Installation, use and maintenance instructions

Gas Burners

RS 70/M - 100/M - 130/M

Low-High-Low or Modulating Operation

C6505056 - 2915766 (0)

2

CONTENTS

TECHNICAL DATA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page

3

Burner models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Packaging - Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Max. dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Minimum furnace dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 7Ignition pilot adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Adjustments before first firing. . . . . . . . . . . . . . . . . . . . . . . . . . . 10Servomotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Burner starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13High gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Low gas pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Flame present check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Factory wiring diagram -burner mounted LFL . . . . . . . . . . . . . . 15Field wiring diagram - burner mounted LFL . . . . . . . . . . . . . . . . 16Factory wiring diagram - remote panel. . . . . . . . . . . . . . . . . . . . 17Appendix - Burner firing rates according to air density. . . . . . . . 18 Siemens LFL control sequence of operations . . . . . . . . . . . . . . 19Siemens LFL controltroubleshooting guide . . . . . . . . . . . . . . . . 20Burner 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 main-tenance can cause property damage, personal injury or death. Refer to this manual for instructional or additional in-formation. Consult a certified installer, service representative or the gas supplier for further assistance.

Burner shall be installed in accordance with manufacturers requirements as outlined in this manual, local codes and au-thorities having juristiction.

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.4, with zero pressure in the combustion chamber, with open gas ring 2)(B)p.8 an maximum burner output(2) Sound pressure measured in manufacturer’s combustion laboratory, with burner operating on test boiler and at maximum rated output.

Burner models designations

ACCESSORIES

(optional):

•

Kit for LPG operation:

The kit allows the RS 70-100-130/M burners to operate on LPG.

•

Kit for lengthening the combustion head

L = Standard lengthL1 = Length obtainable with the kit

COD. 3010259 L = 9

27/32

“ L1 = 15

5/32

“ • RS 70/MCOD. 3010260 L = 9

27/32

“ L1 = 15

5/32

“ • RS 100/MCOD. 3010261 L = 11

1/32

“ L1 = 16

11/32

“ • RS 130/M

•

Gas train according to UL regulation:

see page 9.

MODEL RS 70/M RS 100/M RS 130/M

Output

(1)

MAX. MBtu/hrkW

1761 - 3084516 - 904

2644 - 4405775 - 1291

3521 - 55451032 - 1625

MIN. MBtu/hrkW

512150

570167

607178

Fuel Natural or Propane gas- Max. delivery SCFH 3084 4405 5545- Pressure at max. delivery

(2)

“WC 4.06 3.66 3.20

Operation Low - high or modulatingStandard applications Boilers: water, steam, thermal oilAmbient temperature °F 32 - 104 (0 - 40 °C)Combustion air temperature °F max 140 (60 °C)Main electrical supply (+/- 10%) V/Ph/Hz 208 - 230/460/575/3/60Fan motor rpm

W - HPVA

34001100 - 1.5

208-230/460/5754.8/2.8/2.3

34001800 - 2.5

208-230/460/5756.7/3.9/3.2

34002200 - 3

208-230/460/5758.8/5.1/4.1

Ignition transformer V1 - V2I1 - I2

120 V - 1 x 8 kV1.7 A - 20 mA

Electrical power consumption W max 1400 2200 2600Electrical protection NEMA 1Noise levels

(3)

dBA 75 77 78,5

Model Code Voltage Flame safeguard

RS 70/M

C9524300

(3787070)

C9524301

(3787070)

C9624300

(3787072)

C9624301

(3787072)

208-230/460/3/60575/3/60

208-230/460/3/60575/3/60

Burner mountedBurner mountedRemote panelRemote panel

RS 100/M

C9525300

(3787270)

C9525301

(3787270)

C9625300

(3787272)

C9625301

(3787272)

208-230/460/3/60575/3/60

208-230/460/3/60575/3/60

Burner mountedBurner mountedRemote panelRemote panel

RS 130/M

C9526300

(3787470)

C9526301

(3787470)

C9626300

(3787472)

C9626301

(3787472)

208-230/460/3/60575/3/60

208-230/460/3/60575/3/60

Burner mountedBurner mountedRemote panelRemote panel

BURNER RS 70/M RS 100/M RS 130/M

OUTPUT MBtu/hr 918 - 3084 1320 - 4405 1764 - 5545

CODE 3010273 3010274 3010275

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 head2 Ignition electrode3 Screw for combustion head adjustment4 High gas pressure switch5 Servomotor controlling the gas butterfly valve and the

air damper (by means of a variable profile cam mech-anism).When the burner is stopped the air damper will becompletely closed to reduce heat loss

6 Plug-socket on flame rod cable7 Extensions for slide bars 15) (supplied by kit)8 Motor contactor and thermal overload with reset but-

ton9 Power switch for different operations:

automatic - manual - offButton for:power increase - power reduction

10 Terminal strip for electrical connection11 Pilot burner attachment12 Flame safeguard with lock-out pilot light and lock-out

reset button13 Flame inspection window14 Low air pressure switch

(differential operating type)15 Slide bars for opening the burner and inspecting the

combustion head16 Gas pressure test point and head fixing screw17 Air pressure test point18 Flame sensor probe (flame rod)19 Pilot burner20 Air inlet to fan21 Screws securing fan to sleeve22 Gas input pipework23 Gas butterfly valve24 Boiler mounting flange25 Flame stability disk26 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 measurementsThe maximum dimensions of the burners are given in(C).Bear in mind that inspection of the combustion headrequires the burner to be opened by withdrawing therear part on the slide bars.The maximum dimension of the burner, when open isgive by measurement I.

STANDARD EQUIPMENT

1 - Gas train flange1 - Flange gasket4 - Flange fixing screws

3/8

W x 1”1 - Burner head gasket2 - Extensions 7)(A) for slide bars 15)(A)

(for kit)4 - Screws to secure the burner flange to the boiler:

1/2

W1 - Instruction booklet1 - Spare parts list

(A)

(B)

D2388

D36

D731

inch A (1) B C lbs

RS 70/M 4627/32“ - 525/32“ 291/8“ 271/4“ 154

RS 100/M 4627/32“ - 525/32“ 291/8“ 271/4“ 161

RS 130/M 4627/32“ - 525/32“ 291/8“ 271/4“ 168

(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 70/M 201/8“ 1121/32“ 815/32“ 2127/32“ 331/16“ 927/32“ - 155/32“ 71/32“ 1629/32“ 4511/16“ - 511/32“ 813/32“ 59/32“ 811/16“ 2”

RS 100/M 203/4“ 129/32“ 815/32“ 2127/32“ 331/16“ 927/32“ - 155/32“ 71/32“ 1629/32“ 4511/16“ - 511/32“ 813/32“ 59/32“ 811/16“ 2”

RS 130/M 2125/32“ 135/16“ 815/32“ 2127/32“ 331/16“ 111/32“ - 1611/32“ 73/32“ 1629/32“ 4511/16“ - 511/32“ 813/32“ 59/32“ 811/16“ 2”

5

FIRING RATES (A)

During operation, burner output varies between:

• MAXIMUM OUTPUT

, selected within area A,

•

and

MINIMUM OUTPUT

, which must not be lowerthan the minimum limit in the diagram.

RS 70/M = 512 MBtu/hrRS 100/M = 568 MBtu/hrRS 130/M = 607 MBtu/hr

Note

In order to utilize also area B (RS 130/M) it is necessaryto perform the calibration of the combustion head asexplained on page 7.

Important

The FIRING RATE area values have been obtained con-sidering an ambient temperature of 68 °F (20 °C), andan 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 beenreduced by 10% with respect to the maximum range thatcan be reached.

Consult Appendix on page 18 for operation at differentsurrounding temperatures and/or altitudes.

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 testcombustion chamber.

Example:

Output 2579 MBtu/hr:diameter = 24 inch; length 6.6 ft

(A)

com

bust

ion

cham

ber p

ress

ure

“W

C

RS 70/M

RS 100/M

RS 130/M

D2389

(B)

com

bust

ion

cham

ber p

ress

ure

“W

Cco

mbu

stio

n ch

ambe

r pre

ssur

e “

WC

D2919

Diameter (inches)

Leng

th (

ft)F

urna

ce d

imen

sion

s

6

GAS PRESSURE

The adjacent tables show minimum pressure lossesalong the gas supply line depending on the maximumburner output operation with natural gas.

Column 1Pressure loss at combustion head.Gas pressure measured at test point 1)(B), with:• Combustion chamber at 0 “WC• Burner operating at maximum output• Gas ring 2)(B)p.8 adjusted as indicated in diagram

(C)p.8.

Column 2Pressure loss at gas butterfly valve 2)(B) with maximumopening: 90°.

Calculate the approximate maximum output of theburner 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 col-

umn 1 of the table for the burner in question.- Read off the corresponding output on the left.

Example - RS 100/M:

• Maximum output operation• Natural gas• Gas ring 2)(B)p.8 adjust as indicated in diagram

(C)p.8• Gas pressure at test point 1)(B) = 3.15 “WC• Pressure in combustion chamber = 1.18 “WC

3.15 - 1.18 = 1.97 “WCA maximum output of 2815 MBtu/hr shown in Table RS100/M corresponds to 1.97 “WC pressure, column 1.This value serves as a rough guide, the effective deliv-ery must be measured at the gas meter.

To calculate the required gas pressure at test point1)(B), set the maximim output required from the burneroperation:- Find the nearest output value in the table for the

burner in question.- Read off the pressure at test point 1)(B) on the right in

column 1.- Add this value to the estimated pressure in the com-

bustion chamber.

Example - RS 100/M:

• Required burner maximum output operation: 2815 MBTU/h

• Natural gas• Gas ring 2)(B)p.8 adjust as diagram (C)p.8• Gas pressure at burner output of 2815 MBtu/hr, taken

from table RS 100/M, column 1 = 1.97 “WC• Pressure in combustion chamber = 1.18 “WC

1.97 + 1.18 = 3.15 “WCpressure required at test point 1)(B).

(A)

RS 70/M ∆p (“WC)

RS 100/M ∆p (“WC)

RS 130/M ∆p (“WC)

MBtu/hr kW 1 2

1761 516 1.65 0.08

1952 572 1.89 0.08

2139 627 2.20 0.12

2330 683 2.52 0.12

2518 738 2.87 0.12

2709 794 3.27 0.16

2897 849 3.66 0.16

3084 904 4.06 0.16

MBtu/hr kW 1 2

2631 771 1.46 0.16

2880 844 1.65 0.16

3125 916 1.97 0.20

3371 988 2.28 0.20

3617 1060 2.56 0.24

3862 1132 2.87 0.28

4108 1204 3.27 0.31

4405 1291 3.66 0.31

MBtu/hr kW 1 2

3521 1032 1.50 0.39

3825 1121 1.77 0.43

4129 1210 2.01 0.51

4432 1299 2.28 0.59

4736 1388 2.56 0.67

5036 1476 2.83 0.71

5340 1565 3.11 0.75

5545 1625 3.20 0.77

D2390(B)

7

INSTALLATION

BOILER PLATE (A) Drill the combustion chamber mounting plate as shownin (A). The position of the threaded holes can be markedusing the burner head gasket supplied with the burner.

BLAST TUBE LENGTH (B) The length of the blast tube must be selected accordingto the indications provided by the manufacturer of theboiler, it must be greater than the thickness of the boilerdoor complete with its insulation. The length available, L(inches), is as follows:

Blast tube 12) RS 70/M RS 100/M RS 130/M• short 927/32“ 927/32“ 111/32“• long (with kit) 155/32“ 155/32“ 1611/32“

For boilers with front flue passes 15) or flame inversionchambers, protective insulation material 13), must beinserted between the boiler refractory 14) and the blasttube 12).This protective insulation must not compromise theextraction of the blast tube.For boilers having a water-cooled front, the insulation13)-14) is not required unless it is required by the boilermanufacturer.

SECURING THE BURNER TO THE BOILER (B) Before securing the burner to the boiler, check throughthe blast tube opening to make sure that the flame sen-sor probe (flame rod) is correctly set in position, asshown 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 slidebars.

COMBUSTION HEAD CALIBRATIONAt this point check, for model RS 130/M, whether themaximum delivery of the burner at high fire operation iscontained in area A or in area B of the firing rate. Seepage 5.If it is in area A then no operation is required.If, on the other hand, it is in area B:- unscrew the screws 1)(D) and disassemble the blast

tube 2);- move the fixing of the rod 3)(D) from position A to

position B, thereby causing the shutter 4) to retract;- now refit the blast tube 2)(D) and the screws 1).

Once this operation has been carried out (if it wasrequired), secure the flange 11)(B) to the boiler plate,inserting the gasket 9)(B). Use the 4 screws, also sup-plied with the unit, after first protecting the thread with ananti-locking product. The seal between burner and boilermust be airtight.

If you noticed any irregularities in the positions of theflame rod or ignition electrode during the check men-tioned above, remove screw 1)(E), extract the internalpart 2)(E) of the head and set up the two componentscorrectly.

IGNITION PILOT ADJUSTMENTPlace the pilot and electrode as shown in fig. (C). The pilot works correctly at pressures ranging from 5 -12” WC.ImportantTo set the pilot without main burner operaton, proceedas follows:- Move the jumper from terminals "30-V11" to terminals

"30-VP", as given in fig. (F), this way the main valve iscut out.

- With the burner in the manual position, hold the airdamper in the minimum position and make the setting.

- When the setting is correct, replace the jumper on “30-V11”.

(A)

(B)

inch A B C

RS 70/MRS 100/MRS 130/M

79/32“79/32“721/32“

1013/16“ - 1225/32“1013/16“ - 1225/32“1013/16“ - 1225/32“

1/2 W1/2 W1/2 W

D455

D2404

Electrode

Probe

D2391(C)

D738(D)

D2398(E)

(F)MB - Burner terminal strip

D2317

Ignitionpilot

8

COMBUSTION HEAD SETTINGInstallation operations are now at the stage where theblast tube and sleeve are secured to the boiler as shownin fig. (A). It is now a very simple matter to set up thecombustion head, as this depends solely on the MAXoutput 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: air and gas deliveries.

In diagram (C) find the notch to use for adjusting the airand the gas, and then proceed as follows:

Air adjustment (A) Turn screw 4)(A) until the notch identified is aligned withthe front surface 5)(A) of the flange.Gas adjustment (B)Loosen the 3 screws 1)(B) and turn ring 2) until thenotch identified is aligned with index 3).Tighten the 3 screws 1) fully down.

Example RS 70/MMAX output = 2200 MBtu/hr.If we consult diagram (C) we find that for this output, airmust be adjusted using notch 3, as shown in figs. (A)and (B).

NoteDiagram (C) shows the ideal settings for the ring 2)(B). Ifthe gas main pressure is too low to reach the maximumoutput operation pressure indicated on page 6, and ifthe ring 2)(B) is not fully open, it can be opened wider by1 or 2 notches.

Continuing with the previous example, page 6 indicatesthat for burner RS 70/M with output of 2200 MBtu/hr apressure of approximately 2.36 “WC is necessary at testpoint 6)(A). If the pressure cannot be reached, open thering 2)(B) to notch 4 or 5.Make sure that the combustion characteristics are satis-factory and free of pulsations.

Once you have finished setting up the head, refit theburner to the slide bars 3)(D) at approximately 4” fromthe sleeve 4)(D) - burner positioned as shown in fig.(B)p.7 - insert the flame rod cable and the ignition elec-trode cable and then slide the burner up to the sleeve sothat it is positioned as shown in fig. (D).Refit screws 2) on slide bars 3).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.

ImportantWhen fitting the burner on the two slide bars, it is advis-able to gently draw out the high tension cable and flamedetection probe cable until they are slightly stretched.

(A)

(C)

(D)

D2399

(B)

Notches (Air=Gas)

Maximum burner outputD2392

D2400

9

GAS PIPING• The main gas train must be connected to the gas

attachment 1)(A), using flange 2), gasket 3) andscrews 4) supplied with the burner.

• The gas train can enter the burner from the right or leftside, depending on which is the most convenient, seefig. (A).

• The gas safety shut-off valves 5)-6)(A) must be asclose as possible to the burner to ensure gas reachesthe combustion head within the safety time range.

• The pilot gas train must be connected to the gasattachment 5)(A) and can enter the burner from theright or left side.

GAS TRAIN (B)It must be type-approved according to required stand-ards and is supplied separately from the burner.

NoteSee the accompanying instructions for the adjustment ofthe gas train.

KEY (A)1 - Gas input pipe2 - Manual valve3 - Pressure regulator4 - Low gas pressure switch5 - 1st safety shut off valve VS6 - 2nd safety shut off valve VR7 - Standard issue burner with flange gasket8 - Gas adjustment butterfly valve *9 - Burner10 - High gas pressure switch *

* On the burner

(B)

(A) D2393

D2438

TYPICAL UL SCHEMATIC GAS PIPING

GAS PILOT LINE

MAIN GAS LINE

10

ADJUSTMENTS BEFORE FIRST FIRINGAdjustment of the combustion head, and air and gas deliveries has been illustrated on page 8. In addition, the following adjustments must also bemade: - 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 testpoint on the sleeve.The manometer readings are used to calculate theMAX. burner power using the table on page 6.

Before starting up the burner it is good practice to adjustthe gas train so that ignition takes place in conditions ofmaximum safety, i.e. with gas delivery at the minimum.

(D) D2401

(A)

LOW GAS PRESSURE SWITCH AIR PRESSURE SWITCHHIGH GAS PRESSURE SWITCH

(B) (C)

D2547 D2547 D2548

11

SERVOMOTORThe servomotor gives simultaneous regulation of the airdamper through the variable cam profile 4)(F) and thegas butterfly valve.It rotates by 130° in approx. 35 s.The factory settings must not be changed for the first fir-ing, just check that they comply with the details below.To open the servomotor, remove the screws and pull thecover outward, fig. (A).

CAMS AND TRIM POTENTIOMETERS FUNC-TIONS

Cam 1: 130°Limits rotation towards maximum for gas.

Cam 2: 0°Limits rotation towards minimum, air damper closed onstand by.

Cam 3: 20° Limits gas ignition position.

Cams 4 - 5 - 6 - 7 - 8: not used

Trim potentiometer MAXLimits maximum modulation.It must be set near the stroke end (cam 1) to exploit asfar as possible the variable profile cam and maximumopening of the gas butterfly valve.

Trim potentiometer MINLimits minimum modulation.It must be set near the stroke end (cam 2) to exploit asfar as possible the variable profile cam.

Trim potentiometer POSLimits an intermediate operating position between MAXand MIN, supplying power to the "P" terminal in the ser-vomotor (through an external command). This functioncuts out any external signals.NoteUsing the slide switch to select MAX or MIN, the servo-motor goes into the position for the respective settings ofthe MAX and MIN TRIM POTENTIOMETERS.

When the settings are complete, place the slide switchon OPE.

(D)

(F)

(E)

(C)

1 Servomotor2 Graduated sector for gas

butterfly valve3 Index for graduated sector 24 Adjustable profile cam5 Adjustment screws for cam

starting profile6 Adjustment fixing screws7 Adjustment screws for cam

and profile

Slide switch

Trim potentiometersPosition jumpers

D2277

D2585

D2594

D2593

(A)

(B)

NO

Figure above shows how the servo-motor is released to manually checkthere is no binding though its motion.

Don’t release the button indi-cated in this figure: the syn-cronization of the camsmade in factory would bechanged.

YES

12

BURNER STARTINGClose the control circuit, with the switch in fig. C) in theAUTO position.On firing (pilot burner and main valve) turn the switch (C)to MAN and the switch 1)(E) in the AUT position.

MAXIMUM OUTPUTUsing button (B), "increase output" until it stops, app.130° (cam 1).Place the slide switch on MAX and set the relative MAXtrim potentiometer (setting must be very near to 130°) toexploit 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 trainregulator and, if necessary, on the gas valve. The air setting must be made on the variable profile cam4)(D) by turning the screws 5), after loosening the screws6).

MINIMUM OUTPUTWith 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 mod-ulation minimum using the relative MIN trim potentiome-ter.Set the air using the variable profile cam 4)(D).If a lower modulation minimum is required than the levelset on cam 3 of the servomotor (20°), decrease the camsetting.

INTERMEDIATE OUTPUTSWith the switch (C) in the AUTO position, the slide switchin the OPE position and the switch 1)(E) in the MAN po-sition, move the button 2)(E) in various intermediate lev-els between maximum and minimum and set the variableprofile cam 4)(D) to achieve optimum combustion, byturning the screws 5).

If possible, do not change the previously set maximumand minimum levels.Check the various setting levels with a combustion anal-ysis.

ImportantMake a progressive adjustment of the profile, withoutsharp changes.When the setting is complete, lock the cam profile usingscrews 6)(D).Turn the burner off, release the servomotor as shown infig. (B) page 11 and manually turn cam 4)(D) to checkthere is no binding.

Finally fix the adjustment by turning the screws 6)(D).

(B) (C)

(D)

1 Servomotor2 Graduated sector for gas butterfly valve3 Index for graduated sector 24 Adjustable profile cam5 Adjustment screws for cam starting profile6 Adjustment fixing screws7 Adjustment screws for cam and profile

(A)

Slide switch

Trim potentiometersPosition jumpers

(E) D791

1 2

D2593

D2594

13

AIR PRESSURE SWITCH (A)Adjust the air pressure switch after having performed allother burner adjustments with the air pressure switch setto the start of the scale (A).With the burner operating at min. output, increase adjust-ment pressure by slowly turning the relative dial clock-wise until the burner locks out.Then turn the dial anti-clockwise by about 20% of the setpoint and repeat burner starting to ensure it is correct.If the burner locks out again, turn the dial anti-clockwisea little bit more.

Attention:As a rule, the air pressure switch must prevent the forma-tion of CO.To check this, insert a combustion analyser into thechimney, slowly close the fan suction inlet (for examplewith cardboard) and check that the burner locks out,before the CO in the fumes exceeds 400 ppm.

The air pressure switch may operate in "differential"operation in two pipe system. If a negative pressure inthe combustion chamber during pre-purging preventsthe air pressure switch from switching, switching may beobtained by fitting a second pipe between the air pres-sure switch and the suction inlet of the fan. In such amanner the air pressure switch operates as differentialpressure switch.

HIGH GAS PRESSURE SWITCH (B)Adjust the high gas pressure switch after having per-formed all other burner adjustments with the maximumgas pressure switch set to the end of the scale (B).With the burner operating at MAX output, reduce theadjustment pressure by slowly turning the adjustmentdial anticlockwise until the burner locks out.Then turn the dial clockwise by 0.8” WC and repeatburner firing.If the burner locks out again, turn the dial again clock-wise by 0.4” WC.

LOW GAS PRESSURE SWITCH (C)Adjust the low gas pressure switch after having per-formed all the other burner adjustments with the pressureswitch set at the start of the scale (C).With the burner operating at MAX output, increase ad-justment pressure by slowly turning the relative dialclockwise until the burner locks out.Then turn the dial anti-clockwise by 0.8” WC and repeatburner starting to ensure it is uniform.If the burner locks out again, turn the dial anti-clockwiseagain by 0.4” WC.

FLAME PRESENT CHECK (D)The burner is fitted with an ionisation (flame rod) systemwhich ensures that a flame is present. The minimumcurrent for reliable operation is 6 µA (see manufacturersdocumentation). The burner provides a much higher cur-rent, so that controls are not normally required. How-ever, if it is necessary to measure the ionisation current,disconnect the plug-socket 6)(A)p.4 on the ionisationprobe cable and insert a direct current microamperome-ter with a base scale of 100 µA. Carefully check polari-ties.

(A)

AIR PRESSURE SWITCH

(B)

HIGH GAS PRESSURE SWITCH

(C)

LOW GAS PRESSURE SWITCH

(D)D795

DA

D2548

D2547

D2547

14

MAINTENANCECombustionThe optimum calibration of the burner requires an analy-sis of the flue gases. Significant differences with respectto the previous measurements indicate the points wheremore care should be exercised during maintenance.

Gas leaksMake sure that there are no gas leaks on the pipeworkbetween the gas meter and the burner.

Flame inspection windowClean the flame inspection window (A).

Combustion headOpen the burner and make sure that all components ofthe combustion head are in good condition, notdeformed by the high temperatures, free of impuritiesfrom the surroundings and correctly positioned. If indoubt, disassemble the elbow fitting 5)(B).

ServomotorDisengage the cam 4)(D)p. 12 from the servomotor andturn it backwards and forwards by hand to make sure itmoves freely.

BurnerCheck for excess wear or loose screws in the mecha-nisms controlling the air damper and the gas butterflyvalve. Also make sure that the screws securing the elec-trical leads in the burner terminal strip are fully tight-ened.Clean the outside of the burner, taking special care withthe swivel joints and cam.

CombustionAdjust the burner if the combustion values found at thebeginning of the operation do not comply with the regu-lations in force, or do not correspond to good combus-tion. Record the new combustion values; they will beuseful 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 sec-

tor 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 andelectrode leads and then pull the burner fully back.

Now extract the gas distributor 5) after having removedthe screw 6) and disconnecting the pilot gas line.

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.

(A)

FLAME INSPECTION WINDOW

(B)

OPENING THE BURNER

D709

D2402

15

LAYOUT (A)Burner RS 70-100-130/M• Models RS 70-100-130/M leave the factory preset for 208-230 V power supply.• If 460 V power supply is used, change the motor connection from delta to star and change the setting of the thermal cut-out as well.

Key to Layout (A)CMV - Motor contactorDA - LFL Control boxMB - Burner terminal stripMV - Fan motorPA - Air pressure switchPGM - High gas pressure switchSM - ServomotorSO - Ionisation probe (flame rod)SP - Plug-socketTA - Ignition transformerTB - Burner ground

Factory Wiring DiagramRS 70/M - RS 100/M - RS 130/M with burner mounted Siemens LFL control

D2332

(A) D2878

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.

16

(A)

D2333

RS 70/M RS 100/M RS 130/M

208 - 230 V

460 V 575 V208 - 230 V

460 V 575 V208 - 230 V

460 V 575 V

F A T10 T6 T6 T15 T10 T6 T15 T10 T10

S AWG 14 14 14 14 14 14 14 14 14

ELECTRICAL CONNECTIONSUse flexible cables according to local Regulations.

LAYOUT (A)Electrical connection RS 70-100-130/M burners

Fuses and wire size layout (A), see table (B).Wire size when not indicated: AWG18.

KEY TO LAYOUT (A)IN - Burner manual stop switchMB - Burner terminal stripPG - Min. gas pressure switchPS - Remote lock-out resetH1 - Remote lock-out signalH2 - Burner on signalH4 - Power on signalH5 - Permission okOC - Operating controlOC2 - High-low controlHL - High limit

VP - Pilot adjustment valveVPS - Pilot valve (safety)VR - Adjustment valveVS - Safety valve

NOTES• The setting of the thermal overload must be according to the total

burner amperage draw.

• The RS 70-100-130/M burners leave the factory preset for 208-230 V power supply. If 460 V power supply is used, change the fanmotor connection from delta to star and change the setting of thethermal overload as well.

• The RS 70-100-130/M burners have been type-approved for inter-mittent operation. This means they should compulsorily bestopped at least once every 24 hours to enable the control box tocheck its own efficiency at start-up. Burner halts are normally pro-vided for automatically by the boiler load control system.If this is not the case, a time switch should be fitted in series to INto provide for burner shut-down at least once every 24 hours.

(B)

Field Wiring DiagramRS 70-100-130/M with burner mounted Siemens LFL control

17

ELECTRICAL SYSTEM

LAYOUT (B)Burner RS 70-100-130/MThe flame safeguard is in remote panel.See the internal electrical systems of the remote panel in order to have the complete wiring diagram.

Key to Layout (A)CMV - Motor contactorDA - Control boxMB - Burner terminal stripMV - Fan motorPA - Air pressure switchPGM - High gas pressure switchSM - ServomotorSO - Ionisation probe (flame rod)SP - Plug-socketTA - Ignition transformerTB - Burner ground

(A)

Factory Wiring DiagramRS 70/M - RS 100/M - RS 130/M with remote control panel

D2397

18

The FIRING RATE area values have been obtained considering a surround-ing temperature of 68°F (20°C), and an atmospheric pressure of 398” W.C.and with the combustion head adjusted as shown on page 8.The burner may be required to operate with combustion air at a higher tem-perature and/or at higher altitudes.Heating of air and increase in altitude produce the same effect: the expan-sion of the air volume, i.e. the reduction of air density.The burner fan's delivery remains substantially the same, but the oxygencontent per cubic meter and the fan's head are reduced. It is therefore important to know if the maximum output required of the burnerat a given combustion chamber pressure remains within the burner's firing rate range even at different temperature and altitude con-ditions. Proceed as follows to check the above:

1 -Find the correction factor F in the Table (A) for the plant's air temperature and altitude.2 -Divide the burner's delivery Q by F in order to obtain the equivalent delivery Qe:

3 - In the firing rate range of the burner, Fig. (B), indicate the work point defined by:Qe = equivalent deliveryH1 = combustion chamber pressureThe resulting point A must remain within the firing rate range.

4 -Plot a vertical line from Point A as shown in Figure (B) and find the maximum pressure H2 of the firing rate.5 -Multiply H2 by F to obtain the maximum reduced pressure H3 of the firing rate.

If H3 is greater than H1, as shown in Fig. (B), the burner delivers the output required.If H3 is lower than H1, the burner's delivery must be reduced. A reduction in delivery is accompanied by a reduction of the pressure inthe combustion chamber:Qr = reduced deliveryH1r = reduced pressure

Example , a 5% delivery reduction:

Qr = Q x 0.95

H1r = H1 x (0.95)2

Steps 2 - 5 must now be repeated using the new Qr and H1r values.

Important: the combustion head must be adjusted in respect to the equivalent delivery Qe.

Qe = Q : F (MBtu/hr)

H3 = H2 x F (“ W.C.)

Qe MBTU/h

A

H2

H1H3

“ W.C.

(B)

D2617

APPENDIX - Burner firing rates according to air density

above sea levelaverage barom.

pressure

CORRECTION FACTOR F

Air temperature°F (°C)

ft m “ W.C. mbar 0 (0°C) 41 (5°C) 50 (10°C) 59 (15°C) 68 (20°C) 77 (25°C) 86 (30°C) 104 (40°F)

0329658987

131616451974230326322961329039474605526359216579

0100200300400500600700800900

100012001400160018002000

399394389385380376372367363358354346337329321313

10131000989978966955944932921910898878856836815794

1,0871,0731,0611,0501,0371,0251,0131,0000,9880,9770,9640,9420,9190,8970,8750,852

1,0681,0541,0421,0311,0181,0070,9950,9820,9710,9590,9460,9250,9020,8810,8590,837

1,0491,0351,0241,0131,0000,9890,9770,9650,9540,9420,9300,9090,8860,8660,8440,822

1,0311,0171,0060,9950,9830,9720,9600,9480,9370,9260,9140,8930,8710,8510,8290,808

1,0131,0000,9890,9780,9660,9550,9440,9320,9210,9100,8980,8780,8560,8360,8150,794

0,9960,9830,9720,9620,9500,9390,9280,9160,9060,8950,8830,8630,8420,8220,8010,781

0,9800,9670,9560,9460,9340,9230,9130,9010,8910,8800,8680,8490,8280,8080,7880,768

0,9480,9360,9260,9160,9040,8940,8840,8720,8620,8520,8410,8220,8010,7830,7630,743

(A)

H1r = H1 x ( )Qr

Q

2

19

BURNER OPERATION

BURNER STARTING• Load control close.

Fan motor starts.• Servomotor starts:

130° rotation to right, until contact is made on cam1)(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.

STEADY STATE OPERATIONAt the end of the starting cycle, the servomotor controlthen passes to the load control for boiler pressure ortemperature.(The LFL control box continues, however, to check thatthe flame is present and that the air pressure switch is inthe correct position.)• If the temperature or pressure is low, the burner pro-

gressively increases its output to the MAX. value.• If the temperature or pressure is high, the burner pro-

gressively decreases its output to the MIN. value.And so on.

• The burner locks out when demand for heat is lessthan 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 dampercloses completely to reduce thermal dispersion to aminimum.

Every time output is changed, the servomotor automati-cally modifies gas delivery (gas butterfly valve) and airdelivery (fan air damper).

Switching times are given in seconds, in the burner star-tup sequence.

Legend for the timest1 Pre-purge time with air damper opent2 Safety timet3 Pre-ignition time, short (ignition transformer on

terminal 16)t4 Interval between start of t2 and release of valve

at terminal 19t5 Interval between end of t4 and release of load

controller or valve at terminal 20t5 Running time of air damper into OPEN positiont6 Running time of air damper into low-flame posi-

tion (MIN)t7 Permissible after-burn time t8 Interval until OPEN command for the air damper

is given t9 Running time of pilot

FIRING FAILUREIf the burner does not fire, it locks out within 2.5 secondsfrom opening the pilot valve and then within 5 secondsfrom opening the main valves.

BURNER FLAME GOES OUT DURING OPERATIONIf the flame should accidentally go out during operation,the burner will lock out within 1s.

LFL 1.335 Series 01

t1t2t3t4t5

3024

20optional

t6t7t8t9

optional124

16

(A)

Full Modulation

D2273

Low - High

D2274(B)

20

BURNER FAULTS

Control program under fault conditions and lock-out indication

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!

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!

Lock-out , because no flame signal is present after completion of the (1st) safety time.

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 wich 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.

P

1

2

21

BURNER START UP REPORT

Model number:

Project name:

Installing contractor:

Serial number:

Start-up date:

Phone number:

GAS OPERATION

Gas Supply Pressure:

Main Power Supply:

Control Power Supply:

Burner Firing Rate:

Manifold Pressure:

Pilot Flame Signal:

Low Fire Flame Signal:

High Fire Flame Signal:

CO2: Low Fire

O2: Low Fire

CO: Low Fire

NOX: Low Fire

Net Stack Temp - Low Fire:

Comb. Efficiency - Low Fire:

Overfire Draft:

High Fire

High Fire

High Fire

High Fire

High Fire:

High Fire:

OIL OPERATION

Oil supply pressure:

Oil suction pressure:

Control Power Supply:

Burner Firing Rate:

Low Fire Flame Signal:

High Fire Flame Signal:

Low Fire Nozzle Size:

High Fire Nozzle Size:

CO2: Low Fire

O2: Low Fire

CO: Low Fire

NOX: Low Fire

Net Stack Temp - Low Fire:

Comb. Efficiency - Low Fire:

Overfire Draft:

Smoke number:

High Fire

High Fire

High Fire

High Fire

High Fire:

High Fire:

CONTROL SETTINGS

Operating Setpoint:

High Limit Setpoint:

Low Gas Pressure:

High Gas Pressure:

Low Oil Pressure:

High Oil Pressure:

Flame Safeguard Model Number:

Modulating Signal Type:

NOTES

Represented By:Power Equipment Company

2011 Williamsburg RoadRichmond, VA 23231

Ph: 804-236-3800Fx: 804-236-3882www.peconet.com