Siemens LFL Series Technical data

Installation, use and maintenance instructions
Gas Burners
RS 160/M LN
Low-High-Low or Modulating Operation
C6505073 - 2915849 (6) - 05/2009
WARNING
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
4
4
4
4
5
5
5
6
If you smell gas:
•
•
•
•
Do not touch any electrical items.
Open all windows.
Close all gas supply valves.
Contact your local gas authority immediately.
Do not store flammable or hazardous materials in the vicinity
of fuel burning appliances.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or
death. Refer to this manual for instructional or additional information. Consult a certified installer, service representative
or the gas supplier for further assistance.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boiler mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustments before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maximum output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Minimum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Intermediates outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Procedure to refer burner operating condition in high
altitude plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Siemens LFL control sequence of operations . . . . . . . . . . . . . . 16
Siemens LFL controltroubleshooting guide . . . . . . . . . . . . . . . . 17
Factory wiring diagram -burner mounted LFL . . . . . . . . . . . . . . 18
Field wiring diagram - burner mounted LFL . . . . . . . . . . . . . . . . 19
Factory wiring diagram - remote panel. . . . . . . . . . . . . . . . . . . . 20
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Burner start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Burner shall be installed in accordance with manufacturers
requirements as outlined in this manual, local codes and authorities having jurisdiction.
2
TECHNICAL DATA
MODEL
RS 160/M LN
MAX.
Output (1)
kW
MBtu/hr
kW
MBtu/hr
MIN.
Fuel
- max. delivery
- pressure at max. delivery (2)
1032 - 2065 (1847 *)
3521 - 7046 (6302 *)
333
1136
Natural gas
7046
7
SCFH
“ WC
Operation
Standard applications
Ambient temperature
Combustion air temperature
Main power supply (+/-10%)
Fan motor
Low - high or modulating
Boilers: water, steam, thermal oil
32 - 104 (0 - 40 °C)
140 (60 °C)
208 - 230/460/575/3/60
3400
4000 - 5.5
208 - 230 / 460 / 575
15.8 - 9.1 - 6
120 V - 1 x 7 kV
1.6 A - 23 mA
5500
NEMA 1
83.1
°F
°F max
V/Ph/Hz
rpm
W - HP
V
A
V1 - V2
I1 - I2
W max
Ignition transformer
Electrical power consumption
Electrical protection
Noise levels (3)
dBA
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394” WC - Altitude 329 ft.
(2) Pressure at test point 17)(A)p.4, with zero pressure in the combustion chamber, with open gas ring 2)(B)p.6 at maximum burner output
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
*
Firing rate for C-UL Canadian Listing (CNL)
Burner models designations:
Model
Code
Voltage
Flame safeguard
RS 160/M LN
C9544000 (3788070)
C9544001 (3788075)
C9744000 (3788073)
C9744001 (3788073)
208-230/460/3/60
575/3/60
208-230/460/3/60
575/3/60
Burner mounted
Burner mounted
In an auxiliary panel (see Accessories)
In an auxiliary panel (see Accessories)
ACCESSORIES (optional):
• Available auxiliary panels
Control panel code
Flame safeguard type
3010332
Fireye
3010336
Landis
3010338
Honeywell
• TUBES KIT (see page 5): cod. 3010249
• GAS TRAIN ACCORDING TO UL STANDARDS: see page 9.
Important:
The installer is responsible for the supply and installation of any safety device(s) not indicated in this manual.
3013980: Thermal overload for 460 V power supply.
3
BURNER DESCRIPTION (A)
1
2
3
4
5
6
(A)
Combustion head
Ignition electrode
Screw for combustion head adjustment
High gas pressure switch
Sleeve
Servomotor controlling the gas butterfly valve and
the air damper (by means of a variable profile cam
mechanism).
When the burner is stopped the air damper will be
completely closed to reduce heat loss.
7 Plug-socket on flame rod cable
8 Extensions for slide bars 16) (supplied by kit)
9 Motor contactor and thermal overload with reset button
10 Power switch for different operations:
automatic - manual - off
Button for:
Power increase - power reduction
11 Terminal strip for electrical connection
12 Pilot burner attachment
13 Flame safeguard with lock-out pilot light and lock-out
reset button
14 Flame inspection window
15 Low air pressure switch
(differential operating type)
16 Slide bars for opening the burner and inspecting the
combustion head
17 Gas pressure test point and head fixing screw
18 Air pressure test point
19 Flame sensor probe (flame rod)
20 Air damper
21 Air inlet to fan
22 Screws securing fan to sleeve
23 Gas input pipework
24 Gas butterfly valve
25 Boiler mounting flange
26 Flame stability disk
27 Pilot burner
D2791
A
B
C
lbs
523/4“
281/2“
3029/32“
198
(B)
Two types of burner failure may occur:
• FLAME SAFEGUARD LOCK-OUT:
if the flame relay 13)(A) pushbutton lights up, it indicates that the burner is in lock-out.
To reset, press the pushbutton.
• MOTOR TRIP:
release by pressing the pushbutton on thermal overload 9)(A).
D36
PACKAGING - WEIGHT (B) - Approximate measurements
• The burners are shipped skid mounted.
Outer dimensions of packaging are indicated in (B).
• The weight of the burner complete with packaging is
indicated in Table (B).
MAX. DIMENSIONS (C) - Approximate measurements
The maximum dimensions of the burners are given in
(C).
Bear in mind that inspection of the combustion head
requires the burner to be opened by withdrawing the
rear part on the slide bars.
The maximum dimension of the burner, when open is
give by measurement I.
D1702
A
B
C
D
E
F (1)
G
H
I (1)
L
M
N
O
2613/16“ 1413/32“ 1213/32“ 2127/32“ 3331/32“ 1411/16“-1913/16“ 811/16” 1615/16” 5649/64”- 6231/64” 921/64” 529/32” 75/16” 2”
(1) Blast tube: short - long (with kit)
(C)
4
STANDARD EQUIPMENT
1 - Gas train flange
1 - Flange gasket
4 - Flange fixing screws
1 - Burner head gasket
4 - Screws to secure the burner flange to the boiler:
1/ 2 W x 13/8”
1 - Cap for combustion head
1 - Disc for combustion head
1 - Instruction booklet
1 - Spare parts list
FIRING RATES (A)
RS 160/M LN
Combustion chamber pressure
“WC
During operation, burner output varies between:
• MAXIMUM OUTPUT, selected within area A,
• and MINIMUM OUTPUT, which must not be lower
than the minimum limit in the diagram.
RS 160 /M LN
Important
The FIRING RATE area values have been obtained
considering an ambient temperature of 68 °F (20 °C),
and an atmospheric pressure of 394 “WC and with the
combustion head adjusted as shown on page 8.
Note:
The FIRING RATE areas given in figure (A) have been
reduced by 10% with respect to the maximum range that
can be reached.
Consult Procedure on page 15 to refer burner operating
condition in high altitude plants.
Firing rate for C-UL Canadian Listing (CNL)
MINIMUM FURNACE DIMENSIONS (B)
6302 MBtu/hr
(A)
D2798
Diameter (inches)
Recommended furnace dimensions
= 1136 MBtu/hr = 333 kW
The firing rates were set in relation to certified test boilers.
Figure (B) indicates the diameter and length of the test
combustion chamber.
Example:
Output 2579 MBtu/hr:
diameter = 23.6 inch; length 6.6 ft
Length (feet)
COMMERCIAL BOILERS (C) - IMPORTANT
The RS 160/M LN burner is suitable for operation on either flame-inversion boilers* or boilers with combustion
chambers featuring flow from the base (three flue passes) on which the best results are obtained in terms of low
NOx emissions.
The maximum thickness of the boiler’s front door must
not exceed 10” (see fig. C).
(B)
D2919
10” max
D1079
(C)
5
(*) For flame inversion boilers, a kit is available to reduce
CO emissions if required.
The kit includes 5 gas pipes, identical to the other 5
already fitted to the burner head. In standard conditions, the burner head is fitted with a second group of
pipes, with gas outlet in a different direction with respect to the others. With this Kit, the second group of
pipes is replaced, so that all the pipes are the same.
After fitting the kit, ensure they work correctly by
measuring the CO and flue gases emissions.
GAS PRESSURE
The adjacent diagram shows minimum pressure losses
along the gas supply line depending on the maximum
burner output operation with natural gas.
Δp [“WC]
Column 1
Gas manifold pressure measured at test point 1)(B),
with:
• Combustion chamber at 0” WC;
• Burner operating at maximum output;
• Combustion head adjusted as indicated in diagram
(C)p. 8.
(A)
D3188
Calculate the approximate maximum output of the
burner as follows:
- subtract the combustion chamber pressure from the
gas pressure measured at test point 1)(B).
- Find the nearest pressure value to your result in
diaram (A).
- Read off the corresponding output on the left.
Example
• Maximum output operation
• Natural gas
• Gas pressure at test point 1)(B)
= 4.09“ WC
• Pressure in combustion chamber = 1.18“ WC
4.09 - 1.18 = 2.91“ WC
A maximum output of 4094 MBtu/hr shown in diagram
(A) corresponds to 2.91” WC pressure.
This value serves as a rough guide, the effective delivery must be measured at the gas meter.
1
2
(B)
D2441
6
INSTALLATION
A
91/16“
B
1225/32“
-
BOILER PLATE (A)
Drill the combustion chamber mounting plate as shown
in (A). The position of the threaded holes can be marked
using the burner head gasket supplied with the burner.
C
141/2“
5/8
W
(A)
D455
BLAST TUBE LENGTH (B)
The length of the blast tube must be selected according
to the indications provided by the manufacturer of the
boiler, it must be greater than the thickness of the boiler
door complete with its insulation. The length available, L
(inches), is 1411/16“.
For boilers with front flue passes 15) or flame inversion
chambers, protective insulation material 13), must be
inserted between the boiler refractory 14) and the blast
tube 12).
This protective insulation must not compromise the
extraction of the blast tube.
For boilers having a water-cooled front, the insulation
13)-14) is not required unless it is required by the boiler
manufacturer.
SECURING THE BURNER TO THE BOILER (B)
Before securing the burner to the boiler, check through
the blast tube opening to make sure that the flame sensor probe (flame rod) is correctly set in position, as
shown in (C).
D2800
(B)
Now detach the combustion head from the burner, fig.
(B):
- loosen the four screws 3) and remove the cover 1);
- disengage the swivel joint 7) from the graduated sector
8);
- remove the screws 2) from the slide bars 5);
- remove the two screws 4) and pull the burner back on
slide bars 5) by about 4”;
- disconnect the wires from the flame rod and the electrode and then pull the burner completely off the slide
bars.
Electrode
Ignition
pilot
Probe
Secure the flange 11)(B) to the boiler plate, inserting the
gasket 9)(B). Use the 4 screws, also supplied with the
unit, after first protecting the thread with an anti-locking
product.
The seal between burner and boiler must be airtight.
(C)
D2799
If you noticed any irregularities in the positions of the
flame rod or ignition electrode during the check mentioned above, remove screw 1)(D), extract the internal
part 2)(D) of the head and set up the two components
correctly.
IGNITION PILOT ADJUSTMENT
(D)
D1706
MB - Burner terminal strip
(E)
D2317
7
Place the pilot and electrode as shown in fig. (C).
The pilot works correctly at pressures ranging from 5 12” WC.
Important
To set the pilot without main burner operaton, proceed
as follows:
- Move the jumper from terminals "30-V11" to terminals
"30-VP", as given in fig. (E), this way the main valve is
cut out.
- With the burner in the manual position, hold the air
damper in the minimum position and make the setting.
- When the setting is correct, replace the jumper on “30V11”.
COMBUSTION HEAD ADJUSTMENT
Installation operations are now at the stage where the
blast tube and sleeve are secured to the boiler as shown
in fig. (A). It is now a very simple matter to set up the
combustion head, as this depends solely on the maximum output developed by the burner.
It is therefore essential to establish this value before proceeding to set up the combustion head.
There are two adjustments to make on the head:
• outside air R1;
• central air R2.
In diagram (C) find the notch for:
Outside air adjustment R1 (A)
Turn screw 4)(A) until the notch identified is aligned with
the front surface 5)(A) of the connector.
IMPORTANT: In order to facilitate adjustment,
loosen screw 6)(A), adjust and then tighten.
D1707
(A)
(B)
Notches (Air = Gas)
Central air adjustment R2 (B)
Loosen the 3 screws 1)(B) and turn ring 2) until the
notch identified is aligned with index 3). Tighten the 3
screws 1) fully down.
Example
RS 160 /M LN
max. burner output = 5681 MBtu/hr
If we consult diagram (C) we find that for this output the
adjustments are:
• outside air:
R1 = notch 8.6;
• central air:
R2 = notch 0.
NOTES
• R2 adjustment (diagram C) is an indication only. If
possible, always keep the ring nut closed (notch 0); if air
recovery is required the nut may be opened following
the indications in diagram (C).
• Diagram (C) indicates an optimal regulation for a type
of boiler seen in fig. (B) page 5.
Make sure that the combustion characteristics are satisfactory and free of pulsations.
Burner max output
(C)
D2801
Once you have finished setting up the head, refit the
burner to the slide bars 3)(D) at approximately 4” from
the sleeve 4)(D) - burner positioned as shown in fig. (B)
pag. 7 - insert the flame rod cable and the ignition electrode cable and then slide the burner up to the sleeve so
that it is positioned as shown in fig. (D).
Refit screws 2) on slide bars 3) after mounting the
extension bracket and relative extensions.
Secure the burner to the sleeve by tightening screw 1).
Reconnect the swivel joint 7) to the graduated sector 6).
Connect gas train and pilot train as shown in fig. (A)
page 9.
Important
When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cable and flame
detection probe cable until they are slightly stretched.
D2367
(D)
8
GAS PIPING
• The main gas train must be connected to the gas
attachment 1)(A), using flange 2), gasket 3) and
screws 4) supplied with the burner.
• The gas train can enter the burner from the right or left
side, depending on which is the most convenient, see
fig. (A).
• The gas safety shut-off valves 5)-6)(A) must be as
close as possible to the burner to ensure gas reaches
the combustion head within the safety time range.
• The pilot gas train must be connected to the gas
attachment 5)(A).
GAS TRAIN (B)
It must be type-approved according to required standards and is supplied separately from the burner.
(A)
D2846
TYPICAL UL SCHEMATIC GAS PIPING
Note
See the accompanying instructions for the adjustment of
the gas train.
KEY (A)
1 - Gas input pipe
2 - Manual valve
3 - Pressure regulator
4 - Low gas pressure switch
5 - 1st safety shut off valve
6 - 2nd safety shut off valve
7 - Standard issue burner with flange gasket
8 - Gas adjustment butterfly valve *
9 - Burner
10 - High gas pressure switch *
GAS PILOT LINE
* On the burner
MAIN GAS LINE
(B)
D2438
9
LOW GAS PRESSURE SWITCH
(A)
HIGH GAS PRESSURE SWITCH
AIR PRESSURE SWITCH
(B)
ADJUSTMENTS BEFORE FIRST FIRING
Adjustment of the combustion head, and air and gas
deliveries has been illustrated on page 8.
In addition, the following adjustments must also be
made:
- Open manual valves up-stream from the gas train.
- Adjust the low gas pressure switch to the start of the
scale (A).
- Adjust the high gas pressure switch to the end of the
scale (B).
- Adjust the air pressure switch to the zero position of
the scale (C).
- Purge the air from the gas line.
Fit a U-type manometer (D) to the gas pressure test
point on the sleeve.
The manometer readings are used to calculate the
MAX. burner power using the diagram on page 6.
(C)
Before starting up the burner it is good practice to adjust
the gas train so that ignition takes place in conditions of
maximum safety, i.e. with gas delivery at the minimum.
D2368
(D)
10
SERVOMOTOR
The servomotor gives simultaneous regulation of the air
damper through the variable cam profile 4)(F) and the
gas butterfly valve.
It rotates by 130° in approx. 35 s.
The factory settings must not be changed for the first firing, just check that they comply with the details below.
To open the servomotor, remove the screws and pull the
cover outward, fig. (A).
CAMS AND TRIM POTENTIOMETERS FUNCTIONS
(A)
D2277
YES
Cam 1:
130°
Limits rotation towards maximum for gas.
NO
Cam 2:
0°
Limits rotation towards minimum, air damper closed on
stand by.
Cam 3:
20°
Limits gas ignition position.
Cams 4 - 5 - 6 - 7 - 8: not used
Don’t release the button indicated in this figure: the syncronization of the cams
made in factory would be
changed.
D2585
Figure above shows how the servomotor is released to manually check
(B) there is no binding though its motion.
Position jumpers
Trim potentiometer MAX
Limits maximum modulation.
It must be set near the stroke end (cam 1) to exploit as
far as possible the variable profile cam and maximum
opening of the gas butterfly valve.
Trim potentiometer MIN
Limits minimum modulation.
It must be set near the stroke end (cam 2) to exploit as
far as possible the variable profile cam.
Trim potentiometer POS
Limits an intermediate operating position between MAX
and MIN, supplying power to the "P" terminal in the servomotor (through an external command). This function
cuts out any external signals.
Note
Using the slide switch to select MAX or MIN, the servomotor goes into the position for the respective settings of
the MAX and MIN TRIM POTENTIOMETERS.
Trim potentiometers
Slide switch
When the settings are complete, place the slide switch
on OPE.
(C)
(D)
(E)
D2593
1 Servomotor
2 Graduated sector for gas
butterfly valve
3 Index for graduated sector 2
4 Adjustable profile cam
5 Adjustment screws for cam
starting profile
6 Adjustment fixing screws
7 Adjustment screws for cam
and profile
(F)
D2594
11
BURNER STARTING
Position jumpers
Close the control circuit, with the switch in fig. C) in the
AUTO position.
On firing (pilot burner and main valve) turn the switch (C)
to MAN and the switch 1)(E) in the AUT position.
Trim potentiometers
Slide switch
(A)
(B)
(C)
D2593
MAXIMUM OUTPUT
Using button (B), "increase output" until it stops, app.
130° (cam 1).
Place the slide switch on MAX and set the relative MAX
trim potentiometer (setting must be very near to 130°) to
exploit as far as possible the variable profile cam 4)(D)
and have the gas butterfly valve on maximum opening,
graduated sector 2) on index 3) fig. (D).
The setting of the gas flow must be made on the gas train
regulator and, if necessary, on the gas valve.
The air setting must be made on the variable profile cam
4)(D) by turning the screws 5), after loosening the screws
6).
MINIMUM OUTPUT
With the slide switch on the OPE position, use button (B)
"decrease output" until it stops at app. 20° (cam 3).
Put the slide switch in the MIN position and set the modulation minimum using the relative MIN trim potentiometer.
Set the air using the variable profile cam 4)(D).
If a lower modulation minimum is required than the level
set on cam 3 of the servomotor (20°), decrease the cam
setting.
INTERMEDIATE OUTPUTS
With the switch (C) in the AUTO position, the slide switch
in the OPE position and the switch 1)(E) in the MAN position, move the button 2)(E) in various intermediate levels between maximum and minimum and set the variable
profile cam 4)(D) to achieve optimum combustion, by
turning the screws 5).
If possible, do not change the previously set maximum
and minimum levels.
Check the various setting levels with a combustion analysis.
1
2
3
4
5
6
7
Important
Make a progressive adjustment of the profile, without
sharp changes.
When the setting is complete, lock the cam profile using
screws 6)(D).
Turn the burner off, release the servomotor as shown in
fig. (B) page 11 and manually turn cam 4)(D) to check
there is no binding.
Servomotor
Graduated sector for gas butterfly valve
Index for graduated sector 2
Adjustable profile cam
Adjustment screws for cam starting profile
Adjustment fixing screws
Adjustment screws for cam and profile
Finally fix the adjustment by turning the screws 6)(D).
(D)
D2594
1
(E)
2
D791
12
AIR PRESSURE SWITCH (A)
AIR PRESSURE SWITCH
Adjust the air pressure switch after having performed all
other burner adjustments with the air pressure switch set
to the start of the scale (A).
With the burner operating at min. output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.
Then turn the dial anti-clockwise by about 20% of the set
point and repeat burner starting to ensure it is correct.
If the burner locks out again, turn the dial anti-clockwise
a little bit more.
Attention:
As a rule, the air pressure switch must prevent the formation of CO.
To check this, insert a combustion analyser into the
chimney, slowly close the fan suction inlet (for example
with cardboard) and check that the burner locks out,
before the CO in the fumes exceeds 400 ppm.
D2548
(A)
HIGH GAS PRESSURE SWITCH
The air pressure switch may operate in "differential"
operation in two pipe system. If a negative pressure in
the combustion chamber during pre-purging prevents
the air pressure switch from switching, switching may be
obtained by fitting a second pipe between the air pressure switch and the suction inlet of the fan. In such a
manner the air pressure switch operates as differential
pressure switch.
HIGH GAS PRESSURE SWITCH (B)
Adjust the high gas pressure switch after having performed all other burner adjustments with the maximum
gas pressure switch set to the end of the scale (B).
With the burner operating at MAX output, reduce the
adjustment pressure by slowly turning the adjustment
dial anticlockwise until the burner locks out.
Then turn the dial clockwise by 0.8” WC and repeat
burner firing.
If the burner locks out again, turn the dial again clockwise by 0.4” WC.
D2547
(B)
LOW GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH (C)
Adjust the low gas pressure switch after having performed all the other burner adjustments with the pressure
switch set at the start of the scale (C).
With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial
clockwise until the burner locks out.
Then turn the dial anti-clockwise by 0.8” WC and repeat
burner starting to ensure it is uniform.
If the burner locks out again, turn the dial anti-clockwise
again by 0.4” WC.
D2547
FLAME PRESENT CHECK (D)
The burner is fitted with an ionisation (flame rod) system
which ensures that a flame is present. The minimum
current for reliable operation is 6 μA (see manufacturers
documentation). The burner provides a much higher current, so that controls are not normally required. However, if it is necessary to measure the ionisation current,
disconnect the plug-socket 7)(A)p.4 on the ionisation
probe cable and insert a direct current microamperometer with a base scale of 100 μA. Carefully check polarities.
(C)
DA
D1711
(D)
13
MAINTENANCE
FLAME INSPECTION WINDOW
Combustion
The optimum calibration of the burner requires an analysis of the flue gases. Significant differences with respect
to the previous measurements indicate the points where
more care should be exercised during maintenance.
Gas leaks
Make sure that there are no gas leaks on the pipework
between the gas meter and the burner.
Flame inspection window
Clean the flame inspection window (A).
Combustion head
Open the burner and make sure that all components of
the combustion head are in good condition, not
deformed by the high temperatures, free of impurities
from the surroundings and correctly positioned. If in
doubt, disassemble the elbow fitting 5)(B).
(A)
Servomotor
Disengage the cam 4)(D)p. 12 from the servomotor and
turn it backwards and forwards by hand to make sure it
moves freely.
D709
OPENING THE BURNER
Burner
Check for excess wear or loose screws in the mechanisms controlling the air damper and the gas butterfly
valve. Also make sure that the screws securing the electrical leads in the burner terminal strip are fully tightened.
Clean the outside of the burner, taking special care with
the swivel joints and cam.
Combustion
Adjust the burner if the combustion values found at the
beginning of the operation do not comply with the regulations in force, or do not correspond to good combustion. Record the new combustion values; they will be
useful for subsequent controls.
TO OPEN THE BURNER (B):
- Switch off the electrical power.
- Loosen screws 1) and withdraw cover 2).
- Disengage the swivel joint 7) from the graduated sector 8).
- Fit the two extensions onto the slide bars 4).
- Remove screws 3), and pull the burner back by about
4” on the slide bars 4). Disconnect the probe and
electrode leads and then pull the burner fully back.
Now extract the gas distributor 5) after having removed
the screw 6) and disconnecting the pilot gas line.
D2369
(B)
TO CLOSE THE BURNER (B):
- Push the burner until it is about 4” from the sleeve.
- Re-connect the leads and slide in the burner until it
comes to a stop.
- Refit screws 3), and pull the probe and electrode
leads gently out until they are slightly stretched.
- Re-couple the swivel joint 7) to the graduated sector
8).
- Remove the two extensions from the slide bars 4).
- Connect the pilot gas line.
14
PROCEDURE TO REFER BURNER OPERATING CONDITION IN HIGH ALTITUDE PLANTS
-
Find the corrected burner capacity for the plant’s altitude in chart 1 and the corrected pressure in chart 2.
Check in the firing rate graph of the burner (page 5), if the working point defined by the values above is within the range limits.
If not, higher burner size is needed.
Note
Charts are based only on altitude variation
(reference temperature = 68°F , 20°C)
To get the combined correction in case of different
air temperature, a compensation of 1000 ft each
20°F (305 m each 11°C) is applicable.
1
Rated Capacity
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
Average barometric
Pressure (20°C)
Average barometric
Pressure (68°F)
2
Rated Pressure
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
4,50
5,00
5,50
6,00
6,50
7,00
7,50
8,00
8,50
9,00
9,50
10,00
Average barometric
Pressure (20°C)
Average barometric
Pressure (68°F)
Example
Rated capacity = 3000 MBtu/hr - Rated air pressure = 1.5”w.c.
Real altitude = 5000 ft - Real temperature = 108°F
Δ = 108°F - 68°F (reference temp.) = 40°F (equivalent 2000 ft variation)
Proceeding as descripted above and considering a “virtual altitude” of (5000 + 2000) ft:
- the corrected capacity is 3847 MBtu/hr;
Burner RS 160/M LN is OK
- the corrected burner air pressure is 1.92.
CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE
m. a.s.l.
ft a.s.l
0
0
494
987
1481
1974
2468
2962
3455
3949
4442
4936
5429
5923
6417
6910
7404
7897
8391
8885
9378
9872
100
328
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
305
1000
512
1023
1535
2046
2558
3069
3581
4092
4604
5116
5627
6139
6650
7162
7673
8185
8697
9208
9720
10231
610
2000
530
1061
1591
2121
2652
3182
3712
4243
4773
5303
5834
6364
6894
7425
7955
8485
9016
9546
10076
10607
Altitude
915
3000
551
1101
1652
2202
2753
3303
3854
4404
4955
5505
6056
6606
7157
7708
8258
8809
9359
9910
10460
11011
1220
4000
571
1142
1713
2284
2855
3425
3996
4567
5138
5709
6280
6851
7422
7993
8564
9135
9705
10276
10847
11418
1525
5000
593
1186
1778
2371
2964
3557
4149
4742
5335
5928
6520
7113
7706
8299
8892
9484
10077
10670
11263
11855
1830
6000
616
1232
1848
2464
3079
3695
4311
4927
5543
6159
6775
7391
8006
8622
9238
9854
10470
11086
11702
12318
2135
7000
641
1282
1924
2565
3206
3847
4488
5130
5771
6412
7053
7694
8335
8977
9618
10259
10900
11541
12183
12824
2440
8000
669
1337
2006
2675
3343
4012
4680
5349
6018
6686
7355
8024
8692
9361
10029
10698
11367
12035
12704
13373
mbar
1013
1000
977,4
942,8
908,2
875,8
843,5
811,85
779,8
747,8
"w.c.
399
394
385
371
358
345
332
320
307
294
CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE
m. a.s.l.
ft a.s.l
0
0
0,49
0,99
1,48
1,97
2,47
2,96
3,46
3,95
4,44
4,94
5,43
5,92
6,42
6,91
7,40
7,90
8,39
8,88
9,38
9,87
100
328
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
4,50
5,00
5,50
6,00
6,50
7,00
7,50
8,00
8,50
9,00
9,50
10,00
305
1000
0,51
1,02
1,53
2,05
2,56
3,07
3,58
4,09
4,60
5,12
5,63
6,14
6,65
7,16
7,67
8,18
8,70
9,21
9,72
10,23
610
2000
0,53
1,06
1,59
2,12
2,65
3,18
3,71
4,24
4,77
5,30
5,83
6,36
6,89
7,42
7,96
8,49
9,02
9,55
10,08
10,61
Altitude
915
3000
0,55
1,10
1,65
2,20
2,75
3,30
3,85
4,40
4,95
5,51
6,06
6,61
7,16
7,71
8,26
8,81
9,36
9,91
10,46
11,01
1220
4000
0,57
1,14
1,71
2,28
2,85
3,43
4,00
4,57
5,14
5,71
6,28
6,85
7,42
7,99
8,56
9,13
9,71
10,28
10,85
11,42
1525
5000
0,59
1,19
1,78
2,37
2,96
3,56
4,15
4,74
5,33
5,93
6,52
7,11
7,71
8,30
8,89
9,48
10,08
10,67
11,26
11,86
1830
6000
0,62
1,23
1,85
2,46
3,08
3,70
4,31
4,93
5,54
6,16
6,77
7,39
8,01
8,62
9,24
9,85
10,47
11,09
11,70
12,32
2135
7000
0,64
1,28
1,92
2,56
3,21
3,85
4,49
5,13
5,77
6,41
7,05
7,69
8,34
8,98
9,62
10,26
10,90
11,54
12,18
12,82
2440
8000
0,67
1,34
2,01
2,67
3,34
4,01
4,68
5,35
6,02
6,69
7,35
8,02
8,69
9,36
10,03
10,70
11,37
12,04
12,70
13,37
mbar
1013
1000
977,4
942,8
908,2
875,8
843,5
811,85
779,8
747,8
"w.c.
399
394
385
371
358
345
332
320
307
294
Reference conditions (Charts 1-2): Ambient temperature 68 °F (20 °C) - Barometric pressure 394” WC (1000 mbar) - Altitude 328 ft a.s.l. (100 m a.s.l.)
15
BURNER OPERATION
LFL 1.335 Series 01
BURNER STARTING
• Load control close.
Fan motor starts.
• Servomotor starts:
130° rotation to right, until contact is made on cam
1)(A) page 12.
The air damper is positioned to MAX. output.
• Pre-purge stage with air delivery at MAX. output.
• After pre-purge stage, servomotor rotates to left up to
the angle set on cam 3)(A) page 12 for MIN. output.
• The air damper and the gas butterfly are positioned to
MIN. output.
• Ignition electrode strikes a spark.
• Pilot valve opens. The pilot flame is ignited.
• After about 12 s the main flame ignites and starting
cycle ends.
Full Modulation
(A)
D2273
Low - High
STEADY STATE OPERATION
At the end of the starting cycle, the servomotor control
then passes to the load control for boiler pressure or
temperature.
(The control box continues, however, to check that the
flame is present and that the air pressure switch is in the
correct position.)
• If the temperature or pressure is low, the burner progressively increases its output to the MAX. value.
• If the temperature or pressure is high, the burner progressively decreases its output to the MIN. value.
And so on.
• The burner locks out when demand for heat is less
than the heat supplied by the burner at min. output.
Load control opens. The servomotor returns to the 0°
angle limited by contact with cam 2. The air damper
closes completely to reduce thermal dispersion to a
minimum.
Every time output is changed, the servomotor automatically modifies gas delivery (gas butterfly valve) and air
delivery (fan air damper).
Switching times are given in seconds, in the burner startup sequence.
LFL 1.335 Series 01
t1
t2
t3
t4
(B)
D2274
30
2
4
20
t5
t6
t7
t8
optional
optional
12
4
Legend for the times
t1
Pre-purge time with air damper open
t2
Safety time
t3
Pre-ignition time, short (ignition transformer on
terminal 16)
t4
Interval between start of t2 and release of valve
at terminal 19
t5
Interval between end of t4 and release of load
controller or valve at terminal 20
t5
Running time of air damper into OPEN position
t6
Running time of air damper into low-flame position (MIN)
t7
Permissible after-burn time
t8
Interval until OPEN command for the air damper
is given
FIRING FAILURE
If the burner does not fire, it locks out within 2.5 seconds
from opening the pilot valve and then within 5 seconds
from opening the main valves.
BURNER FLAME GOES OUT DURING OPERATION
If the flame should accidentally go out during operation,
the burner will lock out within 1s.
16
BURNER FAULTS
Control program under fault
conditions and lock-out
indication
LFL 1.335 Series 01
In case of any disturbance, the sequence mechanism stops and with it the lock-out indicator. The symbol
above the reading mark of the indicator gives the type of disturbance:
No start, e.g. because one contact is not closed. Lock-out during or after control program sequence
due to extraneous light (e.g. non-extinguished flames, leaking fuel valves, defects in the flame
supervision circuit, etc.)
Interruption of startup sequence, because the OPEN signal has not been delivered to terminal 8
by limit switch “a”. Terminals 6, 7 and 14 remain under voltage until the fault has been corrected!
P
Lockout, because there is no air pressure indication at the beginning of air pressure control.
Every air pressure failure after this moment in time leads to lock-out, too!
Lock-out due to a fault in the flame supervision circuit.
Interruption of startup sequence, because the position signal for the low-flame position has not
been delivered to terminal 8 by auxiliary switch “m”. Terminals 6, 7 and 14 remain under voltage
until the fault has been corrected!
1
Lock-out, because no flame signal is present after completion of the (1st) safety time.
2
Lock-out, because no flame signal has been received on completion of the 2nd safety time (flame
signal of the main flame with interrupted pilot burners).
Lock-out, because the flame signal has been lost during burner operation.
If lock-out occurs at any other moment in time between the start and the pre-ignition which is not marked by
a symbol, this is usually caused by a premature, i.e. faulty flame signal, e.g. caused by a self-igniting UV
tube.
17
Factory Wiring Diagram
RS 160/M LN
with burner mounted Siemens LFL control
D2332
(A)
Field Wiring Diagram
RS 160/M LN
with burner mounted Siemens LFL control
D2333
Motor Connection
RS 160/M LN
208 460 V 575 V
230 V
F
A
T25
T20
T15
S
AWG
12
12
12
D3686
Wire size when not indicated: AWG18.
(B)
18
Factory Wiring Diagram
RS 160/M LN
with burner mounted Siemens LFL control
Continuous fan operation
Change the wire connection from terminal 6 to terminal 1, move the jumper from terminals 12-13 to terminals 4-12 and
remove the wire from terminal 13 of control box as indicated below.
D2878
(C)
LAYOUT (A) - (B) - (C)
Burner RS 160/M LN
PA
PG
PGM
PS
RT
SM
SO
SP
TA
TB
Y0
Y10
Y11
Y13
Key to Layouts
CMV
- Motor contactor
DA
- LFL Control box
HL
- High limit
H1
- Remote lock-out signal
H2
- Burner on signal
H4
- Power on signal
H5
- Permission ok
IN
- Burner manual stop switch
MB
- Burner terminal strip
MV
- Fan motor
OC
- Operating control
OC2
- High-low control
-
Air pressure switch
Min. gas pressure switch
High gas pressure switch
Remote lock-out reset
Thermal overload
Servomotor
Ionisation probe (flame rod)
Plug-socket
Ignition transformer
Burner ground
Pilot adjustment valve
Adjustment valve
Safety valve
Pilot valve (safety)
NOTES
• For electrical connection use flexible cables according to local Regulations.
• The setting of the thermal overload must be according to the total burner amperage draw.
• The RS 160/M LN burners leave the factory preset for:
- 208-230 V power supply: only in this case, if 460 V power supply is required, change the fan motor connection from delta to star and change
the thermal overload as well (see page 3);
- or 575 V power supply;
depending on the burner model (see page 3).
• The RS 160/M LN burners have been type-approved for intermittent operation. This means they should compulsorily be stopped at least once every
24 hours to enable the control box to check its own efficiency at start-up. Burner halts are normally provided for automatically by the boiler load control system.
If this is not the case, a time switch should be fitted in series to IN to provide for burner shut-down at least once every 24 hours.
Important note
When installing for the first time and after any maintenance work, make sure the gas valves are connected properly to the orange
terminals before proceeding to ignite the burner. Insert auxiliary lamps or check, with the aid of a tester, that power is not being supplied to
the valves during standby or pre-purging. Burner ignition with the gas valves open during pre-purging may cause an explosive condition.
19
Factory Wiring Diagram
RS 160/M LN with auxiliary control panel
20
Layout (A)
LAYOUT (A) page 20
Burner RS 160/M LN
The flame safeguard is in an auxiliary panel.
See the internal electrical systems of the auxiliary panel in order to have the complete wiring diagram.
Key to layout
B4
- Ionisation probe (flame rod)
F1
- Fan motor thermal overload
K1
- Fan motor contactor
MB
- Burner terminal strip
MV
- Fan motor
S10
- Air pressure switch
S12
- High gas pressure switch
SM
- Servomotor
T1
- Ignition transformer
TB
- Burner ground (earth) connection
XQ1
- Plug
XQ2
- Plug
XQ3
- Plug
XQ4
- Plug
21
22
23
75
19
22
20
25
21
8
SPARE PARTS LIST
17
30
7
9
31
4
6
12
29
15
40
26
5
28
13
3
74
28
14
32
11
39
37
27
38
43
44
10
73
36
41
33
1
52
2
76
42
35
46
45
16
45
54
53
34
69
51
24
56
65
60
57
65
50
62
65
47
49
70
61
64
65
55
68
18
63
66
58
48
67
72
71
59
C9744000 (3788073)*
C9744001 (3788073)*
C5360008
3012583
3013684
3003086
3013683
3012553
3013682
3003763
3013090
3012976
3013137
3013126
3012080
3012956
3013001
3012627
3013686
3012948
3013127
3013205
3012955
3012014
3006096
3012343
3006097
3007627
3012934
3012978
3013062
3012979
3012944
3012972
3012587
3003481
3013681
3003891
3012628
3012629
3012959
3013091
3012178
3012631
3013092
3012633
3012634
3013093
C9544001 (3788075)
1
1
2
2
3
3
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5
6
7
7
8
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C9544000 (3788070)
N. CODE
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* = Versione minima - Minimum Version
DESCRIPTION
DESCRIZIONE
AIR DAMPER ASSEMBLY
AIR DAMPER ASSEMBLY
GRID
GRID
SOUND DAMPING
SOUND DAMPING
INSPECTION WINDOW
PILOT TUBE
FAN
OVERLOAD+CONTACTOR 208-230V
OVERLOAD+CONTACTOR 575V
SWITCH
TRANSFORMER
U BOLT
BAR EXTENSION
BAR EXTENSION
AIR PRESSURE SWITCH
BASE PLATE
BASE PLATE
CONTROL BOX LFL 1.335
FERRULE
GAS REGULATOR
SUPPORT
FLAT SPRING
MEMBRAN
COVER
MOTOR
MOTOR
ANCHOR PLATE
SERVOMOTOR
SHAFT
HALF-SHELL
SCREW
SCREW
CONNECTOR
BAR
BRACKET
H.T. LEAD
ELECTROD
PROBE
TUBE
AIR DIFFUSER
GAS HEAD
INTERIOR TUBE
SUPPORT
GRUPPO SERRANDA
GRUPPO SERRANDA
PROTEZIONE
PROTEZIONE
FONOASSORBENTE
FONOASSORBENTE
VISORE
TUBO PILOTA
GIRANTE
RELE' + CONTATTORE 208-230V
RELE' + CONTATTORE 575V
INTERRUTTORE
TRASFORMATORE
CAVALLOTTO
PROLUNGA PERNO
PROLUNGA PERNO
PRESSOSTATO ARIA
MENSOLA
MENSOLA
APPRECCHIATURA LFL 1.335
GHIERA
REGOLATORE GAS
SUPPORTO
MOLLA
MEMBRANA
COFANO
MOTORE 208-230/460V
MOTORE 575V
PIASTRA
SERVOMOTORE
ALBERO
GUSCIO
VITE
VITE
RACCORDO
PERNO
STAFFA
COLLEGAMENTO ELETTRODO
ELETTRODO
SONDA
TUBETTO
TAZZA
DISTRIBUTORE
TUBO INTERNO
SUPPORTO
BURNER SERIAL NUMBER
MATRICOLA BRUCIATORE
≤ 02356XXXXXX
≥ 02366XXXXXX
≤ 02356XXXXXX
≥ 02366XXXXXX
≤ 02356XXXXXX
≥ 02366XXXXXX
≤ 02356XXXXXX
≥ 02366XXXXXX
≤ 02356XXXXXX
≥ 02366XXXXXX
≤ 02356XXXXXX
≤ 02356XXXXXX
C5360002
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C9744001 (3788073)*
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C9744000 (3788073)*
C5332011
3013094
3012637
3012958
3007891
3013095
3012969
3003996
3005482
3012971
3012352
3003841
3012356
3012646
3012594
3012595
3012049
3012639
3012640
3012641
3012642
3012643
3012647
3003322
3013096
3006132
3012644
3012600
3003543
3006098
3012601
3012354
3012358
3012350
3012357
3012602
3012603
3013055
3013010
3013229
3013685
C9544001 (3788075)
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C9544000 (3788070)
N. CODE
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* = Versione minima - Minimum Version
DESCRIPTION
DESCRIZIONE
EXTERIOR TUBE
ELBOW
PROBE LEAD
SEAL
CONNECTOR
GAS PRESSURE SWITCH
PLUG
SEAL
FLANGE AND ELBOW
BAR
BEARING
SPRING
TIE ROD
ANCHOR PLATE
AIR INTAKE
SCREW
CONTROL DEVICE
SLEEVE
BRACKET
SHUTTER
END CONE
CENTERING SUPPORT
CONNECTOR
MANIFOLD
SHAFT AND RING
GRADUATE SECTOR
TIE ROD
TIE ROD
PIN JOINT
LEVER
LEVER
CAM
LEVER
BEARING
SUPPORT
BAR
TUBE
CONTROL BOX BASE
PLUG
PLATES ASSEMBLY
TUBO ESTERNO
GOMITO
COLLEGAMENTO SONDA
GUARNIZIONE
RACCORDO
PRESSOSTATO GAS
TAPPO
GUARNIZIONE
FLANGIA E GOMITO
PERNO
CUSCINETTO
MOLLA
TIRANTE
PIASTRA
BOCCA D'ASPIRAZIONE
VITE
GRUPPO REGOLATORE
CILINDRO
STAFFA
OTTURATORE
IMBUTO FIAMMA
BASETTA
RACCORDO
MANICOTTO
ALBERO E ANELLO
QUADRANTE
TIRANTE
TIRANTE
SNODO SFERICO
LEVA
LEVA
CAMMA
LEVA
CUSCINETTO
SUPPORTO
PERNO
TUBO
ZOCCOLO
SPINA
GRUPPO PIASTRE
BURNER SERIAL NUMBER
MATRICOLA BRUCIATORE
≤ 02356XXXXXX
≤ 02356XXXXXX
≤ 02356XXXXXX
≥ 02366XXXXXX
≥ 02366XXXXXX
BURNER START UP REPORT
Model number:
Serial number:
Project name:
Start-up date:
Installing contractor:
Phone number:
GAS OPERATION
Gas Supply Pressure:
CO2: Low Fire
High Fire
Main Power Supply:
O2: Low Fire
High Fire
Control Power Supply:
CO: Low Fire
High Fire
Burner Firing Rate:
NOX: Low Fire
High Fire
Manifold Pressure:
Net Stack Temp - Low Fire:
High Fire:
Pilot Flame Signal:
Comb. Efficiency - Low Fire:
High Fire:
Low Fire Flame Signal:
Overfire Draft:
High Fire Flame Signal:
OIL OPERATION
Oil supply pressure:
CO2: Low Fire
High Fire
Oil suction pressure:
O2: Low Fire
High Fire
Control Power Supply:
CO: Low Fire
High Fire
Burner Firing Rate:
NOX: Low Fire
High Fire
Low Fire Flame Signal:
Net Stack Temp - Low Fire:
High Fire:
High Fire Flame Signal:
Comb. Efficiency - Low Fire:
High Fire:
Low Fire Nozzle Size:
Overfire Draft:
High Fire Nozzle Size:
Smoke number:
CONTROL SETTINGS
Operating Setpoint:
Low Oil Pressure:
High Limit Setpoint:
High Oil Pressure:
Low Gas Pressure:
Flame Safeguard Model Number:
High Gas Pressure:
Modulating Signal Type:
NOTES
25
RIELLO S.p.A.
I - 37045 Legnago (VR)
Tel.: +39.0442.630111
http:// www.rielloburners.com
RIELLO BURNERS NORTH AMERICA
1-800-4-RIELLO
35 Pond Park Road
Hingham, Massachusetts,
1-800-474-3556
U.S.A. 02043
2165 Meadowpine Blvd.
Mississauga, Ontario,
Canada L5N 6H6
http://www.riello-burners.com
Subject to modifications