Riello RS 68/M LN Quick start guide

Installation, use and maintenance instructions
Gas Burners
RS 68/M LN - RS 120/M LN
Low-High-Low or Modulating Operation
C6505072 - 2915848 (5) - 06/2011

2
CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Standard equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Commercial boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Boiler mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion head adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustments before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maximum output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Minimum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Intermediates outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Procedure to refer burner operating condition in high
altitude plants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Siemens LFL control sequence of operations . . . . . . . . . . . . . . 17
Siemens LFL control troubleshooting guide. . . . . . . . . . . . . . . . 18
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Factory wiring diagram -burner mounted LFL . . . . . . . . . . . . . . 20
Field wiring diagram - burner mounted LFL . . . . . . . . . . . . . . . . 20
Calibration of the thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . 21
Factory wiring diagram - remote panel. . . . . . . . . . . . . . . . . . . . 22
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Burner start up report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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-
quirementsasoutlinedin thismanual, localcodesandauthorities
having jurisdiction.

3
TECHNICAL DATA
(1) Reference conditions: Ambient temperature 68 °F (20 °C) - Barometric pressure 394 “WC - Altitude 329 ft a.s.l.
(2) Pressure at test point 16)(A)p.5, with zero pressure in the combustion chamber, with open gas ring 2)(B)p.9 at maximum burner output.
(3) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.
Fan motor IE1
Three phase burner
Model RS 68/M LN RS 120/M LN
Output (1) MAX. MBtu/hr
kW 1327 - 3258 389 - 955 2272 - 4924 666 - 1443
MIN. MBtu/hr
kW 570 167 1136 333
Fuel Natural gas
- Max. delivery SCFH 3258 4924
- Pressure at max. delivery (2) “WC 4.60 8.85
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) dBA 75 77
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 208 - 230/3/60
Fan motor rpm
W - HP
V
A
3360
1800 - 2.4
208 - 230
7.4
3400
2200 - 3
208 - 230
8.5
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2350 2750
Electrical control circuit coms. W750
Total electrical consumption W3100 3500
Electrical protection NEMA 1
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 460/3/60
Fan motor rpm
W - HP
V
A
3360
1800 - 2.4
460
4.3
3400
2200 - 3
460
4.9
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2750 3150
Electrical control circuit coms. W750
Total electrical consumption W3500 3900
Electrical protection NEMA 1
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 575/3/60
Fan motor rpm
W - HP
V
A
3420
1800 - 2.4
575
2.8
3400
2200 - 3
575
3.7
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2250 2900
Electrical control circuit coms. W750
Total electrical consumption W3000 3650
Electrical protection NEMA 1

4
Fan motor IE2/EPACT
Three phase burner
Burner models
ACCESSORIES (optional):
• Available auxiliary panels
•Tubes kit (see page 8):
RS 68/M LN cod. 3010247
RS 120/M LN cod. 3010248
• Gas train according to UL regulation: see page 10.
Important: The installer is responsible for the supply and installation of any safety device(s) not indicated in this manual.
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 208-230/3/60
Fan motor rpm
W - HP
V
A
3500
2200 - 3
208-230
7.8
3500
2200 - 3
208-230
7.8
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2600
Electrical control circuit coms. W750
Total electrical consumption W3350
Electrical protection NEMA 1
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 460/3/60
Fan motor rpm
W - HP
V
A
3500
2200 - 3
460
3.9
3500
2200 - 3
460
3.9
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2600
Electrical control circuit coms. W750
Total electrical consumption W3350
Electrical protection NEMA 1
Model RS 68/M LN RS 120/M LN
Control circuit power supply V/Ph/Hz 120/1/60
Main electrical supply (+/- 10%) V/Ph/Hz 575/3/60
Fan motor rpm
W - HP
V
A
3500
2200 - 3
575
3.1
3500
2200 - 3
575
3.1
Ignition transformer V1 - V2
I1 - I2 120 V - 1 X 8 kV 1.6 A - 20 mA
Electrical power consumption W max 2600
Electrical control circuit coms. W750
Total electrical consumption W3350
Electrical protection NEMA 1
Model Code Voltage Flame safeguard
RS 68/M LN C9542000 (3897470) C9542001 (3897475)
C9742001 (3897473)
208-230/460/3/60
575/3/60
575/3/60
Burner mounted
Burner mounted
In an auxiliary panel (see Accessories)
RS 120/M LN
C9543000 (3897670)
C9543001 (3897675)
C9743000 (3897673)
C9743001 (3897673)
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)
Control panel code Flame safeguard type
3010332 Fireye
3010336 Landis
3010338 Honeywell

5
BURNER DESCRIPTION (A)
1 Combustion head
2 Ignition electrode
3 Screw for combustion head adjustment
4 High gas pressure switch
5 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
6 Plug-socket on ionisation proble cable
7 Extensions for slide bars 15) (supplied by kit)
8 Motor contactor and thermal overload with reset but-
ton
9 Power switch for different operations:
automatic - manual - off
Button for:
power increase - power reduction
10 Terminal strip for electrical connection
11 Pilot burner attachment
12 Flame safeguard with lock-out pilot light and lock-out
reset button
13 Flame inspection window
14 Low air pressure switch
(differential operating type)
15 Slide bars for opening the burner and inspecting the
combustion head
16 Gas pressure test point and head fixing screw
17 Air pressure test point
18 Flame sensor probe (flame rod)
19 Pilot burner
20 Air inlet to fan
21 Screws securing fan to sleeve
22 Gas input pipework
23 Gas butterfly valve
24 Boiler mounting flange
25 Flame stability disk
26 Air damper
Two types of burner failure may occur:
• FLAME SAFEGUARD LOCK-OUT:
if the flame relay 12)(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 8)(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 burner 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 3/8W x 1”
1 - Burner head gasket
2 - Extensions 7)(A) for slide bars 15)(A)
(for kit)
4 - Screws to secure the burner flange to the boiler:
1/2 W
1 - Instruction booklet
1 - Spare parts list
(A)
(B)
D2792
D36
D731
inch A (1) B C lbs
RS 68/M LN 4627/32“ - 525/32“29
1/8“27 1/4“154
RS 120/M LN 4627/32“ - 525/32“29
1/8“27 1/4“167
(C)
(1) Blast tube: short - long (obtainable with kit)
inch A B C D E F (1) G H I (1) L M N O
RS 68/M 203/4“12
9/32“8 15/32“21 27/32“33 1/16“ 10“ - 153/8“7 7/16“16 29/32“45 11/16“ - 511/32“8 13/32“5 9/32“8 11/16“2”
RS 120/M 2125/32“13
5/16“8 15/32“21 27/32“33 1/16“ 10“ - 153/8“7 7/16“16 29/32“45 11/16“ - 511/32“8 13/32“5 9/32“8 11/16“2”