Riello RS 160/M LN Quick start guide

2915849 (8) - 06/2014
Installation, use and maintenance instructions
Gas burners
Low-High-Low or Modulating Operation
CODE MODEL
20011691 RS 160/M LN
3788070 RS 160/M LN
3788075 RS 160/M LN
GB

1
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner models designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Firing rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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
Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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
Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Burner faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Procedure to refer burner operating condition in high
altitude plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
APPENDIX
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Burner start up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
WARNING
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 mainte-
nance can cause property damage, personal injury or death. Re-
fer to this manual for instructional or additional information.
Consult a certified installer, service representative or the gas
supplier for further assistance.
Burner shall be installed in accordance with manufacturers re-
quirementsasoutlined inthismanual,localcodesand authorities
having jurisdiction.

2
TECHNICAL DATA
(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)
ELECTRICAL DATA
Model RS 160/M LN
Output
(1)
MAX. kW
MBtu/hr 1032 - 2065 (1847 *) 3521 - 7046 (6302 *)
MIN. kW
MBtu/hr 333 1136
Fuel Natural gas
- max. delivery SCFH 7046
- pressure at max. delivery
(2)
“WC 7
Operation Low - high or modulating
Standard applications 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) 83.1
Model RS 160/M LN
Control circuit power supply
Main power supply (+/-10%) V/Ph/Hz V/Ph/Hz 120/1/60 208-220/3/60 120/1/60 460/3/60 120/1/60 575/3/60
Fan motor IE2
rpm
kW - HP
V
A
3430
4.0 - 5.5
208-230
13.2
3430
4.0 - 5.5
460
6.6
3540
4.0 - 5.5
575
5.3
Ignition transformer V1 - V2
I1 - I2 120 V - 1 x 8 kV 1.6 A - 20 mA
Electrical power consumption W 4550 4550 4600
Electrical control circuit cons. W max 750 750 750
Total electrical consumption W 5300 5300 5350
Electrical protection NEMA 1

3
BURNER MODELS DESIGNATIONS
ACCESSORIES (optional):
• TUBES KIT (see page 5): cod. 3010249
• THERMAL OVERLOAD
3013980: Thermal overload for 460 V power supply.
• GAS TRAIN ACCORDING TO UL STANDARDS: see page 9.
Model RBNA Code Riello Code Voltage Flame safeguard
RS 160/M LN tbd 20011691 208-230/3/60 Burner mounted
RS 160/M LN C9544000 3788070 460/3/60 Burner mounted
RS 160/M LN C9544001 3788075 575/3/60 Burner mounted
Important:
The installer is responsible for the supply and installation of any safety device(s) not indicated in this manual.

4
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 High gas pressure switch
5 Sleeve
6 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 but-
ton
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
Two types of burner failure may occur:
• FLAME SAFEGUARD LOCK-OUT:
if the flame relay 13)(A) pushbutton lights up, it indi-
cates that the burner is in lock-out.
To reset, press the pushbutton.
• MOTOR TRIP:
release by pressing the pushbutton on thermal over-
load 9)(A).
PACKAGING - WEIGHT (B) - Approximate measure-
ments
• 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.
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 1
3/8
”
1 - Cap for combustion head
1 - Disc for combustion head
1 - Instruction booklet
1 - Spare parts list
(A)
A B C lbs
52
3/4
“ 28
1/2
“ 30
29/32
“198
D36
(B)
A B C D E F (1) G H I (1) L M N O
26
13/16
“ 14
13/32
“ 12
13/32
“ 21
27/32
“ 33
31/32
“ 14
11/16
“ - 19
13/16
“ 8
11/16
” 16
15/16
” 56
49/64
” - 62
31/64
” 9
21/64
” 5
29/32
” 7
5/16
”
2 ”
(C)
D2791
D1702
(1) Blast tube: short - long (with kit)

5
FIRING RATE (A)
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 = 1136 MBtu/hr = 333 kW
Important
The FIRING RATE area values have been obtained con-
sidering an ambient temperature of 68 °F (20 °C), and
an atmospheric pressure of 394 “WC and with the com-
bustion 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.
MINIMUM FURNACE DIMENSIONS (B)
The firing rates were set in relation to certified test boil-
ers.
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
COMMERCIAL BOILERS (C) - IMPORTANT
The RS 160/M LN burner is suitable for operation on ei-
ther flame-inversion boilers*or boilers with combustion
chambers featuring flow from the base (three flue pass-
es) 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).
(*) 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 condi-
tions, the burner head is fitted with a second group of
pipes, with gas outlet in a different direction with re-
spect 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.
(A)
D2798
Combustion chamber pressure
“WC
(B)
D2919
10” max
D1079
(C)
Diameter (inches)
Length (feet)
Recommended furnace dimensions
Firing rate for C-UL Canadian Listing (CNL)
6302 MBtu/hr

6
GAS PRESSURE
The adjacent diagram shows minimum pressure losses
along the gas supply line depending on the maximum
burner output operation with natural gas.
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.
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 deliv-
ery must be measured at the gas meter.
(A)
D2441
(B)
1
2
D3188
∆p
[
“WC
]

7
INSTALLATION
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.
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 14
11/16
“.
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 sen-
sor probe (flame rod) is correctly set in position, as
shown in (C).
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 elec-
trode and then pull the burner completely off the slide
bars.
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.
If you noticed any irregularities in the positions of the
flame rod or ignition electrode during the check men-
tioned above, remove screw 1)(D), extract the internal
part 2)(D) of the head and set up the two components
correctly.
IGNITION PILOT ADJUSTMENT
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 “30-
V11”.
(C)
A B C
9
1/16
“ 12
25/32
“ - 14
1/2
“
5/8
W
D455
(A)
(E)
Probe
Electrode
(B)
D1706
Ignition
pilot
D2799
(D)
MB - Burner terminal strip
D2800
D2317

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. (A). It is now a very simple matter to set up the
combustion head, as this depends solely on the maxi-
mum output developed by the burner.
It is therefore essential to establish this value before pro-
ceeding 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.
➤ 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 satis-
factory and free of pulsations.
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 elec-
trode 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 advis-
able to gently draw out the high tension cable and flame
detection probe cable until they are slightly stretched.
IMPORTANT: In order to facilitate adjustment,
loosen screw 6)(A), adjust and then tighten.
(A)
(C)
(B)
Notches (Air = Gas)
Burner max output
(D)
D2801
D1707
D2367