Montage und Bedienungsanleitung Manuel d entretien Installation, use and maintenance instructions Installatie-, gebruiks- en onderhoudsvoorschriften Instrucciones de instalación, uso y mantenimiento Οδηγίες εγκατάστασης, χρήσης και συντήρησης D F GB NL E GR Öl-Gebläsebrenner Brûleur fioul domestique Light oil burner Stookoliebrander Quemadores de gasóleo Καυστήρας Πετρελαίου Zweistufiger Betrieb Fonctionnement à allures Two stage operation Tweetrapsbranders Funcionamiento de dos llamas ιβάθµια λειτουργία CODE - CÓDIGO ΚΩ ΙΚΟΣ MODELL - MODELE MODEL - MODELO - ΜΟΝΤΕΛΟ TYP - TYPE TIPO - ΤΥΠΟΣ 79850 RG5D 98T 90 (5)
INDEX. BURNER DESCRIPTION............. Burner equipment.................. TECNICAL DATA................. Technical data..................... Overall dimensions................. Working field...................... WORKING....................... 6. Combustion adjustment.............. 6. Recommended nozzles.............. 6. Combustion head setting............. 7. Electrodes adjustment............... 7.5 Pump pressure and air output......... 7.6 Burner start-up cycle................ 8. INSTALLATION.................... Boiler fixing....................... Fuel supply....................... ydraulic systems.................. Electrical wiring................... 5 5. MAINTENANCE................... 8 6. FAULTS / SOLUTIONS.............. 9. BURNER DESCRIPTION Two stage light oil burner. CE Certification No.: 006 05/0 as 9//EEC. The burner meets protection level of IP 0, EN 6059. Burner with CE marking in conformity with EEC directives: EMC 89/6/EEC, Low Voltage 7//EEC, Machines 98/7/EEC and Efficiency 9//EEC. Pump Electronic start delaying device Control-box Reset button with lock-out lamp 5 Flange with insulating gasket 6 nd stage air damper adjustment assembly 7 Nozzles holder assembly 8 Photoresistance 9 ydraulic jack 0 pole socket nd stage valve st stage valve Valve casing assembly 5 6 7 8 9 Fig. S7 0. BURNER EQUIPMENT Flange with insulating gasket....no. Screw and nuts for flange to be fixed to boiler... No. Screw and nuts for flange......no. Flexible oil pipes with nipples................ No. 7 pin plug...................no. pin plug............................... No. GB
. TECNICAL DATA. TECNICAL DATA TYPE 98T Output - Thermal power 8 / 5 kg/h 95 / 96 kw Fuel Light oil, viscosity 6 mm /s at 0 C Electrical supply Single phase, ~ 50z 0V ± 0% Motor Run current. A - 70 rpm - 86 rad/s Capacitor 8 µf Ignition transformer Secondary 8 kv - 6 ma Pump Pressure: 8 5 bar Absorbed electrical power 0.7 kw. OVERALL DIMENSIONS 7 59 00 7 5 85 5 99 ø 5 99 5,5 60 D590 6 90. WORKING FIELD (as EN 67). Pressure in combustion chamber mbar D59.8..0.6. 0.8 0. 0 8 0 6 8 0 6 Fuel output kg/h 00 0 0 60 80 00 0 0 60 80 00 Thermal power kw GB
. INSTALLATION TE BURNER MUST BE INSTALLED IN CONFORMITY WIT LEGISLATION AND LOCAL STANDARDS.. BOILER FIXING Put on the flange () the screw and two nuts, (see fig. ). Widen, if necessary, the insulating gasket holes (), (see fig. ). Fix the flange () to the boiler door () using screws (5) and (if necessary) the nuts () interposing the insulating gasket (), (see fig. ). After installation ensure that burner is lightly inclined as in fig. 5. Fig. D50 5 Fig. S7 Fig. Fig. 5 D505. FUEL SUPPLY The burner is designed to allow entry of the oil supply pipes on either side. Depending on the oil supply pipes position (to the right or to the left hand side of the burner) the fixing plate () and cable clamp () should be reversed, (see fig. 6). Fig. 6 D59 GB
. YDRAULIC SYSTEMS WARNING: The pump is designed to allow working with two pipes. In order to obtain one pipe working it is necessary to unscrew the return plug (), remove the by-pass screw () and then screw again the plug (), (see fig. 8). Fig. 8 8 7 6 Before starting the burner make sure that the return pipe-line is not clogged. An excessive back pressure would cause the damage of the pump seal. 9 0 5 max. m D595 SYSTEM NOT PERMITTED IN GERMANY Fig. 7 meters - Suction line PRIMING PUMP: - Return line On the system in fig. 7 it is - By-pass screw sufficient to loosen the suction gauge - Gauge connection connection (6, fig. 8) and wait until oil flows out. On the systems in fig. 9 and 0 start the burner and wait for the priming. Should lock-out occur prior to the arrival of the fuel, await at least 0 seconds before repeating the operation. The pump suction should not exceed a maximum of 0. bar (0 cm g). Beyond this limit gas is released from the oil. Oil pipes must be completely tight. In the vacuum systems (fig. 0) the return line should terminate within the oil tank at the same level as the suction line. In this case a non-return valve is not required. Should however the return line arrive over the fuel level, a non-return valve is required. This solution however is less safe than previous one, due to the possibility of leakage of the valve. 0.5.5 L meters ø i 8 mm 0 0 0 60 ø i 0 mm 0 0 80 00 5 - nd stage pressure adjuster 6 - Suction gauge connection 7 - st stage valve 8 - Valve casing assembly 9 - nd stage valve 0 - Auxiliary pressure test point meters 0 0.5.5.5 L meters ø i 8 mm 5 0 5 0 5 8 6 D505 ø i 0 mm 00 00 00 90 70 0 0 max. m Fig. 9 Fig. 0 max. m D59 It is necessary to install a filter on the fuel supply line. = difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes. GB
. ELECTRICAL WIRING WARNING DO NOT EXCANGE NEUTRAL WIT PASE ~ 50z 0V L N Main switch NOTES: Wires of min. mm section. (Unless requested otherwise by local standards and legislation). The electrical wiring carried out by the installer must be in compliance with the rules in force in the Country. Connect nd stage thermostat between clamps T6 - T8 by removing the bridge. TESTING: Check the shut-down of the burner by opening the thermostats and the lock-out by darkening the photoresistance. T6A h st stage hour counter (0V - 0.A max.) h nd stage hour counter (0V - 0.A max.) Safety thermostat T Neutral Limit thermostat T Remote lock-out signal (0V - 0.5A max.) T nd stage thermostat 7 pin plug L N T T S B B5 T6 T7 T8 pin plug CARRIED-OUT IN TE FACTORY 7 pole socket Ignition electrodes CONTROL BOX 55SE M Brown Blue Brown Blue Black White Blue Photoresistance nd stage oil valve pole socket st stage oil valve Capacitor M ~ Motor D56 Burner-earth Blue Brown Black White Blue Fig. M ELECTRONIC DELAYING DEVICE S70 A CONTROL BOX To remove the control-box from the burner, loosen screw (A, fig. ) and pull to the arrow direction, after removing all components, the 7 pin plug and earth wire. In case of disassembly of the control box, retighten the screw (A) with a torque wrench setting of. Nm. 5 GB
. WORKING. COMBUSTION ADJUSTMENT In conformity with Efficiency Directive 9//EEC the application of the burner on the boiler, adjustment and testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO concentration in the flue gases, their temperatures and the average temperature of the water in the boiler. To suit the required appliance output, choose the proper nozzle and adjust the pump pressure, the setting of the combustion head, and the air damper opening in accordance with the following schedule. The values shown in the table are measured on a CEN boiler (as per EN 67). They refer to.5% CO at sea level and with light oil and room temperature of 0 C. Nozzles Pump pressure Burner output Combustion head adjustment Air damper adjustment GP Angle kg/h ± % st stage nd stage st stage nd stage bar st stage nd stage Set-point Set-point Set-point.00.00 60 8.0. 0 0.5..00.00 60 8.0 6. 0.5.0.50.50 60 0. 0.5 6 0...00.00 60.5.6 5,0 8 0,6 6,0. RECOMMENDED NOZZLES Delavan type W - B Steinen type Q Danfoss type S N.B.: If necessary the st stage nozzle can have an output exceeding 50% of the total output. 6 TO FIT NOZZLES CARRY OUT TE FOL- LOWING ACTIONS: (see fig. ) Remove nozzle-holder assembly () after loosing screws () and nuts (), remove the small cables () from the control box and the photoresistance (5). Withdraw the small cables () from the electrodes, remove the diffuser disc assembly (8) from the nozzle-holder assembly () after loosing screws (9). Screw the nozzles (0) correctly and tighten it as shown in figure. 5 7 0 8 Fig. ATTENTION During the reassembly of the nozzle-holder assembly screw the nuts () as shown in the figure below. 068 TIGTEN WITOUT MOVING BACKWARDS TO TE END D568 9 S78 6 GB
. COMBUSTION EAD SETTING (see fig., page 6) It depends on the output of the burner and is carried out by rotating clockwise or counterclockwise the setting screw (6) until the set-point marked on the regulating rod (7) is level with the outside plane of the nozzlesholder assembly (). In the sketch the combustion head is set for an output of.00 +.00 GP at bar. The set-point of the regulating rod is at the same level with the outside plane of the nozzles-holder assembly as shown in the schedule.. ELECTRODES ADJUSTMENT WARNING MEASURES MUST BE RESPECTED. Fig. For prospective adjustments loosen screws () and move the electrodes assembly (), (see fig. ). mm To have access to the electrodes carry out operation as described in chapter. RECOMMENDED NOZZLES (page 6)..5 0.5 mm 0 D506.5 PUMP PRESSURE AND AIR OUTPUT st STAGE ADJUSTMENT ADJUSTMENT OF AIR SUTTER Unloosen the nut (), turn the screw () until the indicator () reaches the position desired. Then lock the nut (), (see fig. ). nd STAGE ADJUSTMENT Fig. 5 6 ADJUSTMENT OF AIR SUTTER Unloosen the nut (), turn the screw (5) until the indicator (6) reaches the position desired. Then lock the nut (), (see fig. ). Fig. 5 PRESSURE REGULATION This is set at bar at the factory. Should it be necessary to re-set or alter such pressure, this can be done, by adjusting screw (8). The pressure gauge must be mounted in place of cap (7), (see fig. 5). 8 When burner shuts down the air damper automatically closes till a max. chimney depressure of 0.5 mbar. 7 D507 S79 7 GB
.6 BURNER START-UP CYCLE st stage thermostat nd stage thermostat Motor Ignition transformer st stage valve st stage flame nd stage valve nd stage flame Lock-out lamp Normal ~s Lock-out due to failure to light 8s ~s 5s B D600 B Lock out is indicated by a lamp on the control box (, fig., page ). 5. MAINTENANCE The burner requires periodic maintenance carried out by a qualified and authorised technician in conformity with legislation and local standards. Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and consequent pollution. Before carrying out any cleaning or control always first switch off the electrical supply to the burner acting on the main switch of the system. TE BASIC CECKS ARE: Check that there are not obstructions or dents in the supply or return oil pipes. Clean the filter in the oil suction line and in the pump. Clean the photoresistance, (8, fig., page ). Check for correct fuel consumption. Replace the nozzles (see fig., page 6) and check the correct position of electrodes (fig., page 7). Clean the combustion head in the fuel exit area, on the diffuser disc. Leave the burner working without interruptions for 0 min. and check the right settings at st and nd stage of all components stated in this manual. Then carry out a combustion check verifying: Smoke temperature at the chimney; Content of CO (%); Content of CO (ppm); Smoke value according to opacity smokes index according to Bacharach scale. 8 GB
6. FAULTS / SOLUTIONS ere below you can find some causes and the possible solutions for problems that could cause a failure to start or a bad working of the burner. A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box (, fig., page ). When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the burner functions correctly, the lock-out can be attributed to a temporary fault. If however the lock out continues the cause must be determined and the solution found. FAULTS POSSIBLE CAUSES SOLUTION Check presence of voltage in the L - N clamps of the 7 pin plug. The burner doesn t start when the limit thermostat closes. Burner runs normally in the prepurge and ignition cycle and locks out after 5 seconds ca. Burner starts with an ignition delay. Lack of electrical supply. The photoresistance sees false light. Thermostats are faulty. The connections in the control box are wrongly inserted. The photoresistance is dirty. The photoresistance is defective Flame moves away or fails. The ignition electrodes are wrongly positioned. Air output is too high. Nozzle dirty or worn. Check the conditions of the fuses. Check that safety thermostat is not lock out. Eliminate the light. Replace them. Check and connect completely all the plugs. Clear it. Change it. Check pressure and output of the fuel. Check air output. Change nozzle. Check the coil of solenoid valve st stage. Adjust them according to the instructions of this manual. Set the air output according to the instructions of this manual. Replace it. WARNING The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error in installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the technical instruction enclosed with the burner, or due to the intervention of unqualified personnel. 9 GB