Installation, use and maintenance instructionsInstrucciones de Instalación, Funcionamiento y MantenimientoInstruções de Instalação, Funcionamento e Manutenção

Bruciatori di gasolioQuemadores de gasóleoQueimadores a gasóleo

One stage operationFuncionamiento a una llamaFuncionamento a uma chama

2916092 (0)

CODE - CÓDIGO MODEL - MODELO TYPE - TIPO

3472080 RL 28/1 657 T80

3472081 RL 28/1 657 T80

GB

E

P

1

CONTENTS

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Packaging - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Max. dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Firing rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Test boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Boiler plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Blast tube length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 5Choice of nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Combustion head setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Fan gate adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Burner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Burner operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Burner start-up cycle diagnostics. . . . . . . . . . . . . . . . . . . . . . . 13Resetting the control box and using diagnostics. . . . . . . . . . . 13Fault - Probable cause - Suggested remedy . . . . . . . . . . . . . . . 14Status (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

N.B.Figures mentioned in the text are identified as follows:1)(A) =part 1 of figure A, same page as text;1)(A)p.3 =part 1 of figure A, page number 3.

NOTEIn conformity with Efficiency Directive 92/42/EEC the applicationof the burner on the boiler, adjustment and testing must be car-ried out observing the instruction manual of the boiler, includingverification of the CO and CO2 concentration in the flue gases,their temperatures and the average temperature of the water inthe boiler.

GB

2

TECHNICAL DATA

(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1000 mbar - Altitude 100 m a.s.l.(2) Sound pressure measured in manufacturers combustion laboratory, with burner operating on test boiler and at maximum rated output.

VARIANTS

ACCESSORIES (optional):

• STATUS (see page 15): code 3010321

• DEGASSING UNITIt may occur that a certain amount of air is contained in the light oil sucked up by the pump. This air may originate from the light oil itself as aconsequence of depressurization or air leaking past imperfect seals.In double-pipe systems, the air returns to the tank from the return pipe; in single-pipe systems, the air remains in circulation causing pressure var-iations in the pump and burner malfunctions.For this reason, we advise installing a degassing unit near the burner in single-pipe installations. Degassing units are provided in two versions:

CODE 3010054 without filterCODE 3010055 with filter

Degassing unit characteristics• Burner delivery : 80 kg/h max• Light oil pressure : 0,7 bar max• Ambient temperature : 40 °C max• Light oil temperature : 40 °C max• Attachment connectors : 1/4 inch

MODEL RL 28/1

TYPE 657 T80

OUTPUT (1)

DELIVERY (1)

kW 178 - 332

153 - 286

15 - 28

Mcal/h

kg/h

FUEL LIGHT OIL

- Net calorific value kWh/kgMcal/kg

11.810.2 (10200 kcal/kg)

- Density kg/dm3 0.82 - 0.85

- Viscosity at 20 °C mm2/s max 6 (1.5 °E - 6 cSt)

OPERATION • Intermittent (min. 1 stop in 24 hours).• Single-stage (all - nothing).

NOZZLES numero 2

STANDARD APPLICATIONS Boilers: water, steam, diathermic oil

AMBIENT TEMPERATURE °C 0 - 40

COMBUSTION AIR TEMPERATURE °C max 60

ELECTRICAL SUPPLY VHz

220-230 ~ +/-10%60 - single-phase

ELECTRIC MOTOR rpmWVA

2800300

220 - 2402,4

MOTOR CAPACITOR µF/V 12.5/450

IGNITION TRASFORMER V1 - V2I1 - I2

230 V - 2 x 5 kV1.9 A - 30 mA

PUMP delivery (at 20 bar)pressure rangefuel temperature

kg/hbar

° C max

4510 - 18

60

ELECTRICAL POWER CONSUMPTION W max 370

ELECTRICAL PROTECTION IP 44

IN CONFORMITY WITH EEC DIRECTIVES 89/336 - 73/23 - 92/42 - 89/392

NOISE LEVELS (2) dBA 70.0

Model Code Electricalsupply

Blast tubelenght mm

RL 28/1 34720803472081

single-phasesingle-phase

216351

3

BURNER DESCRIPTION (A)1 Ignition electrodes2 Combustion head3 Screw for combustion head adjustment4 Photocell for flame presence control5 Screw for fixing fan to flange6 Indexed selector.

Opens the fan gate to the value necessary atthe burner delivery

7 Slide bars for opening the burner and inspect-ing the combustion head

8 Valve assembly 9 Pump 10 Plate prearranged to drill 4 holes for the pas-

sage of hoses and electrical cables.11 Air inlet to fan12 Fan pressure test point13 Boiler mounting flange14 Flame stability disk15 Flame inspection window16 Extensions for slide bars 7)17 Motor capacitor18 Control box with lock-out pilot light and lock-

out reset button 19 Plugs for electrical connections20 Air gate valve 21 Pump pressure adjustment

N.B.If the control box 18)(A) pushbutton (red led)lights up, it indicates that the burner is in lock-out. To reset, hold the pushbutton down for between1 and 3 seconds.

PACKAGING-WEIGHT (B) Approximate measurements• The burner is shipped in cardboard boxe with

the maximum dimensions shown in table (B).• The weight of the burner complete with pack-

aging is indicated in table (B).

MAX. DIMENSIONS (C)Approximate measurements.The maximum dimensions of the burner are giv-en in (C).Bear in mind that inspection of the combustionhead requires the burner to be opened and therear part withdrawn on the slide bars.The maximum dimension of the burner, withoutcasing, when open is give by measurement H.

STANDARD EQUIPMENT2 - Flexible hoses2 - Gaskets for flexible hoses2 - Nipples for flexible hoses1 - Thermal insulation screen2 - Extensions 16)(A) for slide bars 7)(A)

(for model with 351 mm blast tube)4 - Screws to secure the burner flange to the

boiler: M 8 x 252 - Fairleads for electrical connections1 - Instruction booklet1 - Spare parts lis

(A)

(B)

mm A B C kg

RL 28 /1 1010 620 495 35

(1) Blast tube: short-lang

mm A B C D (1) E F G H (1)

RL 28 /1 476 474 468 216 - 351 140 352 52 672 - 807

(C)

D452

D88

D3261

D3260

D583

4

FIRING RATES (A)The burner delivery must be selected within areaof the adjacent diagram. This area is called firing rate and provides thedelivery of the burner in relation to the pressurein the combustion chamber.

The work point may be found by plotting a verti-cal line from the desired delivery and a horizontalline from the pressure in the combustion cham-ber. The intersection of these two lines is thework point which must lie within firing rate.

ImportantThe FIRING RATE area values have been ob-tained considering a surrounding temperature of20 °C, and an atmospheric pressure of 1000mbar (approx. 100 m above sea level) and withthe combustion head adjusted as shown on page6.

TEST BOILER (B)The firing rate was set in relation to special testboilers in accordance with the methods definedin EN 267 standards.Figure (B) indicates the diameter and length ofthe test combustion chamber.Example: delivery 25 kg/hour: diameter = 50 cm; length = 1,25 m.

Whenever the burner is operated in a muchsmaller commercially-available combustionchamber, a preliminary test should be per-formed.

(A)

(B)

D585

D586

pres

sure

m

bar

Com

bust

ion

cham

ber

Com

bust

ion

cham

ber

leng

th

m

5

INSTALLATION

BOILER PLATE (A) Drill the combustion chamber locking plate asshown in (A). The position of the threaded holes can bemarked using the thermal screen supplied withthe burner.

BLAST TUBE LENGTH (B)The length of the blast tube must be selected ac-cording to the indications provided by the manu-facturer of the boiler, and in any case it must begreater than the thickness of the boiler door com-plete with its fettling. The range of lengths avail-able, L, is as follows:

Blast tube 7): • short 216 mm• long 351 mm

For boilers with front flue passes 10) or flame in-version chambers, protective fettling in refractorymaterial 8) must be inserted between the boiler'sfettling 9) and the blast tube 7).This protective fettling must not compromise theextraction of the blast tube.For boilers having a water-cooled front the refrac-tory fettling 8)-9)(B) is not required unless it is ex-pressly requested by the boiler manufacturer.

SECURING THE BURNER TO THE BOILER (B)Disassemble the blast tube 7) from the burner 4)by proceeding as follows:- Remove the screws 2) from the two slide bars 3).- Remove the screw 1) fixing the burner 4) to

the flange 5).- Withdraw the blast tube 7) complete with

flange 5) and slide bars 3).

Secure flange 5)(B) to the boiler plate interpos-ing the supplied gasket 6). Use the 4 suppliedscrews provided after having protected thethread with antiscruffing products (high-tempera-ture grease, compounds, graphite). The burner-boiler seal must be airtight.

CHOICE OF NOZZLES Choose the couple of nozzles among those giv-en in table (C).Use nozzles with a 60° spray angle at the recom-mended pressure of 12 bar.When the burner fires only the first nozzle works.Its delivery is higher than that of the second noz-zle in order to assure a good flame stabilisationto the stability disk, though the fan delivery hasbeen adjusted for both working nozzles.Whenever ignition takes place with unusualnoise or pulsations, you should reduce the firstnozzle delivery making sure that the flame stabi-lisation is still satisfactory.Subsequently also the second nozzle startsworking.The burner»s operating delivery consists of thesum of the two nozzles deliveries.

Example Boiler output = 230 kW Efficiency 90 %Output required by the burner =230 : 0,9 = 255 kWIn table (C) the following nozzles are recom-mended:1° = 3,0 GPH + 2° = 2,0 GPH - 60° - 12 bar.

(A)

(B)

(C)

(1) We get the indicated delivery when both nozzles are working and light oil has the following characteristics:Density 0,84 kg/dm3 - Viscosity 4,2 cSt/20 °C - Temperature 10 °C.

GPH kg/h (1) kW12 bar

1° 2° 10 bar 12 bar 14 bar

2,252,502,753,003,003,503,504,004,00

+++++++++

1,501,751,752,002,252,252,502,753,00

14,416,317,319,220,222,123,025,926,9

15,918,019,121,222,324,425,428,629,7

17,319,620,723,024,226,527,731,132,3

189213226251264289301339352

D587

D588

6

NOZZLE ASSEMBLYAt this stage of installation the burner is still dis-assembled from the blast tube; it is thereforepossible to fit two nozzles with the box spanner1)(A) (16 mm), after having removed the plasticplugs 2)(A), fitting the spanner through the cen-tral hole in the flame stability disk. Do not use anysealing products such as gaskets, sealing com-pound, or tape. Be careful to avoid damaging thenozzle sealing seat. The nozzles must bescrewed into place tightly but not to the maxi-mum torque value provided by the wrench.The firing nozzle is the one lying beneath the fir-ing electrodes fig. (B).

Make sure that the electrodes are positioned asshown in fig. (B).Finally remount the burner 4)(C) to the slide bars3) and slide it up to the flange 5), keeping itslightly raised to prevent the flame stability diskfrom pressing against the blast tube.Tighten the screws 2) on the slide bars 3) andscrew 1) that attaches the burner to the flange.

If it proves necessary to change a nozzle with theburner already fitted to the boiler, proceed asoutlined below:- Retract the burner on its slide bars as shown

in fig. (B)p.5.- Remove the nuts 1)(D) and the disk 2).- Use spanner 3)(D) to change the nozzles.

COMBUSTION HEAD SETTINGThe setting of the combustion head depends ex-clusively on the delivery of the burner, in otherwords, the combined delivery of the two nozzlesselected on page 5. Turn screw 4)(E) until the notch shown in dia-gram (F) is level with the front surface of flange5)(E).

Example RL 28/1:with nozzles: 1° = 2.75 GPH + 2° = 1.75 GPH and 14 bar pumppressure.Find the delivery of the two nozzles in Table(C)p.5 , 20.7 kg/h.Diagram (F) indicates that for a delivery of 20.7kg/h the RL 28/1 Model requires the combustionhead to be set to approx. three notches, asshown in fig. (E).

FAN GATE ADJUSTMENTThe fan gate is set using the indexed selector1)(G), after having loosened the nut 2)(G).The first time the burner is fired, this settingshould be left as originally set by the manufactur-er: notch 2, see fig. (G).

2 mm

÷4 mm3.5

(A)

(C)

COMBUSTION HEAD SETTING

(G)

(E)

Notches nr.

Light oil delivery kg/h

(D)

(F)

(B)

D460

D591

D462

D592

D593

D3263

D589

7

HYDRAULIC SYSTEM

FUEL SUPPLY

Double-pipe circuit (A)The burner is equipped with a self-priming pumpwhich is capable of feeding itself within the limitslisted in the table at the side.The tank higer than the burner AThe distance "P" must not exceed 10 meters inorder to avoid subjecting the pump's seal to ex-cessive strain; the distance "V" must not exceed4 meters in order to permit pump self-primingeven when the tank is almost completely empty.The tank lower than the burner BPump depression values higher than 0.45 bar(35 cm Hg) must not be exceeded because athigher levels gas is released from the fuel, thepump starts making noise and its working life-span decreases.It is good practice to ensure that the return andsuction lines enter the burner from the sameheight; in this way it will be less probable that thesuction line fails to prime or stops priming.

The loop circuitA loop circuit consists of a loop of piping departingfrom and returning to the tank with an auxiliarypump that circulates the fuel under pressure. Abranch connection from the loop goes to feed theburner. This circuit is extremely useful wheneverthe burner pump does not succeed in self-primingbecause the tank distance and/or height differ-ence are higher than the values listed in the table.

Key (A)H = Pump/Foot valve height differenceL = Piping lengthÆ = Inside pipe diameter1 = Burner2 = Pump3 = Filter4 = Manual on/off valve5 = Suction line6 = Foot valve7 = Rapid closing manual valve remote con-

trolled (only Italy)8 = On/off solenoid valve (only Italy)9 = Return line10 = Check valve (only Italy)

HYDRAULIC CONNECTIONS (B)The pumps are equipped with a by-pass thatconnects return line with suction line. The pumpsare installed on the burner with the by-passclosed by screw 6)(B)p.11.It is therefore necessary to connect both hosesto the pump.The pump will break down immediately if it is runwith the return line closed and the bj-pass screwinserted.Remove the plugs from the suction and returnconnections of the pump.Insert the hose connections with the suppliedseals into the connections and screw themdown.Take care that the hoses are not stretched ortwisted during installation.Route the hoses through the holes in the plate,preferably using those on the rh side, fig. (B):unscrew the screws 1), now divide the insertpiece into its two parts 2) and 3) and remove thethin diaphragm blocking the two passages 4).Install the hoses where they cannot be steppedon or come into contact with hot surfaces of theboiler.Now connect the other end of the hoses to thesupplied nipples, using two wrenches, one tohold the nipple steady while using the other oneto turn the rotary union on the hose.

(A)

(B)

9

10

7

5

8

4

7

9

5 3

2

16

6

10 cm

+ H

V

P

- H

B

A

+ H- H(m)

L (m)

Æ (mm)

8 10 12

+ 4,0 52 134 160

+ 3,0 46 119 160

+ 2,0 39 104 160

+ 1,0 33 89 160

+ 0,5 30 80 160

0 27 73 160

- 0,5 24 66 144

- 1,0 21 58 128

- 2,0 19 43 96

- 3,0 15 28 65

- 4,0 - 12 33

D3264

D3265

8

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM as set up by the manu-facturer

LAYOUT (A)Burner RL 28/1 (single-phase)

Key to layout (A)C - CapacitorRMO88.53A2 - Control boxF - PhotocellMV - Fan motorTA - Ignition transformerTB - Burner groundVA - 1st nozzle solenoid valveVF - 2nd nozzle solenoid valveXP1 - Connector for STATUSXP7 - 7 pole socket

NOTEFor remote-reset, connect a push-button switch(NO) between terminal 3 and neutral of the con-trol box (terminals 15, 16, 17 and 18).

ELECTRICAL CONNECTIONS (B)set by installer

All the wires to connect to the burner plugs 3)(B)must be routed through the fairleads, supplied bythe manufacturer for insertion into the holes inthe plate, preferably those on the left side, afterhaving removed the thin diaphragm effectivelyclosing the aperture, as already explainedabove.

1 - Pg 11 Single-phase power supply2 - Pg 9 Control deviceTL

LAYOUT (C)RL 28/1 burner electrical connectionCable section not indicated: 1,5 mm2

Key to layout (C)h1 - HourcounterIN - Manual burner stop switchS - Remote lock-out signalTL - Limit control device system: this shuts

down the burner when the boiler tempera-ture or pressure exceeds the setpointvalue.

TS - Safety control device system: this oper-ates when TL is faulty.

X7 - 7 pole plug

NOTEThe RL 28/1 burner has been type-approved forintermittent operation. This means it shouldcompulsorily be stopped at least once every 24hours to enable the control box to check its ownefficiency at start-up. Burner halts are normallyprovided for automatically by the boiler loadcontrol system.If this is not the case, a time switch should be fit-ted in series to IN to provide for burner shut-down at least once every 24 hours.

WARNINGDo not invert the neutral with the phasewire in the electricity supply line.

ELECTRICAL EQUIPMENT FACTORY-SET

(A)

(B)

(C)

ELECTRICAL CONNECTION

ELECTRICAL CONNECTION

D3225

D3282

D3266

Bla

ckW

hite

Blu

e

9

PUMP (A)1 - Suction G 1/4"2 - Return G 1/4"3 - Pressure gauge attachment G 1/8"4 - Vacuum meter attachment G 1/8"5 - Pressure adjustment screw

A - Min. delivery rate at 12 bar pressureB - Delivery pressure rangeC - Max. suction depressionD - Viscosity rangeE - Light oil max. temperatureF - Max. suction and return pressureG - Pressure calibration in the factoryH - Filter mesh width

PUMP PRIMING- Before starting the burner, make sure that

the tank return line is not clogged.Obstructions in the line could cause thesealing organ located on the pump shaft tobreak. (The pump leaves the factory with theby-pass closed).

- In order for self-priming to take place, one ofthe screws 3)(A) of the pump must be loos-ened in order to bleed off the air contained inthe suction line.

- Start the burner by closing the control devicesand the electrical network switch. The pumpmust rotate in the direction of the arrowmarked on the cover.

- The pump can be considered to be primedwhen the light oil starts coming out of thescrew 3). Stop immediately the burner andtighten the screw 3).

The time required for this operation dependsupon the diameter and length of the suction tub-ing. If the pump fails to prime at the first startingof the burner and the burner locks out, wait ap-prox. 15 seconds, reset the burner, and then re-peat the starting operation as often as required.After 5 or 6 starting operations allow 2 or 3 min-utes for the transformer to cool.Do not illuminate the photocell or the burner willlock out; the burner should lock out anywayabout 10 seconds after it starts.

Important:The a.m. operation is possible because thepump is already full of fuel when it leaves the fac-tory. If the pump has been drained, fill it with fuelthrough the opening on the vacuum meter priorto starting; otherwise, the pump will seize. When-ever the length of the suction piping exceeds 20-30 meters, the supply line must be filled using aseparate pump.

(A)

AN 57 C

ABCDEFGH

kg/hbarbarcSt°Cbarbarmm

4510 - 18

0,452 - 75

602

120,150

PUMP SUNTEC AN 57 C

D602

10

BURNER CALIBRATION

FIRINGDuring the first firing, when the 2nd nozzle pipingis being filled, a temporary decrease in fuel pres-sure takes place. This lowering of the fuel pres-sure can cause the burner to lock-out and cansometimes give rise to pulsations.Once the following adjustments have beenmade, the firing of the burner must generate anoise similar to the noise generated during oper-ation. If one or more pulsations or a delay in firingin respect to the opening of the light oil solenoidvalve occur, see the suggestions provided on p.14: causes 29 to 35.

OPERATIONThe optimum calibration of the burner requiresan analysis of the flue gases at the boiler outletand interventions on the following points:

• 1st and 2nd nozzlesSee the information listed on page 5: ≈Choice ofnozzles∆.

• Combustion headThe adjustment of the combustion head alreadycarried out (see, page 6) need not be alteredunless the delivery of the burner is changed.

• Pump pressure12 bar: This is the pressure calibrated in the fac-tory which is usually sufficient for most purposes.Sometimes, this pressure must be adjusted to :10 bar in order to reduce fuel delivery. This ad-justment is possible only if the surrounding tem-perature remains above 0°C;14 bar in order to increase fuel delivery or to en-sure firings even at temperatures of less than0°C.In order to adjust pump pressure, use the screw5)(A)p. 9.

• Fan air gate valveAdjust the fan air gate valve by using the indexedselector 1)(A) after having loosened the nut2)(A). This setting must be adapted case by case to theburner's delivery (while both nozzles are operat-ing) and combustion chamber pressure. Air pressure at attachment 1)(B) must be approx-imately the same as the pressure specified in ta-ble (B) plus the combustion chamber pressuremeasured at attachment 2). Refer to the exam-ple in the adjacent figure.

(A)

(B)

AIR PRESSURE IN 1) WITH ZERO PRESSURE IN 2)

kg/h mbar

1516182022242628

7,67,57,37,06,86,66,25,7

D593

D597

11

BURNER OPERATION

BURNER STARTING (A) - (B)Starting phases with progressive time intervalsshown in seconds:• Control device TL closes.

After about 3s:• 0 s : The control box starting cycle begins.• 2 s : The fan motor starts.• 3 s : The ignition transformer is connected.

The pump 3) sucks the fuel from the tankthrough the piping 1) and the filter 2) andpumps it under pressure to delivery. The pis-ton 4) rises and the fuel returns to the tankthrough the piping 5) - 7). The screw 6) closesthe by-pass heading towards suction and thesolenoid valves 8) - 11), de-energized, closethe passage to the nozzles.Prepurging begins with the max. air delivery.

• 22 s : The solenoid valve 8) opens and thefuel passes through the piping 9) and filter 10)and is then sprayed out through the 1st noz-zle, igniting when it comes into contact withthe spark. This is the ignition flame.

• 29 s: The ignition transformer switches off.• 36 s: The solenoid valve 11) opens, the fuel

passes through the piping 13) and filter 14)and is then sprayed out through the 2nd noz-zle. This is the operating flame The starting cycle comes to an end.

STEADY STATE OPERATIONWhen the boiler temperature or pressureincreases until control device TL opens, theburner shuts down.

FIRING FAILUREIf the burner does not fire, it goes into lock-out with-in 5 s of the opening of the 1st nozzle valve and 30s after the closing of control device TL. The control box red pilot light will light up.

UNDESIRED SHUTDOWN DURING OPERA-TIONIf the flame goes out during operation, the burnershuts down automatically within 1 second andautomatically attempts to start again by repeat-ing the starting cycle.

Figure (B)M = Pressure gaugeV = Vacuum meter

(A)

(B)

D3262

D601

LEDRMO *

D3268

Off Yellow Green Red

For further details see page 13.

*

LEDRMO *

12

FINAL CHECKS• Obscure the photocell and switch on the con-

trol devices: the burner should start and thenlock-out about 5 s after opening of the 1st noz-zle operation valve.

• Illuminate the photocell and switch on the con-trol devices: the burner should start and thengo into lock-out after about 10 s.

• Obscure the photocell while the burner is op-erating, the following must occur in sequence:flame extinguished within 1 s, pre-purging forabout 20 s, sparking for about 5 s, burner goesinto lock-out.

• Switch off control device TL while the burner isoperating: the burner should stop.

MAINTENANCECombustionThe optimum calibration of the burner requiresan analysis of the flue gases. Significant differ-ences with respect to the previous measure-ments indicate the points where more careshould be exercised during maintenance.PumpThe delivery pressure must be stable at 12 bar. The depression must be less than 0.45 bar.Unusual noise must not be evident during pumpoperation.If the pressure is found to be unstable or if thepump runs noisily, the flexible hose must be de-tached from the line filter and the fuel must besucked from a tank located near the burner. Thismeasure permits the cause of the anomaly to betraced to either the suction piping or the pump.If the pump is found to be responsible, check tomake sure that the filter is not dirty. The vacuummeter is installed upstream from the filter andconsequently will not indicate whether the filter isclogged or not.Contrarily, if the problem lies in the suction line,check to make sure that the filter is clean andthat air is not entering the piping.Filters (A)Check the following filter boxes: • on line 1) • in the pump 2) • at the nozzle 3), andclean or replace as required.If rust or other impurities are observed inside thepump, use a separate pump to lift any water andother impurities that may have deposited on thebottom of the tank.Then clean the insides of the pump and the cov-er sealing surface.FanCheck to make sure that no dust has accumulat-ed inside the fan or on its blades, as this condi-tion will cause a reduction in the air flow rate andprovoke polluting combustion.Combustion headCheck to make sure that all the parts of the com-bustion head are in good condition, positionedcorrectly, free of all impurities, and that no defor-mation has been caused by operation at hightemperatures.NozzlesDo not clean the nozzle openings; do not evenopen them. The nozzle filters however may becleaned or replaced as required.Replace the nozzles every 2-3 years or whenev-er necessary.PHOTOCELL (B)Clean the glass cover from any dust that mayhave accumulated. Photocell 1) is held in posi-tion by a pressure fit and can therefore be re-moved by pulling it outward forcefully.Flame inspection window (C)Clean the glass whenever necessary.Flexible hosesCheck to make sure that the flexible hoses arestill in good condition and that they are notcrushed or otherwise deformed.Fuel tankApproximately every 5 years, or whenever nec-essary, suck any water or other impuritiespresent on the bottom of the tank using a sepa-rate pump.BoilerClean the boiler as indicated in its accompanyinginstructions in order to maintain all the originalcombustion characteristics intact, especially theflue gas temperature and combustion chamberpressure.TO OPEN THE BURNER (D)- Switch off the electrical power- Remove screw 1 and withdraw the casing 2)- Unscrew screw 3)- Fit the two extensions 4) supplied with the

burner onto the slide bars 5) (model with 351mm blast tube)

- Pull part A backward keeping it slightly raisedto avoid damaging the disk 6) on blast tube 7).

FUEL PUMP AND/OR COUPLINGS RE-PLACEMENT (E)In conformity with fig. (E).

(A)

(B) (C)

(D)

(E)

D484

D482

D1108

D603

D604

13

BURNER START-UP CYCLE DIAGNOSTICSDuring start-up, indication is according to the followin table:

RESETTING THE CONTROL BOX AND USING DIAGNOSTICSThe control box features a diagnostics function through which any causes of malfunctioning are easily identified (indicator: RED LED).To use this function, you must wait at least 10 seconds once it has entered the safety condition (lock-out), and then press the reset button. The control box generates a sequence of pulses (1 second apart), which is repeated at constant 3-second intervals. Once you have seen how many times the light pulses and identified the possible cause, the system must be reset by holding the buttondown for between 1 and 3 seconds.

The methods that can be used to reset the control box and use diagnostics are given below.

RESETTING THE CONTROL BOX To reset the control box, proceed as follows:- Hold the button down for between 1 and 3 seconds.

The burner restarts after a 2-second pause once the button is released.If the burner does not restart, you must make sure the limit thermostat is closed.

VISUAL DIAGNOSTICS Indicates the type of burner malfunction causing lock-out.To view diagnostics, proceed as follows:- Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.

A yellow light pulses to tell you the operation is done.Release the button once the light pulses. The number of times it pulses tells you the cause of the malfunction, according to the codingsystem indicated in the table on page 14.

SOFTWARE DIAGNOSTICSReports burner life by means of an optical link with the PC, indicating hours of operation, number and type of lock-outs, serial number ofcontrol box etc ...To view diagnostics, proceed as follows:- Hold the button down for more than 3 seconds once the red LED (burner lock-out) remains steadily lit.

A yellow light pulses to tell you the operation is done. Release the button for 1 second and then press again for over 3 seconds until the yellow light pulses again.Once the button is released, the red LED will flash intermittently with a higher frequency: only now can the optical link be activated.

Once the operations are done, the control box»s initial state must be restored using the resetting procedure described above.

The sequence of pulses issued by the control box identifies the possible types of malfunction, which are listed in the table on page 14.

COLOUR CODE TABLE

Sequences Colour code

Pre-purging

Ignition phase

Operation, flame ok

Operating with weak flame signal

Electrical supply lower than ~ 170V

Lock-out

Extraneous light

Key: Off Yellow Green Red

BUTTON PRESSED FOR CONTROL BOX STATUS

Between 1 and 3 seconds Control box reset without viewing visual diagnostics.

More than 3 secondsVisual diagnostics of lock-out condition:(LED pulses at 1-second intervals).

More than 3 seconds starting from the visualdiagnostics condition

Software diagnostics by means of optical interface and PC (hours of operation, malfunc-tions etc. can be viewed)

Press resetfor > 3s 3sPulses Pulses

RED LED onwait at least 10s

IntervalLock-out

14

SIGNAL FAULT PROBABLE CAUSE SUGGESTED REMEDY

No blink The burner does not start

1 - No electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . Close all switches - Check fuses2 - A limit or safety control device is open . . . . . . . . . . . . . . . . . . . Adjust or replace3 - Control box lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reset control box (no sooner than 10 s after the

lock-out)4 - Pump is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace5 - Erroneous electrical connections . . . . . . . . . . . . . . . . . . . . . . . Check connections6 - Defective control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace7 - Defective electrical motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace8 - Defective capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace

4 x blinks The burner starts and then goes into lock-out

9 - Photocell short-circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace photocell10 - Light is entering or flame is simulated. . . . . . . . . . . . . . . . . . . . Eliminate light or replace control box

2 x blinks After pre-purge and the safety time, the burner goes to lock-out at the end of the safety time

11 - No fuel in tank; water on tank bottom . . . . . . . . . . . . . . . . . . . . Top up fuel level or suck up water12 - Inappropriate head and air damper adjustments . . . . . . . . . . . Adjust, see page 21 and 2713 - Light oil solenoid valves fail to open (1st nozzle) . . . . . . . . . . . Check connections; replace coil14 - 1st nozzle clogged, dirty, or deformed . . . . . . . . . . . . . . . . . . . Replace15 - Dirty or poorly adjusted firing electrodes. . . . . . . . . . . . . . . . . . Adjust or clean16 - Grounded electrode due to broken insulation . . . . . . . . . . . . . . Replace17 - High voltage cable defective or grounded. . . . . . . . . . . . . . . . . Replace18 - High voltage cable deformed by high temperature . . . . . . . . . . Replace and protect19 - Ignition transformer defective . . . . . . . . . . . . . . . . . . . . . . . . . . Replace20 - Erroneous valves or transformer electrical connections . . . . . . Check21 - Control box defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace22 - Pump unprimed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime pump and see ≈Pump unprimes∆ 23 - Pump/motor coupling broken . . . . . . . . . . . . . . . . . . . . . . . . . . Replace24 - Pump suction line connected to return line . . . . . . . . . . . . . . . . Correct connection25 - Valves up-line from pump closed . . . . . . . . . . . . . . . . . . . . . . . Open26 - Filters dirty: line - pump - nozzle . . . . . . . . . . . . . . . . . . . . . . . . Clean27 - Defective photocell or control box . . . . . . . . . . . . . . . . . . . . . . . Replace photocell or control box28 - Dirty photocell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean

7 x blinks Flame detachment 29 - Poorly adjusted head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust, see page 6, fig. (F)30 - Poorly adjusted or dirty firing electrodes . . . . . . . . . . . . . . . . . . Adjust, see page 6, fig. (B)31 - Poorly adjusted fan air gate: too much air . . . . . . . . . . . . . . . . Adjust32 - 1st nozzle is too big (pulsation) . . . . . . . . . . . . . . . . . . . . . . . . . Reduce 1st nozzle delivery33 - 1st nozzle is too small (flame detachment) . . . . . . . . . . . . . . . . Increase 1st nozzle delivery34 - 1st nozzle dirty, or deformed. . . . . . . . . . . . . . . . . . . . . . . . . . . Replace35 - Inappropriate pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust

Uneven fuel supply 36 - Check if cause is in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed burner from tank or fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . located near burner

Internally rusted pump 37 - Water in tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suck water from tank bottom with separate pump

Noisy pump, unstable pressure

38 - Air has entered the suction line . . . . . . . . . . . . . . . . . . . . . . . . Tighten connectors- Depression value too high (higher than 35 cm Hg):

39 - Tank/burner height difference too great . . . . . . . . . . . . . . . . . . Feed burner with loop circuit40 - Piping diameter too small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Increase41 - Suction filters clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean42 - Suction valves closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open43 - Paraffin solidified due to low temperature . . . . . . . . . . . . . . . . . Add additive to light oil

Pump unprimes after prolonged pause

44 - Return pipe not immersed in fuel . . . . . . . . . . . . . . . . . . . . . . . Bring to same height as suction pipe45 - Air enters suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten connectors

Pump leaks light oil 46 - Leakage from sealing organ . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace pump

Smoke in flame- dark Bacharach

- yellow Bacharach

47 - Not enough air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan gate, see page 6 and 1048 - Nozzle worn or dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace49 - Nozzle filter clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or replace50 - Erroneous pump pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust to between 10 - 14 bar51 - Flame stability spirat dirty, loose, or deformed . . . . . . . . . . . . . Clean, tighten in place, or replace52 - Boiler room air vents insufficient . . . . . . . . . . . . . . . . . . . . . . . . Increase53 - Too much air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust head and fan gate, see page 6 and 10

Dirty combustion head 54 - Nozzle or filter dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace55 - Unsuitable nozzle delivery or angle . . . . . . . . . . . . . . . . . . . . . See recommended nozzles, page 556 - Loose nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten57 - Impurities on flame stability spiral . . . . . . . . . . . . . . . . . . . . . . . Clean58 - Erroneous head adjustment or not enough air . . . . . . . . . . . . . Adjust, see page 10; open gate valve59 - Blast tube length unsuited to boiler . . . . . . . . . . . . . . . . . . . . . . Contact boiler manufacturer

10 x blinks 60 - Connection or internal fault

15

STATUSAccessory available on request. See page 2.

ASSEMBLYThe burners are preset to accept the Status. Toassemble, proceed as follows:- Connect Status 1) using connector 2) fitted on

the bracket 3).- Fasten Status to the bracket using the screws

4) supplied with the kit.

The STATUS unit has three functions:

1 - BURNER OPERATING HOURS AND THENUMBER OF FIRINGS ARE SHOWN ONDISPLAY V

Total operating hoursPress button "h1"."h2" not used.Number of firingsPress button "count".Resetting operating hours and number of firingsPress the three ≈reset∆ buttons simultaneously.Non-volatile memoryThe operating hours and the number of firingswill remain in the memory even in the case ofelectrical power failures.

2 - INDICATES THE TIMES RELATIVE TOTHE FIRING STAGE

The leds illuminate in the following sequence,see fig. A:

WITH CONTROL DEVICE TR CLOSED:1 - Burner off, TL open2 - Control device TL closed3 - Motor start:

seconds count starts on read-out V4 - Ignition valve energized5 - Operation valve energized

seconds count stops on read-out V6 - 10 seconds after stage 5 the code I I I I will

appear on the read-out: this indicates thatthe starting phase is terminated.

WITH CONTROL DEVICE TR OPEN:1 - Burner off, TL open2 - Control device TL closed3 - Motor start:

seconds count starts on read-out V4 - Ignition valve energized7 - 30 seconds after stage 4:

seconds count stops on read-out V8 - 10 seconds after stage 7 the code I I I I will

appear on the read-out: this indicates that the starting phase is terminated.

The times, in seconds, shown on read-out V,indicate the succession of the various startingstages described on page 11.

3 - IN THE CASE OF BURNER MALFUNC-TIONS, THE STATUS PANEL INDICATESTHE EXACT TIME AT WHICH THE FAULTOCCURRED

There are 2 possible combinations of illumi-nated leds, see fig. (B). For the causes of the malfunction refer to thenumbers shown between brackets; see the leg-end on page 14 for interpretation of the num-bers.

1 . . . . . . . . . . . (9 … 10)2 . . . . . . . . . . . (11 … 28)

Key to symbols:

= Power present

= Fan motor blocked (red)

= Burner lock-out (red)

= Not used

= 1st stage operation

= Load level reached (Stand-by), led:

on

D3269

2

1

4

3

D3057

Led flashing

Led illuminated

Time in secondsBurner start cycle terminated

STATUS (optional)

Assembly

1 Status2 Connector3 Bracket of the burner4 Fixing screws

D478