Riello RS 510/E FGR TC FS1 3/400/50 Installer Manual

Installation, use and maintenance instructions

20162712 (3) - 08/2021

Forced draught gas burners

Modulating operation

CODE MODEL

20162643 RS 410/E FGR

20162646 RS 510/E FGR

20162647 RS 610/E FGR

GB

Translation of the original instructions

1 20162712

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.......................................................................................................................................................... 8

4.3 Burner categories - Countries of destination ............................................................................................................... 8

4.4 Technical data ............................................................................................................................................................. 8

4.5 Electrical data.............................................................................................................................................................. 9

4.6 Burner weight .............................................................................................................................................................. 9

4.7 Maximum dimensions................................................................................................................................................ 10

4.8 Firing rates ................................................................................................................................................................ 11

4.9 Test boiler.................................................................................................................................................................. 12

4.10 Burner equipment...................................................................................................................................................... 12

4.11 Burner description ..................................................................................................................................................... 13

4.12 Electrical panel description........................................................................................................................................ 14

4.13 Control box for the air/fuel ratio (LMV51.300) ........................................................................................................... 15

4.14 Servomotor................................................................................................................................................................ 17

4.15 Calibration of the thermal relay ................................................................................................................................. 18

5 Installation ................................................................................................................................................................................ 19

5.1 Notes on safety for the installation ............................................................................................................................ 19

5.2 Handling .................................................................................................................................................................... 19

5.3 Preliminary checks .................................................................................................................................................... 19

5.4 Operating position ..................................................................................................................................................... 20

5.5 Preparing the boiler ................................................................................................................................................... 20

5.5.1 Boring the boiler plate ............................................................................................................................................... 20

5.5.2 Blast tube length........................................................................................................................................................ 20

5.6 Securing the burner to the boiler ............................................................................................................................... 20

5.7 Access to head internal part...................................................................................................................................... 21

5.8 Electrodes position .................................................................................................................................................... 22

5.9 Gas butterfly valve..................................................................................................................................................... 22

5.10 Combustion head adjustment.................................................................................................................................... 23

5.11 FGR duct system....................................................................................................................................................... 24

5.11.1 Flue gas recirculation line sizing ............................................................................................................................... 25

5.11.2 Calculating the percentage of recirculated flue gas .................................................................................................. 25

5.12 Gas pressures ........................................................................................................................................................... 26

5.12.1 Gas feeding line ........................................................................................................................................................ 26

5.12.2 Gas train.................................................................................................................................................................... 27

5.12.3 Gas train installation.................................................................................................................................................. 27

5.12.4 Gas pressure............................................................................................................................................................. 28

5.13 Electrical wiring ......................................................................................................................................................... 29

5.13.1 Supply cables and external connections passage .................................................................................................... 30

6 Start-up, calibration and operation of the burner ................................................................................................................. 31

20162712 2 GB

Contents

6.1 Notes on safety for the first start-up...........................................................................................................................31

6.2 Adjustments prior to ignition.......................................................................................................................................31

6.3 Burner start-up ...........................................................................................................................................................32

6.4 FGR commissioning...................................................................................................................................................33

6.5 Air / fuel adjustment ...................................................................................................................................................34

6.5.1 Air adjustment for maximum output ...........................................................................................................................34

6.5.2 Air/fuel adjustment and output modulation system ....................................................................................................34

6.5.3 Burner adjustment......................................................................................................................................................34

6.5.4 Output upon ignition...................................................................................................................................................34

6.5.5 Maximum output ........................................................................................................................................................34

6.5.6 Minimum output .........................................................................................................................................................34

6.6 Final adjustment of the pressure switches.................................................................................................................35

6.6.1 Air pressure switch.....................................................................................................................................................35

6.6.2 Maximum gas pressure switch...................................................................................................................................35

6.6.3 Minimum gas pressure switch....................................................................................................................................36

6.6.4 PVP pressure switch kit .............................................................................................................................................36

6.7 Final checks (with burner operating)..........................................................................................................................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 Checking the air and gas pressure on the combustion head .....................................................................................38

7.2.5 Safety components ....................................................................................................................................................38

7.3 Opening the burner ....................................................................................................................................................39

7.4 Closing the burner......................................................................................................................................................39

8 Faults - Probable causes - Solutions ......................................................................................................................................40

A Appendix - Accessories ...........................................................................................................................................................41

B Appendix - Electrical panel layout...........................................................................................................................................42

3 20162712

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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 burner

Model and type: RS 410/E FGR

RS 510/E FGR

RS 610/E FGR

S029T1

S030T1

S031T1

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

PED 2014/68/EU (only FS2) Pressure Equipment Directive

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

20162712 4 GB

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.

This symbol indicates a list.

5 20162712

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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 20162712

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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 E 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

FGR: Induced Flue Gas Recirculation

FGR FS1/FS2

20162712 8 GB

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: Room temperature 20°C - Gas temperature 15°C - Barometric pressure 1013 mbar - Altitude 0 m a.s.l.

(2) Pressure at the test point 5)(Fig. 5 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.

Version FS1

Designation Voltage Start-up Code

RS 410/E FGR FS1 3/400/50 Direct 20162643

RS 510/E FGR FS1 3/400/50 Star/Delta 20162646

RS 610/E FGR FS1 3/400/50 Star/Delta 20162647

Destination country Gas category

AT - BG - CH - CZ - DK - EE - ES - FI - GB - GR - FR - HU - IE -

IS - IT - LT - LV - NO - PT - RO - SE - SI - SK - TR I2H

BE I2E(R)B

DE - LU - PL I2E

Model RS 410/E FGR RS 510/E FGR RS 610/E 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

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 20162712

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Technical description of the burner

4.5 Electrical data

Tab. D

4.6 Burner weight

The weight of the burner complete with its packaging is shown in

Tab. E.

Tab. E

DIRECT START UP

Model RS 410/E FGR

Main electrical supply 3N ~ 400V +/-10% 50 Hz

Fan motor IE3

rpm

V

kW

A

2920

230/400

9.2

28.6/16.5

Ignition transformer V1 - V2

I1 - I2

230 V - 1 x 8 kV

1 A - 20 mA

Absorbed electrical power kW max 10.6

Protection level IP 54

STAR - TRIANGLE START UP

Model RS 510/E FGR RS 610/E FGR

Main electrical supply 3N ~ 400V +/-10% 50 Hz

Fan motor IE3

rpm

V

kW

A

2920

400/690

12

21/12.2

2915

400/690

15

26.8/15.5

Ignition transformer V1 - V2

I1 - I2

230 V - 1 x 8 kV

1 A - 20 mA

Absorbed electrical power kW max 13.9 16.9

Protection level IP 54

Model kg

RS 410/E FGR 265

RS 510/E FGR 265

RS 610/E FGR 295

Fig. 1

20091888

20162712 10 GB

Technical description of the burner

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

Fig. 2

20131490

mm A B C D E F* G H I L M N O P** R S R2

RS 410 1270 510 178 313 520 DN65 1140 790 370 1100 615 528 290 177 890 DN125 1040

RS 510 1270 510 178 313 520 DN65 1140 790 370 1100 620 528 290 177 890 DN125 1040

RS 610 1270 517 178 336 520 DN65 1215 790 370 1100 632 528 290 177 890 DN150 1060

WARNING

* The gas adaptor is set also for DN 80 bore.

** Maximum position for the extraction of the ser-

vomotor cover.

11 20162712

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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 410/E FGR 595

RS 510/E FGR 660

RS 610/E FGR 912

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 23.

WARNING

Pre-calibration of the combustion head only for

the burner model RS 410/E 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. 15 on page 22.

- area B of the firing rate, no modifications are re-

quired.

Fig. 3

Pressure in

combustion chamber - mbar

Thermal power – kW

Pressure in

combustion chamber - mbar

Limit with active flue gas recirculation system

20164284

RS 410/E

RS 510/E

RS 610/E

Thermal power – kW

20162712 12 GB

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:

Output 5000 kW - diameter 100 cm - length 5 m

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. 8

Stud bolts M16X60 to fix the gas elbow

to the pipe coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Internal shutter (RS 410/E FGR) . . . . . . . . . . . . . . . . . . . . No. 1

Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

20057548

Fig. 4

Combustion chamber

m

13 20162712

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Technical description of the burner

4.11 Burner description

1 Lifting rings

2 Fan

3 Fan motor

4 Air damper servomotor

5 Combustion head gas pressure test point

6 Combustion head

7 Ignition electrodes

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

Fig. 5

20164293

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 21.

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Technical description of the burner

4.12 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 Direct start up line contactor

9 Star/delta start-up line contactor

10 Thermal relay (with reset button)

11 Delta contactor (star/delta start up)

12 Star contactor (star/delta start up)

13 Auxiliary contacts

14 Timer for delta/star start-up

15 Electronic cam

16 “0/AUTO” selector

17 Operator panel with LCD display

18 Control box power supply

19 Emergency button

20 Light signalling “POWER ON”

21 Light signalling burner lock-out and reset button

22 Light signalling “OVERLOAD FAN MOTOR”

Fig. 6

20164316

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Technical description of the burner

4.13 Control box for the air/fuel ratio (LMV51.300)

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. 7

D9301

20162712 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. H

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 20162712

GB

Technical description of the burner

4.14 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. I

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. 8

20162712 18 GB

Technical description of the burner

4.15 Calibration of the thermal relay

The thermal relay serves to avoid damage to the motor due to an

excessive absorption increase or if a phase is missing.

For calibration 2), see the table in the wiring diagram.

To reset, in case of an intervention of the thermal relay, press the

“RESET” button 1) of Fig. 9.

The red “TEST” button 3) opens the NC (95-96) contact and

stops the motor.

CAUTION

The automatic reset (Position “A” button 1) can be

dangerous. This operation is not anticipated in the

burner's operation, leave it always on “H”. There-

fore do not position the “RESET” button 1) on

“A”.

Fig. 9

20073932

3

1

2

RESET

HA

TEST

95 96 97 98

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Riello RS 510/E FGR TC FS1 3/400/50 Installer Manual

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