Riello RS 45/M Quick start guide

20040407 (2) - 11/2014
Installation, use and maintenance instructions
Forced draught gas burner
Progressive two stage or modulating operation
CODE MODEL
20039998 RS 45/M
GB

1
20040407
GB
Contents
1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Delivery of the system and the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Burner models designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Packaging - weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Burner dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Firing rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7.1 Procedure to refer burner operating condition in high altitude plants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Commercial boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Minimum furnace dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Boiler plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7 Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8 Combustion head adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.9 Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.10 Gas supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10.1 Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10.2 Gas train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.10.3 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.11 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.11.1 Supply cables and external connections passage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.11.2 Honeywell control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.11.3 RM7840 ... sequence diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.12 Thermal relay calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.12.1 Electro-mechanical thermal relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.12.2 Electronic thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Notes on safety for the first start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Operations before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Burner start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Burner firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5 Burner calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5.1 Firing output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5.2 Maximum burner output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5.3 Minimum burner output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5.4 Intermediate outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

20040407
2
GB
Contents
5.5.5 Air pressure switch - CO check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5.6 Minimum gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6.1 Preliminary inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6.2 Measuring flame signal with keyboard display module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6.3 Measuring flame signal with a volt ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.4 Flame signal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.5 Inadequate flame signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7 Final checks (with the burner working) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Maintenance programme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.1 Maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.2 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 Opening the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 Closing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A Appendix - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B Appendix - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C Appendix - Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Information and general instructions
3
20040407
GB
1.1 Information about the instruction manual
1.1.1 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 sys-
tem. If the manual is lost or damaged, another copy must be
requested from the Technical Assistance Service 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 youwill see triangular DANGER signs.
Pay great attention to these, as they indicate a situation of potential
danger.
1.1.2 General dangers
The dangers can be of 3 levels, as indicated below.
1.1.3 Other symbols
Abbreviations used
Ch. Chapter
Fig. Figure
Page Page
Sec. Section
Tab. Table
1 Information and general instructions
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 lethal
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 HOOD AND
ALL THE SAFETY AND PROTECTION DEVICES
This symbol signals the obligation to reassemble
the hood 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 ma-
chine with respect for the environment.
IMPORTANT INFORMATION
This symbol indicates important information that
you must bear in mind.
➤This symbol indicates a list.

20040407
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Information and general instructions
1.1.4 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 recommends
the drawing up of a Maintenance Contract.
1.2 Guarantee and responsibility
The manufacturer guarantees its new products from the installation
date, 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 peo-
ple, 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, incorrectly
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;
➤use of the burner even following an error and/or an irregularity;
➤repairs and/or overhauls incorrectly carried out;
➤modification of the combustion chamber with inserts that pre-
vent the regular development of the structurally established
flame;
➤insufficient and inappropriate surveillance and care of those
burner components most likely to be subject to wear and tear;
➤the use of non-original components, including spare parts,
kits, accessories and optional;
➤force majeure.
The manufacturer furthermore declines any and every respon-
sibility for the failure to observe the contents of this manual.
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WARNING
Failure to observe the information given in this
manual, operating negligence, incorrect installation
and carrying out of non authorised modifications
will result in the annulment by the manufacturer of
the guarantee that it supplies with the burner.

Safety and prevention
5
20040407
GB
2.1 Introduction
The burners have been designed and built in compliance with cur-
rent 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, diathermic
oil, and to other uses expressly named by the manufacturer;
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 chamber
and the room temperature must all be within the values indicated in
the instruction manual.
➤Modification of the burner to alter its performance and destina-
tions is not allowed.
➤The burner must be used in exemplary technical safety condi-
tions. 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.
2.2 Personnel training
The user is the person, body or company that has acquired the ma-
chine and intends to use it for the specific purpose. He is responsi-
ble for the machine and for the training of the people working
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 indications
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:
2 Safety and prevention
WARNING
The manufacturer guarantees safety and proper
functioning only if all burner components are intact
and positioned correctly.
➤the user must take all the measures necessary
to prevent unauthorised people gaining access
to the machine;
➤the user must inform the manufacturer if faults
or malfunctioning of the accident prevention
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 manual.

20040407
6
GB
Technical description of the burner
3.1 Technical data
Tab. A
(*) Firing rate for C-UL Canadian Listing (CNL).
(1)
Reference conditions: ambient temperature 68 °F (20°C) - Barometric pressure 394” WC - Altitude 329 ft.
(2)
Pressure at test point 7) (Fig. 6, page 11) with zero pressure in the combustion chamber and maximum burner output.
(3)
Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
3.2 Electrical data
Tab. B
3.3 Burner models designation
Tab. C
3 Technical description of the burner
Model RS 45/M
Output
(1)
High MBtu/hr
kW 717 - 2037 (1969*) 210 - 597 (577*)
Low MBtu/hr
kW 341 100
Fuel Natural or propane gas
• Max delivery
• Pressure at maximum delivery
(2)
natural gas
SCFH
“ WC 2037 5.31
Operation Low - high-low or modulating
Standard application Boilers: water, steam, thermal oil
Ambient temperature °F 32 - 104 (0 - 40 °C)
Combustion air temperature °F max 140 (60 °C)
Noise levels
(3)
dB(A) 72
Model RS 45/EV
Control circuit power supply V/Ph/Hz 120/1/60
Main power supply (+/-10%) V/Ph/Hz 120/1/60
Fan motor
rpm
HP
V
A
3400
0.5
120
5.2
Ignition transformer V1 - V2
I1 - I2 120 V - 1 x 8 kV 1.6 A - 20 mA
Electrical power consumption W 600
Electrical control circuit cons. W max 750
Total electrical consumption W 1350
Electrical protection NEMA 1
Model Code Voltage Flame safeguard
RS 45/M 20039998 120/1/60 Burner mounted

Technical description of the burner
7
20040407
GB
3.4 Packaging - weight
The burners are skid mounted. Outer dimensions of packaging are
indicated in Tab. D.
The weight of the burner complete with packaging is indicated in
Tab. D.
Tab. D
3.5 Burner dimensions
The maximum dimensions of the burners are given in (Fig. 2).
Inspection of the combustion head requires the burner to be
opened and the rear part withdrawn on the slide bars.
The maximum dimension of the burner when open, without casing,
is give in measurement H.
Tab. E
(1)
Blast tube: short - long (obtainable with the kit)
3.6 Standard equipment
Gas train flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
Flange fixing screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 4
Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. 1
inch A B C lbs
RS 45/M 47
1
/
4“
23
5
/
8“
27
31
/
32“
152
Fig. 1
D36
inch A B C D
(1)
E F G H I L M
RS 45/M 25
31
/
32”
20
7
/
32”
26
3
/
4”
9
1
/
32”
- 13
15
/
16”
6
9
/
32”
13
5
/
16”
6
7
/
16”
37
7
/
32”
4
1
/
4”
6
5
/
8”
1
1
/
2”
DG
C
M
L
E
F
IA
B
H
D10233
Fig. 2

20040407
8
GB
Technical description of the burner
3.7 Firing rate
The burner can work in two ways: low and high fire.
MAXIMUM OUTPUT must be selected in area A (Fig. 3).
MINIMUM OUTPUT must not be lower than the minimum limit
shown in the diagram.
Tab. F
NOTE:
the firing rate areas given in Fig. 3 have been reduced by 10% with
respect to the maximum range that can be reached.
Consult procedure below to refer burner operating condition in high
altitude plants.
3.7.1 Procedure to refer burner operating condition
in high altitude plants
Find the CORRECTED BURNER CAPACITY for the plant’s alti-
tude in chart 1 and the CORRECTED PRESSURE in chart 2.
Check in the firing rate graph of the burner (Fig. 3), 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 temper-
ature = 68 °F, 20 °C)
➤To get the combined correction in case of different air temper-
ature, a compensation of 1000 ft each 20 °F (305 m each 11
°C) is applicable (100 ft = 2°F).
Example
Rated capacity = 1500 MBtu/hr - Rated air pressure = 1.5” WC
Real altitude = 3000 ft - Real temperature = 88 °F
∆= 88 °F - 68 °F (reference temp.) = 20 °F
(equivalent 1000 ft variation)
20 : 2 = 10 x 100 = 1000 ft
Proceeding as descripted above and considering a “virtual altitude”
of (3000 + 1000) ft:
– 1500 MBtu/hr at 4000 ft, the corrected capacity is 1713 MBtu/hr
– 1.5” WC at 4000 ft, the corrected burner air pressure is 1.71
Reference conditions:
– Ambient temperature 68 °F (20 °C)
– Barometric pressure 394” WC (1000 mbar)
– Altitude 328 ft a.s.l. (100 m a.s.l.).
Model MBtu/hr kW
RS 45/M 341 100
WARNING
The firing rate area values have been obtained con-
sidering an ambient temperature of 68 °F, and an
atmospheric pressure of 394” WC and with the
combustion head adjusted as shown at page 14.
Fig. 3
Combustion chamber pressure
“WC
Firing rate for C-UL Canadian Listing (CNL) - 1969 MBtu/hr
D2787

Technical description of the burner
9
20040407
GB
CORRECTED BURNER CAPACITY ACCORDING TO ALTITUDE
Altitude
Rated Capacity m a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
500 494 500 512 530 551 571 593 616 641 669
1000 987 1000 1023 1061 1101 1142 1186 1232 1282 1337
1500 1481 1500 1535 1591 1652 1713 1778 1848 1924 2006
2000 1974 2000 2046 2121 2202 2284 2371 2464 2565 2675
2500 2468 2500 2558 2652 2753 2855 2964 3079 3206 3343
3000 2962 3000 3069 3182 3303 3425 3557 3695 3847 4012
3500 3455 3500 3581 3712 3854 3996 4149 4311 4488 4680
4000 3949 4000 4092 4243 4404 4567 4742 4927 5130 5349
4500 4442 4500 4604 4773 4955 5138 5335 5543 5771 6018
5000 4936 5000 5116 5303 5505 5709 5928 6159 6412 6686
5500 5429 5500 5627 5834 6056 6280 6520 6775 7053 7355
6000 5923 6000 6139 6364 6606 6851 7113 7391 7694 8024
6500 6417 6500 6650 6894 7157 7422 7706 8006 8335 8692
7000 6910 7000 7162 7425 7708 7993 8299 8622 8977 9361
7500 7404 7500 7673 7955 8258 8564 8892 9238 9618 10029
8000 7897 8000 8185 8485 8809 9135 9484 9854 10259 10698
8500 8391 8500 8697 9016 9359 9705 10077 10470 10900 11367
9000 8885 9000 9208 9546 9910 10276 10670 11086 11541 12035
9500 9378 9500 9720 10076 10460 10847 11263 11702 12183 12704
10000 9872 10000 10231 10607 11011 11418 11855 12318 12824 13373
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
CORRECTED BURNER AIR PRESSURE ACCORDING TO ALTITUDE
Altitude
Rated Pressure m a.s.l. 0 100 305 610 915 1220 1525 1830 2135 2440
ft a.s.l 0 328 1000 2000 3000 4000 5000 6000 7000 8000
0.50 0.49 0.50 0.51 0.53 0.55 0.57 0.59 0.62 0.64 0.67
1.00 0.99 1.00 1.02 1.06 1.10 1.14 1.19 1.23 1.28 1.34
1.50 1.48 1.50 1.53 1.59 1.65 1.71 1.78 1.85 1.92 2.01
2.00 1.97 2.00 2.05 2.12 2.20 2.28 2.37 2.46 2.56 2.67
2.50 2.47 2.50 2.56 2.65 2.75 2.85 2.96 3.08 3.21 3.34
3.00 2.96 3.00 3.07 3.18 3.30 3.43 3.56 3.70 3.85 4.01
3.50 3.46 3.50 3.58 3.71 3.85 4.00 4.15 4.31 4.49 4.68
4.00 3.95 4.00 4.09 4.24 4.40 4.57 4.74 4.93 5.13 5.35
4.50 4.44 4.50 4.60 4.77 4.95 5.14 5.33 5.54 5.77 6.02
5.00 4.94 5.00 5.12 5.30 5.51 5.71 5.93 6.16 6.41 6.69
5.50 5.43 5.50 5.63 5.83 6.06 6.28 6.52 6.77 7.05 7.35
6.00 5.92 6.00 6.14 6.36 6.61 6.85 7.11 7.39 7.69 8.02
6.50 6.42 6.50 6.65 6.89 7.16 7.42 7.71 8.01 8.34 8.69
7.00 6.91 7.00 7.16 7.42 7.71 7.99 8.30 8.62 8.98 9.36
7.50 7.40 7.50 7.67 7.96 8.26 8.56 8.89 9.24 9.62 10.03
8.00 7.90 8.00 8.18 8.49 8.81 9.13 9.48 9.85 10.26 10.70
8.50 8.39 8.50 8.70 9.02 9.36 9.71 10.08 10.47 10.90 11.37
9.00 8.88 9.00 9.21 9.55 9.91 10.28 10.67 11.09 11.54 12.04
9.50 9.38 9.50 9.72 10.08 10.46 10.85 11.26 11.70 12.18 12.70
10.00 9.87 10.00 10.23 10.61 11.01 11.42 11.86 12.32 12.82 13.37
Average barometric
pressure (20°C) mbar 1013 1000 977.4 942.8 908.2 875.8 843.5 811.85 779.8 747.8
Average barometric
pressure (68°F) "w.c. 399 394 385 371 358 345 332 320 307 294
1
2

20040407
10
GB
Technical description of the burner
3.8 Commercial boilers
The burner is suitable for operation on either flame-inversion boil-
ers 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 ex-
ceed 8” (see Fig. 4).
3.9 Minimum furnace dimensions
The firing rates were set in relation to certified test boilers.
Fig. 5 indicates the diameter and length of the test combustion
chamber.
Example
Output 1388 MBtu/hr:
diameter 20 inch - length 4.9 ft
Fig. 4
8” max
D1079
D2918
Length (ft)
Furnace dimensions
Diameter (inches)
Fig. 5

Technical description of the burner
11
20040407
GB
3.10 Burner description
1 Combustion head
2 Ignition pilot
3 Screw for combustion head adjustment
4 Sleeve
5 Low air pressure switch
6 Air pressure test point
7 Gas pressure test point and head fixing screw
8 Screw securing fan to sleeve
9 Slide bars for opening the burner and inspecting the combus-
tion head
10 “ALARM” signal
11 Pilot attachment
12 Ignition transformer “TA”
13 Servomotor
14 UV scanner
15 Plate with four hole knock-outs for electrical cable routing
16 Air inlet to fan
17 Gas input connection
18 Boiler mounting flange
19 Flame stability disk
20 Flame inspection window
21 “ALARM SILENCE” button
22 Fan motor contactor and thermal overload with reset button
23 Flame safeguard with lock-out pilot light and lock-out reset
button
24 “AUTO - MAN” switch
25 RWF40 terminal board “X3”
26 “K1” relay
27 “K3” relay
28 “K min.” relay
29 “K max.” relay
30 Optional holes
31 Fan motor with capacitor
32 Ground terminals
33 Horn
34 DIN bar available for accessory
35 Auxiliary fuse
36 Power supply entry cable
37 “ON - OFF” switch
38 “POWER ON” signal
39 “CALL FOR HEAT” signal
40 “IGNITION ON” signal
41 “FUEL ON” signal
42 Burner terminal board “X1”
43 “MANUAL +/-” switch
44 RWF40 modulator. Available
45 Knockouts foe electrical connections by installer
Two types of burner failure may occur:
➤Flame safeguard lock-out
If the flame safeguard alarm 23) lights up, it indicates that the
burner is in lock-out. To reset, press the reset pushbutton.
➤Motor trip
release by pressing the pushbutton on thermal overload, see
“Thermal relay calibration” page 21.
3
7
914
15
16
17
18
19
11
5
20
22
23
42
12
25
28
29
26 27
1
2
4
6
30
13
24
21
10
37
8
40 41 30
39
38
43
44
34
35
36
36
32 31
45
33
Fig. 6
D11844

20040407
12
GB
Installation
4.1 Notes on safety for the installation
After carefully cleaning all around the area where the burner will be
installed, and arranging the correct lighting of the environment, pro-
ceed with the installation operations.
4.2 Handling
The packaging of the burner includes a wooden platform, so it is
possible to move the burner (still packaged) with a transpallet truck
or fork lift truck.
4.3 Preliminary checks
Checking the consignment
4.4 Boiler plate
Drill the combustion chamber mounting plate as shown in Fig. 7.
The position of the threaded holes can be marked using the head
gasket supplied with the burner.
Tab. G
4 Installation
DANGER
All the installation, maintenance and disassembly
operations must be carried out with the electricity
supply disconnected.
WARNING
The installation of the burner must be carried out by
qualified personnel, as indicated in this manual and
in compliance with the standards and regulations of
the laws in force.
WARNING
The handling operations for the burner can be high-
ly dangerous if not carried out with the greatest at-
tention: keep any unauthorised people at a
distance; check the integrity and suitableness of the
available means of handling.
Check also that the area in which you are working
is empty and that there is an adequate escape area
(i.e. a free, safe area to which you can quickly move
if the burner should fall).
During the handling, keep the load at not more than
20-25 cm from the ground.
CAUTION
After positioning the burner near the installation
point, correctly dispose of all residual packaging,
separating the various types of material.
Before proceeding with the installation operations,
carefully clean all around the area where the burner
will be installed.
CAUTION
After removing all the packaging, check the integrity
of the contents. In the event of doubt, do not use the
burner; contact the supplier.
The packaging elements (wooden cage or card-
board box, nails, clips, plastic bags, etc.) must not
be abandoned as they are potential sources of dan-
ger and pollution; they should be collected and dis-
posed of in the appropriate places.
WARNING
The output of the burner must be within the boil-
er’s firing rate;
WARNING
A burner label that has been tampered with, re-
moved or is missing, along with anything else that
prevents the definite identification of the burner
makes any installation or maintenance work diffi-
cult.
inch A B C
RS 45/M 6
9
/
32“
8
13
/
16“ 3
/
8
W
D455
Fig. 7

Installation
13
20040407
GB
4.5 Blast tube length
The length of the blast tube must be selected according to the indi-
cations provided by the manufacturer of the boiler, and it must be
greater than the thickness of the boiler door complete with its insu-
lation.
The range of lengths available, L (inch), is as follows:
➤For boilers with front flue passes 6) or flame inversion cham-
bers, protective insulation 4) must be inserted between the
boiler refractory 5) and the blast tube 3).
➤This protective insulation must not compromise the extraction
of the blast tube.
➤For boilers having a water-cooled front the insulation 4)-5)
(Fig. 8) is not required unless it is required by the boiler manu-
facturer.
4.6 Securing the burner to the boiler
➤Secure the flange 2)(Fig. 8) to the boiler plate, inserting the
gasket 1)(Fig. 8).
➤Use the 4 screws, after first protecting the thread with an anti-
locking product.
➤The seal between burner and boiler must be airtight.
4.7 Ignition pilot adjustment
Place the pilot and electrode as shown in Fig. 9.
The pilot works correctly at pressures ranging from 5 - 12” WC.
Model L
(short blast tube) L (long blast tube)
RS 45/M 9
1
/
32
“ 13
15
/
16
“
3
65
4
6
1
2
L
Fig. 8
D10436
5/16"
1/8"
Fig. 9
D10437

20040407
14
GB
Installation
4.8 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. 10.
It is now a very simple matter to set up the combustion head, as this
depends solely on the output developed by the burner at maximum
power.
It is therefore essential to establish this value before proceeding to
set up the combustion head.
There are three adjustments to make on the head:
• outside air R1
• central air R2
• gas deliveries R3
In diagram (Fig. 11) find the notch to use for adjusting the air and
the gas, and then proceed as follows:
Outside air adjustment R1 (Fig. 10)
➤Turn screw 4) until the notch identified is aligned with the front
surface 5) of the flange.
Gas adjustment R3 (Fig. 10)
➤Loosen screws 1)(B) and 4)(B) and turn ring 2) until the notch
identified is aligned with index 3).
Central air adjustment R2 (Fig. 10)
➤Turn choke 5) until the notch identified is aligned with screw
4).
➤Tighten the screws 1) and 4) fully down.
Example
Burner output = 1515 MBtu/hr.
If we consult diagram (Fig. 11) we find that for this output, the ad-
justments are:
• outside air R1 = 5.3
• central air R2 = 2.7
• gas R3 = 0.7
➤Once you have finished setting up the head, insert the ignition
electrode cable and then slide the burner up to the sleeve so
that it is positioned as shown in Fig. 12.
➤Secure the burner to the sleeve by tightening screw 1).
➤Reconnect the swivel connector 8) to the cam 7).
➤Connect gas train and pilot train as shown in Fig. 14.
WARNING
The fan part of the burner shall be completely back-
ward using the guides.
WARNING
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.
6 4 (R1)
0
1
2
3
5
1
2 (R3)
4
3
5 (R2)
Fig. 10
AIR
GAS
D10450
Fig. 11
Burner max output
Notches (Air = Gas)
7
18
Fig. 12
D10237

Installation
15
20040407
GB
4.9 Servomotor
The servomotor (Fig. 13) provides simultaneous adjustment of the
air damper, by means of the variable profile cam, and the gas but-
terfly valve.
The angle of rotation of the servomotor is equal to the angle on the
graduated sector controlling the gas butterfly valve.
The servomotor rotates through 90 degrees in 25 seconds.
Do not alter the factory setting for the cams; simply check that they
are set as indicated below:
•Red cam : 90°
Limits rotation toward maximum position.
When the burner is at max output the gas butterfly valve must
be fully open: 90°.
•Blue cam : 0°
Limits rotation toward the minimum position.
When the burner is shut down the air damper and the gas but-
terfly valve must be closed: 0°.
•Orange cam : 15°
Adjusts the ignition position and the MIN output.
Fig. 13
Blue camRed cam Orange cam
Reset
D2266

20040407
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Installation
4.10 Gas supply
4.10.1 Gas piping
The main gas train must be connected to the gas attachment
1)(Fig. 14), using flange 2), gasket 3) and screws 4) supplied with
the burner.
The main gas train can enter the burner from the right or left side,
depending on which is the most convenient.
Gas safety shut-off valves 5)-6)(Fig. 15) must be as close as pos-
sible 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)(Fig. 14) and can enter the burner from the right or left side.
4.10.2 Gas train
It must be type-approved according to UL Standards and is sup-
plied separately from the burner.
Key to layout
1 Gas input pipe
2 Manual valve
3 Pressure regulator
4 Low gas pressure switch
5 1
st
safety shut off valve
6 2
nd
safety shut off valve
7 Standard issue burner gasket with flange
8 Gas adjustment butterfly valve
9 Burner
Explosion danger due to fuel leaks in the presence
of a flammable source.
Precautions: avoid knocking, attrition, sparks and
heat.
Make sure that the fuel interception tap is closed
before performing any operation on the burner.
WARNING
The fuel supply line must be installed by qualified
personnel, in compliance with current standards
and laws.
DANGER
Disconnect the electrical power using the main sys-
tem switch.
Check that there are no gas leaks.
Beware of train movements: danger of crushing of
limbs.
Make sure that the gas train is properly installed by
checking for any fuel leaks.
The operator must use appropriate tools for instal-
lation.
WARNING
See the accompanying instructions for the ad-
justment of the gas train.
Fig. 14
D2293
Fig. 15
D2294
GAS PILOT LINE
MAIN GAS LINE

Installation
17
20040407
GB
4.10.3 Gas pressure
The Tab. H is used to calculate manifold pressure taking into ac-
count combustion chamber pressure.
Gas manifold pressure measured at test point 1)(Fig. 16), with:
• combustion chamber at 0” WC;
• burner operating at maximum output;
• column 1: gas ring R2-R3)(Fig. 10) adjusted as indicated in di-
agram (Fig. 11);
• column 2: pressure loss at gas butterfly valve 8)(Fig. 15) with
maximum opening: 90°.
Calculate the approximate maximum output of the burner as fol-
lows:
➤subtract the combustion chamber pressure from the gas pres-
sure measured at test point 1)(Fig. 16);
➤find the nearest pressure value to your result in column 2 for
the burner in question;
➤read off the corresponding output on the left.
Example with natural gas G20
– Maximum output operation
– Gas ring 2-5)(Fig. 10) adjusted as indicated in diagram
(Fig. 11)
– Gas pressure at test point 1)(Fig. 16) = 3.69“ WC
– Pressure in combustion chamber = 0.79“ WC
3.69 - 0.79 = 2.90“ WC
A maximum output of 1136 MBtu/hr shown in Tab. H corresponds
to 2.90” WC pressure, column 1.
This value serves as a rough guide, the effective delivery must be
measured at the gas meter.
Tab. H
MBtu/hr kW ∆
∆∆
∆p (“WC)
1 2
720 211 1.38 0.12
949 278 2.16 0.15
1136 333 2.90 0.19
1327 389 3.66 0.23
1515 444 4.21 0.27
1706 500 4.72 0.31
1894 555 5.12 0.35
2085 611 5.31 0.39
Fig. 16
D2786

20040407
18
GB
Installation
4.11 Electrical wiring
Notes on safety for the electrical wiring
Before carrying out any maintenance, cleaning or checking opera-
tions:
If the hood is still present, remove it and proceed with the electrical
wiring according to the wiring diagrams.
4.11.1 Supply cables and external connections
passage
All the cables to be connected to the burner are fed through the
grommets.
The use of the cable grommets can take various forms.
By the way of example we indicate the following mode (Fig. 17)
(according to UL795):
1 Three phase power supply with
1
/
2
” cable grommet;
Single phase power supply with
1
/
2
” cable grommet.
2 Available:
Consents/safety, minimum gas pressure switch, gas valves
and other devices with
3
/
8
” cable grommet.
3 Available: maximum gas pressure switch (kit) and other
4 Horn
5 Available: step down transformer
DANGER
➤The electrical wiring must be carried out with the electrical supply disconnected.
➤Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in force in
the country of destination. Refer to the electrical layouts.
➤The manufacturer declines all responsibility for modifications or connections different from those shown in the electri-
cal layouts.
➤Check that the electrical supply of the burner corresponds to that shown on the identification label and in this manual.
➤Do not invert the neutral with the phase in the electrical supply line.
Any inversion would cause a lockout due to firing failure.
➤The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system, made
according to current standards.
It is necessary to check this fundamental safety requirement. In the event of doubt, have the electrical system
checked by qualified personnel.
Do not use the gas tubes as an earthing system for electrical devices.
➤The electrical system must be suitable for the maximum input power of the device,as indicated on the label and in the
manual, checking in particular that the section of the cables is suitable for the input power of the device.
➤For the main power supply of the device from the electricity mains:
➤- do not use adapters, multiple sockets or extensions;
➤- use an omnipolar switch with an opening of at least
1
/
8
” (overvoltage category) between the contacts, as indicated
by the current safety standards.
➤Do not touch the device with wet or damp body parts and/or in bare feet.
➤Do not pull the electric cables.
DANGER
Disconnect the electrical supply from the burner by
means of the main system switch.
DANGER
Close the fuel interception tap.
DANGER
Avoid condensate, ice and water leaks from form-
ing.
WARNING
The control panel is in compliance with UL508A.
After carrying out maintenance, cleaning or check-
ing operations, reassemble the hood and all the
safety and protection devices of the burner.
D10369
1
2
5
2
4
3
Fig. 17