development Director
RIELLO S.p.A. - Burner Department
Mr. U. Ferretti Mr. F. Comencini
CE-0085CP0166

20175134 4
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Information and general warnings
2.1 Information about the instruction manual
2.1.1 Introduction
The instruction manual supplied with the burner:
is an integral and essential part of the product and must not
be separated from it; it must therefore be kept carefully for
any necessary consultation and must accompany the burner
even if it is transferred to another owner or user, or to
another system. If the manual is lost or damaged, another
copy must be requested from the Technical Assistance Ser-
vice of the area;
is designed for use by qualified personnel;
offers important indications and instructions relating to the
installation safety, start-up, use and maintenance of the
burner.
Symbols used in the manual
In some parts of the manual you will see triangular DANGER
signs. Pay great attention to these, as they indicate a situation of
potential danger.
2.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
2.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
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 20175134
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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.

20175134 6
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Safety and prevention
3.1 Introduction
The burners have been designed and built in compliance with
current regulations and directives, applying the known technical
rules of safety and envisaging all the potential danger situations.
It is necessary, however, to bear in mind that the imprudent and
clumsy use of the equipment may lead to situations of death risk
for the user or third parties, as well as the damaging of the burner
or other items. Inattention, thoughtlessness and excessive confi-
dence often cause accidents; the same applies to tiredness and
sleepiness.
It is a good idea to remember the following:
The burner must only be used as expressly described. Any
other use should be considered improper and therefore dan-
gerous.
In particular:
it can be applied to boilers operating with water, steam, diather-
mic oil, and to other 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 20175134
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Technical description of the burner
4.1 Burner designation
4.2 Models available
Tab. A
4 Technical description of the burner
Range: R
Size
Fuel: Natural gas
Gas oil
Gas oil / Methane
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 TC FS1/FS2* 3/400/50 230/50/60
BASIC DESIGNATION
EXTENDED DESIGNATION
BLU
3N / 400V / 50Hz
3 / 230V / 50Hz
230V / 50-60Hz
110V / 50-60Hz
Heavy oil
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
Adjustment : E Electronic cam
EV Electronic cam and variable speed (with Inverter)
M Mechanical cam
P Proportional air/gas valve
E O2Electronic cam and suitable for Oxygen Control (O2)
EV O2Electronic cam and variable speed (with Inverter) and suitable for Oxygen Control O2
EV O2
WARNING
*The burner leaves the factory set up for FS1 op-
eration. If FS2 operation is required, refer the spe-
cific manual to LMV 5...
Designation Voltage Start-up Code
RS 310/EV O2 BLU FS1/FS2 3/400/50 Inverter 20166004
RS 310/EV O2 BLU FS1/FS2 3/400/50 Inverter 20180649
RS 410/EV O2 BLU FS1/FS2 3/400/50 Inverter 20174935
RS 510/EV O2 BLU FS1/FS2 3/400/50 Inverter 20174936
RS 610/EV O2 BLU FS1/FS2 3/400/50 Inverter 20174937

20175134 8
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Technical description of the burner
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. 5 on page 12) with zero pressure in the combustion chamber and at maximum burner
output.
(3) Sound pressure measured in manufacturer's combustion laboratory, with burner operating on test boiler and at maximum rated output. The sound
power is measured with the “Free Field” method, as per EN 15036, and according to an “Accuracy: Category 3” measuring accuracy, as set out in
EN ISO 3746.
4.5 Electrical data
Tab. D
Gas category Destination country
I2E LU - PL
I2E(R) BE
I2EK NL
I2ELL DE
I2Er FR
I2H AT-GB-CH-CZ-DK-EE-ES-FI-GB-GR-HU-IE-IS-IT-LT-LV-NO-PT-RO-SE-
SI-SK-TR
Model RS 310/EV O2 BLU RS 410/EV O2 BLU RS 510/EV O2 BLU RS 610/EV O2 BLU
Power(1)
Delivery (1)
min - max kW 400/1200 - 3630 500/1500 ÷ 4450 680/1800 ÷ 5250 1000/2200 ÷ 6250
Fuels Natural gas: G20 (methane gas) - G21 - G22 - G23 - G25
Gas pressure at max. output (2)
Gas: G20/G25 mbar 50.1/74.7 53.1/79.2 59.7/89.1 77.6/115.8
Operation FS1: Intermittent (min. 1 stop in 24 hours) - FS2: Continuous (min. 1 stop in 72 hours)
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) 78 89
80
91
82.5
93.5
85
96
Model RS 310/EV O2 BLU RS 410/EV O2 BLU RS 510/EV O2 BLU RS 610/EV O2 BLU
Main electrical supply 3N ~ 400V +/-10% 50 Hz
Fan motor IE2
rpm
V
kW
A
2920
230/400
7.5
23.9 - 13,8
2900
230/400
9,2
29.4 - 17
2900
400/690
12
21.2 - 12.2
2930
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 9.1 10.8 14 17
Protection level IP 54
WARNING
*The burner leaves the factory set up for FS1 op-
eration. If FS2 operation is required, refer the spe-
cific manual to LMV 5...

9 20175134
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Technical description of the burner
4.6 Burner weight
The weight of the burner complete with its packaging is shown in
Tab. E .
Tab. E
4.7 Maximum 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 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. F
Model kg
RS 310/EV O2 BLU 250
RS 410/EV O2 BLU 250
RS 510/EV O2 BLU 250
RS 610/EV O2 BLU 280
Fig. 1
20110496
WARNING
*The gas adaptor is set also for DN 80 bore.
D
N
C
E
F
TP
I
R
A
H
O O
M
L
G
R
A
Fig. 2
20180807
mm A C D E F* G H I L M N O P R T
RS 310/EV O2 BLU 1090 178 306 520 DN65 500 790 446 900 400 528 290 1260 966 565
RS 310/EV O2 BLU 1090 178 306 520 DN65 500 790 346 900 400 528 290 1260 966 465
RS 410/EV O2 BLU 1090 178 313 520 DN65 540 790 340 940 400 528 290 1260 966 517
RS 510/EV O2 BLU 1090 178 313 520 DN65 540 790 340 940 400 528 290 1260 966 517
RS 610/EV O2 BLU 1090 178 334 520 DN65 545 790 365 945 400 528 290 1260 966 517

20175134 10
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Technical description of the burner
4.8 Firing rates
The MAXIMUM OUTPUT is chosen from within the diagram area
(Fig. 3).
The MINIMUM OUTPUT must not be lower than the minimum
limit of the diagram:
Tab. G
Model kW
RS 310/EV O2 BLU 400
RS 410/EV O2 BLU 500
RS 510/EV O2 BLU 680
RS 610/EV O2 BLU 1000
WARNING
The firing rate value (Fig. 3) 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 24.
Fig. 3
Thermal power – kW
Combustion chamber
combustion head - mbar
400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800
0
2
4
6
8
10
12
14
16
18
5200 5600 6000 6400 6800
-2
20
20058566
RS 310/EV O2 BLU
RS 410/EV O2 BLU
RS 510/EV O2 BLU
RS 610/EV O2 BLU

11 20175134
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Technical description of the burner
4.9 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. 4).
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. 4 you can see the diameter and length of the test combus-
tion chamber.
Example: RS 510/EV O2 BLU
Output 5000 kW - diameter 100 cm - length 5m
4.10 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. 4
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
20057548 Fig. 4
Combustion chamber
m

20175134 12
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Technical description of the burner
4.11 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 Air pressure switch
19 Combustion head air pressure test point
20 Maximum gas pressure switch with pressure test point
21 Flame sensor probe
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 Adapt for flame sensor kit
29 Rpm sensor
30 Transparent protection
Fig. 5
ASSEMBLY VIEW
22
10
226
3
23
28
24
12
5
13 118
20
4
11
17
927 22 116 19 615
14
8
21
7
25
29
30
20099837
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 22.

13 20175134
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Technical description of the burner
4.12 Electrical panel description
1 Electrical control box
2 ON/OFF selector
3 Safety button
4 Earth terminal
5 Supply cables and external connections passage. See sec-
tion “Electrical wiring” on page 28
6 Light signalling “POWER ON”
7 Main terminal supply board
8 Relay with clean contacts for signalling the burner is in lock-
out
9 Relay with clean contacts for signalling the burner is operat-
ing
10 Auxiliary circuits fuse (includes a spare fuse)
11 Air pressure switch
12 Ignition transformer
13 Ionisation probe cable
14 Operator panel with LCD display
15 Light signalling burner lockout and reset button
16 Light signalling “OVERLOAD FAN MOTOR”
17 Control box power supply
18 Relay with clean contacts
13
4
4
5
3
2
14
12
15
16
6
4
7
10
1
11
4
4
5
918
8
17
Fig. 6
20166943

20175134 14
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Technical description of the burner
4.13 Control box for the air/fuel ratio (LMV52...)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the LMV52 control box con-
nection area, fully disconnect the system from the power
supply (omnipolar separation). Check the system is not pow-
ered and cannot be accidentally reconnected. Failure to do
this will lead to the risk of electrocution.
Protection against electrocution from the LMV5... control box
and all connected electric components is obtained with cor-
rect assembly.
Before any intervention (assembly and installation opera-
tions, assistance, etc.), ensure the wiring is in order and that
the parameters are correctly set, then make the safety
checks.
Falls and collisions can negatively affect the safety func-
tions.
In this case, the control box must not be operated, even if it
displays no evident damage.
In programming mode, the position check of actuators and
VSD (checking electronic fuel / air ratio control) is different
from the check during automatic operation.
As for automatic operation, the actuators are guided
together to the positions requested and, if an actuator does
not reach the position requested, adjustments are made until
the position is actually reached. However, in contrast to
automatic operation, there are no time limits to these correc-
tive actions.
The other actuators maintain their positions until all actua-
tors have reached the positions currently required.
This is absolutely important to set the fuel / air ratio control
system.
During the time the fuel / air ratio curves are being pro-
grammed, the person making the plant settings must continu-
ously monitor the quality of the combustion process (e.g. by
means of a flue gas analyser).
Also, if combustion levels are poor, or in the event of danger-
ous situations, the commissioning engineer must take
appropriate action (e.g. switching off manually).
To ensure the safety and reliability of the LMV5... system, the fol-
lowing 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 adjustment device with system for checking the seal
of the gas valves
• Electronic fuel/air ratio monitoring device with a maximum of
6 (LMV52…) actuators
• Optional PID temperature / pressure controller (load control-
ler)
• Optional VSD module Mechanical design.
WARNING
To avoid accidents, material or environmental
damage, observe the following instructions!
The LMV52 control box... is a safety device! Avoid
opening or modifying it, or forcing its operation. Ri-
ello S.p.A. cannot assume any responsibility for
damage resulting from unauthorised interven-
tions!
Risk of explosion!
An incorrect configuration can provoke fuel over-
charging, with the consequential risk of explosion!
Operators must be aware that incorrect settings
made on the AZL5… display and operating unit
and incorrect settings of the fuel and / or air actu-
ator positions can lead to dangerous burner oper-
ating conditions.
Fig. 7
D9301

15 20175134
GB
Technical description of the burner
Electrical connection of flame sensor
It is important for signal transmission to be almost totally free
of any disturbances or loss:
• always separate the detector cables from the other cables:
– Line capacitance reduces the magnitude of the flame signal.
– Use a separate cable.
• Respect the allowed cable lengths.
Technical data
Tab. H
LMV52... base
control box
Mains voltage AC 230V -15% / +10%
Mains frequency 50 / 60 Hz ±6 %
Power absorption < 30W (normal)
Safety class I, with components in compliance with II and III, according to
DIN EN 60730-1
Load on ‘input’
terminals
F1 unit fuse (internal) 6.3 AT
Main fuse of perm. network (external) Max. 16 AT
Undervoltage
• Safety switch-off from operating position
to mains voltage
• Restart when mains voltage picks up
< AC 186 V
> AC 188 V
Oil pump / magnetic clutch (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Air pressure switch test valve (nominal voltage)
• Nominal current
• Power factor
0.5A
cos> 0.4
Load on ‘output’
terminals
Total load on the contacts:
• Mains voltage
• Total unit input current (safety circuit)
load on contacts due to:
- Fan motor contactor
- Ignition transformer
- Valve
- Oil pump / magnetic clutch
AC 230 V -15 % / +10 %
Max. 5 A
Single contact loading:
Fan motor contactor (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Alarm output (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Ignition transformer (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.2
Fuel gas valve (nominal voltage)
• Nominal current
• Power factor
2A
cos> 0.4
Fuel oil valve (nominal voltage)
• Nominal current
• Power factor
1A
cos> 0.4
Cable lengths Main line Max. 100 m (100 pF/m)
Environmental
conditions
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-3
Class 3K3
Class 3M3
-20...+60°C
< 95% RH

20175134 16
GB
Technical description of the burner
4.14 Actuator
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 actuator, completely isolate the burner control from the
mains supply (all-polar disconnection).
Ensure protection against electric shock hazard by providing
adequate protection for the connection terminals and by
securing the housing cover.
Check to ensure that wiring is in an orderly state.
Fall or shock can adversely affect the safety functions. Such
units must not be put into operation, even if they do not
exhibit any damage.
Use
The actuator (Fig. 8) is used to drive and position the air damp-
er and the gas butterfly valve, without mechanical leverages
but via the interposition of an elastic coupling.
When used in connection with burner controls or electronic
fuel / air ratio control, the associated controlling elements are
controlled depending on burner output.
Installation notes
• Always run the high-voltage ignition cables separate from the
unit and other cables while observing the greatest possible
distance.
• The holding torque is reduced when the actuator’s power sup-
ply is switched off.
Technical data
Tab. I
WARNING
To avoid injury to persons, damage to prop-
erty or the environment, the following warn-
ing notes should be observed!
Do not open, interfere with or modify the ac-
tuators!
WARNING
The housing cover may only be removed for
short periods of time for wiring or when
making the addressing.
It must be made certain that dust or dirt will
not get inside the actuator while such work
is carried out.
WARNING
When servicing or replacing the actuator, take
care not to invert the connectors.
Model SQM45.295A9
Operating voltage AC 2 x 12 V via bus cable from the
basic unit or via a separate trans-
former
Safety class Extra low-voltage with safe isolation
from mains voltage
Power consumption 9...15 VA
Degree of protection To EN 60 529, IP 54, provided ade-
quate cable entries are used
Electrical connections RAST3.5 terminals
Direction of rotation
(when facing the shaft)
- Standard: counterclockwise
- Reverse: clockwise
Running time (min.)
for 90° 10 s.
Holding torque (max.) 1.5 Nm
Nominal torque (max.) 3 Nm
Weight approx. 1 kg
Environmental conditions:
Operation
Climatic conditions
Mechanical conditions
Temperature range
Humidity
DIN EN 60721-3-1
class 1K3
class 1M2
-20...+60 ×C
< 95 % r.h.
WARNING
Condensation, the formation of ice and the entry
of water are prohibited!
D8271
Fig. 8

17 20175134
GB
Technical description of the burner
4.15 PLL52... module (optional)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit must not be operated, even if it
displays no evident damage.
Assembly notes
• Check the relevant national safety standards are respected.
4.15.1 Terminal ratings, cable lengths and cross-
sectional areas
Tab. J
Technical data
Tab. K
NOTE:
For detailed information, refer to the specific manual of
PLL52 module.
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the de-
vice.
Cable lengths / cross-sectional areas
Electrical connection “X89” Screw terminals up to max. 2.5
mm2
Cable lengths 10 m fino a QGO20...
Cross-sectional areas Refer to description of QGO20...
Analog inputs
Air temperature detector Pt1000 / LG-Ni1000
Flue gas temperature Pt1000 / LG-Ni1000
QGO20... Refer to data sheet N7842
Interface Communication bus for LMV52...
Model PLL52...
Mains voltage “X89-01” AC 230 V -15%/10%
Safety class I class with parts according to II
class (DIN EN 60730-1)
Mains frequency 50 / 60 Hz ±6 %
Power consumption Ca. 4 VA
Degree protection IP54, housing closed
Transformer AGG5.220
- Primary side AC 230V
- Secondary side AC 12 V (3x)
Environmental conditions:
Storage
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60721-3-1
Class 1K3
Class 1M2
-20...+60 °C
<95% r.h.
Transport
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60721-3-2
Class 2K2
Class 2M2
-25...+70 °C
<95% r.h.
Operation
Climatic conditions:
Mechanical conditions:
Temperature range:
Humidity:
DIN EN 60 721-3-1
Class 3K5
Class 3M2
-20...+60 °C
< 95% r.h.
WARNING
Condensation, formation of ice and the entrance
of water are not permitted!
Fig. 9
S9902

20175134 18
GB
Technical description of the burner
4.16 Oxygen sensor QGO20 ... (optional)
Warnings
All interventions (assembly and installation operations,
assistance, etc.) must be carried out by qualified personnel.
Before modifying the wiring in the sensor connection area,
fully disconnect the burner control device from the power
supply (omnipolar separation).
Ensure that the sensor cannot be inadvertently switched on
again and check this by making a voltage test.
To avoid the risk of electrocution, protect the connection ter-
minals in a suitable manner and correctly fix the cover.
During operation, the flange of the sensor connection must
be kept closed; all screws must be tightened securely.
Check the wiring is in order.
Falls and collisions can negatively affect the safety func-
tions. In this case, the unit must not be operated, even if it
displays no evident damage.
Ensure that the device does not get into contact with explo-
sive or inflammable gases.
There is a risk of burning since the measuring cell works at
an operating temperature of 700 °C and other accessible
parts can get very hot too (> 60 °C).
To prevent injury caused by the hot immersion tube, remove
the device only after the equipment has cooled down.
Make certain that the sensor’s inlet and outlet are always
kept free from dirt.
Before cleaning the inlet and outlet, allow the sensor to cool
down for at least 1 hour.
Mount the sensor such that the connecting part (head to
flange) is free so that the exchange of air is ensured. Other-
wise, measurements might get distorted, possibly leading to
dangerous situations.
Ensure that there are no chemicals, such as solvent vapors,
near the sensor.
Installation notes
The flue gas flow passing the measuring cell must be homo-
geneous, with no or only little turbulence. When mounted too
close to air dampers or pipe bends, faulty measurements
can occur.
A number of faults can distort the measurements (this can
lead to dangerous situations in connection with oxygen trim
control):
– If the stack is not tight, false air can join the flue gases.
– In that case, the residual oxygen content indicated by the
sensor is higher than it actually is.
– If the flue gas velocity is low, the sensor’s response is
slower, since the flue gases take more time to pass the
measuring cell. In that case, it is recommended to mount
the sensor in an inclined position (refer to the manual).
– The greater the sensor’s distance from the flame, the
longer the dead time.
NOTE:
For further explanations about the wiring connetions, please
refer to the manual supplied with the accessory code
20045187.
WARNING
To avoid accidents, material or environmen-
tal damage, observe the following instruc-
tions!
Avoid opening, modifying or forcing the oxy-
gen sensor.
WARNING
Condensation, formation of ice and the entrance
of water are not permitted!
S9895
Fig. 10