1

MANUAL OF
. INSTALLATION
. OPERATING
. MAINTENANCE
HEAVY OIL
BURNERS TYPE:
FOREWORD P. 2
PART I: INSTALLATION P. 4
PART II: OPERATIONS P. 21
PART III: MAINTENANCE P. 23
B U R N E R S
B R U L E U R S
B R E N N E R
QUEMADORES
BRUCI ATORI
PNR90 PNR510
PNR91 PNR515
PNR92 PNR520
PR - MD
M03967CA Rev. 00 Ed. 11-97
2
GENERAL INTRODUCTION
* This instruction sheet is supplied as an integral and essential part of the
product and must be delivered to the user.
Carefully read these instructions, as they supply important information on
installation, use, safety and maintenance.
The equipment must be installed in compliance with the regulations in force,
following the manufacturer's instructions, by qualified personnel.
Qualified personnel means those having technical knowledge in the field of
components for civil heating systems and sanitary hot water generation
and, in particular, service centres authorised by the manufacturer.
Improper installation may cause injury to people and animals, or damage to
property, for which the manufacturer cannot be held liable.
* Remove all packaging material and inspect the equipment for integrity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic
bags, foamed polystyrene, etc), should not be left within the reach of children,
as they may prove harmful.
* Before any cleaning or servicing operation, disconnect the unit from the
mains by turning the master switch OFF, and/or through the cut-out devices
that are provided.
* Make sure that inlet or exhaust grilles are unobstructed.
* In case of breakdown and/or defective unit operation, disconnect the unit.
Make no attempt to repair the unit or take any direct action. Contact qualified
personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised by
the manufactureer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit's
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular
intervals, following the manufacturer's instructions.
* When a decision is made to discontinue the use of the equipment, those
parts likely to constitute sources of danger shall be made harmless.
* In case the equipment is to be sold or transferred to another user, or in
case the original user should move and leave the unit behind, make sure
that these instructions accompany the equipment at all times,so that they
can be consulted by the new owner and/or the installer.
* For all the units that have been modified or have options fitted then original
accessory equipment only shall be used.
* This unit shall be employed exclusively for the use for which it is meant.
Any other use shall be considered as improper and, therefore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation and use, and failure to comply
with the instructions supplied by the manufacturer.
2. SPECIAL INSTRUCTIONS FOR BURNERS
*The burner should be installed in a suitable room, with ventilation openings
complying with the requirements of the regulations in force, and sufficient
for good combustion.
* Only burners designed according to the regulations in force should be
used.
* This burner should be employed exclusively for the use for which it was
designed.
* Before connecting the burner, make sure that the unit rating is the same as
delivery mains (electricity, gas gasoil, or other fuel).
*Observe caution with hot burner components. These, are usually near to
the flame and the fuel pre-heating system, if any become hot during the unit
operation they will remain hot for some time after the burner has stopped.
* When the decision is made to discontinue the use of the burner, the user
shall have qualified personnel carry out the following operations:
a) remove the power supply by disconnecting the power cable from
the master
b) disconnect the fuel supply by means of the hand-operated shut-off
valve and remove the control handwheels from their spindles.
SPECIAL WARNINGS
* Make sure that the burner has, on installation, been firmly secured to the
appliance, so that the flame is generated inside the appliance firebox.
* Before the burner is started and, thereafter, at least once a year, have
qualified personnel perform the following operations:
a) Set the burner fuel flow rate depending on the heat input of the
appliance.
b) Set the flow rate of the combustion-supporting air to obtain a
combustion efficiency level at least equal to the lower level required
by the regulations in force.
c) Check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force.
d) Make sure that control and safety devices are operating properly.
e) Make sure that exhaust ducts intended to discharge the products of
combustion are operating properly.
f) On completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened.
g) Make sure that a copy of the burner use and maintenance instructions
is available in the boiler room.
* In case of repeated burner shut-downs, do not continue re-setting the unit
manually. Contact qualified personnel to take care of such defects.
* The unit shall be operated and serviced by qualified personnel only, in
compliance with the regulations in force.
3. GENERAL INSTRUCTIONS DEPENDING ON FUEL USED
3A ELECTRICAL CONNECTION
* For safety reasons the unit must be efficiently earthed and installed as
required by current safety regulations.
* It is vital that all saftey requirements are met. In case of any doubt, ask for
an accurate inspection of electrics by qualified personnel, since the
manufacturer cannot be held liable for damages that may be caused by
failure to correctly earth the equipment.
* Qualified personnel must inspect the system to make sure that it is adequate
PREFACES
NOTICES
- THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE
DELIVERED TO THE USER.
- INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL
FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.
- CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
3
to take the maximum power used by the equipment shown on the equipment
rating plate. In particular, make sure that the system cable cross section is
adequate for the power absorbed by the unit.
* No adaptors, multiple outlet sockets and/or extension cables are permitted
to connect the unit to the electric mains.
An omnipolar switch shall be provided for connection to mains, as required
by the current safety regulations.
The use of any power-operated component implies observance of a few
basic rules, for example:
- do not touch the unit with wet or damp parts of the body and/or with
bare feet;
- do not pull electric cables;
- do not leave the equipment exposed to weather (rain, sun, etc.)
unless expressly required to do so;
- do not allow children or inexperienced persons to use equipment;
* The unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
* When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.) should
be switched off.
/cont' d...
3B FIRING WITH GAS, GASOIL OR OTHER FUELS
GENERAL
* The burner shall be installed by qualified personnel and in compiance with
regulations and provisions in force; wrong installation can cause injuries to
people and animals, or damage to property, for which the manufacturer cannot
be held liable.
* Before installation, it is recommended that all the fuel supply system pipes
be carefully cleaned inside, to remove foreign matter that might impair the
burner operation.
* Before the burner is commissioned, qualified personnel should inspect the
following:
a) the fuel supply system, for proper sealing and pressure soundness;
b) the fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
c) the burner firing system, to make sure that it is supplied for the
designed fuel type;
d) the fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
e) the fuel supply system, to make sure that the system dimensions
are adequate to the burner firing rate, and that the system is
equippped with all the safety and control devices required by the
regulations in force.
* When the burner is to remain idle for some time, the fuel supply tap or taps
should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
* Have qualified personnel inspect the installation to ensure that:
a) the gas delivery line and train are in compliance with the regulations
and provisions in force;
b) all gas connections are tight;
c) the boiler room ventilation openings are such that they ensure the
air supply flow required by the currrent regulations, and in any case
are sufficient for proper combustion.
* Do not use gas pipes to earth electrical equipment.
* Never leave the burner connected when not in use. Always close the gas
valve.
* In case of prolonged absence of the user, the main gas delivery valve to
the burner should be closed.
PREFACES
Precautions if you can smell gas:
a) do not operate electric switches, the telephone, or any other item
likely to generate sparks;
b) immediately open doors and windows to create an air flow to purge
the room;
c) close the gas valves;
d) contact qualified personnel.
* Do not obstruct the ventilation openings of the room where gas appliances
are installed, to avoid dangerous conditions such as the development of
toxic or explosive mixtures.
4
BURNER TYPE PNR90 PNR91 PNR92
Input min. low fire kW 465 698 849
max. high fire kW 1.512 2.093 2.558
min. low fire kcal/h 400.000 600.000 730.000
max. high fire kcal/h 1.300.000 1.800.000 2.200.000
Fuel Heavy Oil Heavy Oil Heavy Oil
Max oil viscosity standard vers.(E at 50 C) 7 7 7
N.D. vers.. (E at 50 C) 50 50 50
Oil flow rate min - max kg/h 40 - 130 60 - 180 73 - 220
Electric supply 230/400V - 50Hz 230/400V - 50Hz 230/400V - 50Hz
Electric comsuption kW 15.5 16.5 24
Fan&Pump motor (2800 rpm) kW 3 4 5.5
A (230/400 V) 11.3/6.5 15.1/8.7 20/11.5
Separate pump motor (2800 rpm) kW - - - - - - - - -
A (230/400 V) - - - - - - - - -
Electric oil heater kW 15.5 22.5 24
A (230/400 V) 31.5/18.2 47.3/24.4 63/35.5
Protection IP40 IP40 IP40
Control available PR - MD PR - MD PR - MD
PART 1: INSTALLATION MANUAL
TECHNICAL DATA
INSTALLATION MANUAL
BURNER TYPE PNR510 PNR515 PNR520
Input min. low fire kW 1.314 1.628 2.326
max. high fire kW 3.953 4.884 6.977
min. low fire kcal/h 1.130.000 1.400.000 2.000.000
max. high fire kcal/h 3.400.000 4.200.000 6.000.000
Fuel Heavy Oil Heavy Oil Heavy Oil
Max oil viscosity standard vers.(E at 50 C) 7 7 7
N.D. vers.. (E at 50 C) 50 50 50
Oil flow rate min - max kg/h 113 - 340 140 - 420 200 - 600
Electric supply 230/400V - 50Hz 230/400V - 50Hz 230/400V - 50Hz
Electric comsuption kW 32 41.5 59.7
Fan&Pump motor (2800 rpm) kW 7.5 11 15
A (230/400 V) 26.8/15.5 38.5/22.3 48/28
Separate pump motor (2800 rpm) kW - - - - - - 2.2
A (230/400 V) - - - - - - 8.1/4.7
Electric oil heater kW 24 12+18 18+24
A (230/400 V) 63/35.5 31.5/18.2 43.7/27.4
+43.7/27.4 +63/35.5
Protection IP40 IP40 IP40
Control available PR - MD PR - MD PR - MD
5
INSTALLATION MANUAL
Fig. 1
Burner identification can be completed by one or more of the following codes:
MD: Fully modulating operation
BL: Extended blast tube version (see dimensions)
ND: Version for high viiscosity (7 tto 50 E at 50C)
MODELLO A B BL C CL D E F G K H P M
PNR90 900 305 485 1205 1380 520 485 1005 246 450 320 300 M14
PNR91 900 305 500 1205 1400 520 485 1005 262 450 320 300 M14
PNR92 900 305 495 1205 1395 520 495 1015 292 450 320 300 M14
PNR510 1050 340 530 1390 1580 550 555 1105 345 500 420 390 M14
PNR515 1050 340 530 1390 1580 550 560 1110 384 500 420 390 M14
PNR520 1050 340 530 1390 1580 650 670 1320 422 500 440 390 M14
DIMENSIONS
BURNER IDENTIFICATION
6
0
2
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6
8
10
12
14
16
18
0 400 800 1200 1600 2000 2400 2800
90 91 92
PNR
0
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6
8
10
12
14
16
18
20
22
24
0 1000 2000 3000 4000 5000 6000 7000 8000
510 520 515
PNR
CAMPI DI LAVORO
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Fig. 3
INSTALLATION MANUAL
7
RESPECT THE BASIC SAFETY RULES. MAKE SURE OF THE CONNECTION TO THE EARTHING SYSTEM. DO NOT
REVERSE THE PHASE AND NEUTRAL CONNECTIONS. FIT A DIFFERENTIAL THERMAL MAGNET SWITCH
ADEQUATE FOR CONNECTION TO THE MAINS.
MOUNTINGS AND CONNECTIONS
Rotation of fan and oiI pump motor
After completing the electrical connection of the burner, remember to check the rotation of the fan and the oil pump motor. The
motor should rotate in an anti-clockwise direction looking at cooling fan of the motor. In the event of incorrect rotation reverse
the three-phase supply and recheck the rotation of the motor.
Fig. 4
Legend
1) Burner
2) Fixing nut
3) Washer
4) Seal
5) Stud bolt
6) Sightglass cleaning tube
7) Blast tube
INSTALLATION MANUAL
Fitting burner to boiIer
After fitting the burner to the boiler see that the space between
the blast tube and the refractory lining is sealed with appropriate
insulating material (ceramic fibre cord or refractory cement).
EIectricaI connection diagram
- Remove the cover of the electrical panel beside the burner.
- Effect the electrical connections to the supply terminal board as per the scheme in fig. 5-6, check the direction of
rotation of the fan motor (see note at end of page) and refit the panel cover.
WARNING: The burner is fitted with an electrical bridge between terminals 6 and 7, in the event of connecting the high/low
flame thermostat remove this bridge before connecting the thermostat.
IMPORTANT: In connecting electric supply wires to burner teminal block be sure that ground wire should be longer than
phase and neutral ones.
Packing
The burners are despatched in wodden crates of dimensions:
Type PNR90 1200-1650-860 mm (lh.x wdth.x ht.)
Type PNR520 1350-1650-970 mm (lh.x wdth.x ht.)
Packing cases of this type are affected by humidity and are not suitable for stacking.
The following are placed in each packing case:
1 burner;
1 gasket made of asbestos-free material to be inserted between the burner and the boiler;
2 flexible oil tubes;
1 oil filter;
1 set of the following documents: this manual, the Guarantee Certificate and the test certificate.
To get rid of the burner's packing and in the event of scrapping of the latter, follow the procedures laid down by current laws
on disposal of materials
Fig. 5 Fig.6
8 INSTALLATION MANUAL
ELECTRIC HEATER CONNECTION DIAGRAM
ELECTRIC MOTOR CONNECTION DIAGRAM
Fig. 7
Fig. 8
Fig. 9
9
OIL SUPPLY
Schemes
To feed the burner refer to the schemes here following
INSTALLATION MANUAL
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10 INSTALLATION MANUAL
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11
VERY IMPORTANT: OIL TEMPERATURE AND PRESSURE
When using heavy oils they must be preheated to allow circulation and therefore the burner must be supplied
with oil at a pressure linked to the temperature. This prevents damage to the pump due to gassification of
the oil and possible unpriming.
Minimum oil temperature must be defined following diagram in fig. 12.; minimum oil pressure is linked to oil
temperature and must be defined following diagram in fig. 13.
Example: oil being used 7 E,15 E, 50 E at 50 C the inlet temperature to the pump must be respectively
35 C, 50 C, and 77 C as indicated by the diagram.
Fig. 12
INSTALLATION MANUAL
12
INLET PRESSURE AND TEMPERATURE TO PUMPS
max. temp.140 C max press. 5 bar
BY-PASS NOZZLE COMBUSTION SYSTEM
By-pass nozzle is quite similar to standard nozzles. The only difference is the presence of a central by- pass duct allowing
oil passage from the turbulence chamber to the return line (see fig. 14 n 11).
The operating principle is as follows (see also fig. 20.21.22): all the fuel coming out of the pump enters in the turbulence
chamber (n 11) through the tangential channels (n 10), the control of oil going out through the outlet spay hole is obtained
controlling the oil flow through the central by-pass duct.
Since all oil flow rate is driven through tangential channels oil speed and turbulence are always very high even if the flow rate
through the outlet spray hole is very low. The oil flow control through the outlet spray hole is obtained by means of the
action of a pressure control valve in the return duct.
As the pressure in the return duct is increased the flow rate through the outlet spay hole is decreased. In extreme working
condition the return hole is completely closed and all the oil driven by the pump goes through the outlet spay hole.
The hydraulic system includes a pressure relief valve, included in the pump, that cuts oil pressure at maximum value 25 -
26 bar, this is the oil feed pressure to the nozzle.
The second important pressure value in the by-pass nozzle system is the return pressure that can be modified between
maximum (return duct completely closed, no return flow to the tank, high firing rate) and the minimum (return duct
completely open, very high return flow to the tank, minimum firing rate). Modification of the oil pressure in the return line are
produced by the servocontrol that acts on the pressure regulator.
Pressure draft losses in the tangential ducts are maximum when return pressure is at minimum and and vice versa; this
produces two important conclusions:
1 The oil flow rate in the tangential ducts is at maximum when the pressure in the turbulence chamber is at minimum
(minimum firing rate). Thus atamization quality is very good also with the burner at minimum output, because the oil is
very well atomized in the turbolence chamber. This is the functional advantage of the by-pass atamization system with
respect to other systems whose performances are reduced as the flow rate decreases.
2 Maximum oil flow rate corresponds to minimum burner output.
The advantages guaranteed by this atomization system are:
1 Only one nozzle positioned in the center (axis) of the combustion head and of the flame.
2 Air - oil mixing is constant all around the nozzle with all flow rates, even if it is lower at minimum burner output due to
lower air speed.
3 Oil atomization is very good with all flow rates (also minimum ones) because oil turbolence is always very high.
4 Smooth control of return pressure allows progressive variation of firing rate; the burner equipment is already arranged for
fully modulation (only a modulating regulator has to be added to the burner, no modification of the hydraulic equipment is
required).
5 The output turn down can be 1:3 or even more, this covers the requirement of most existing plants.
6 The burner ignition can be operated with very low flow rate, thus the thermal stress on the boiler is minimum, pressure
increase in the combustion chamber is very smooth, the start is more silent; as the fire has ignited the burner output
increases slowly to the maximum power (about 30").
Fig. 13
Fig. 14
INSTALLATION MANUAL
13
ADJUSTMENT
HIGH/LOW FLAME ADJUSTMENT
To adjust air delivery for high flame, loosen the socket headed screw RA and move the tie rod T along the
guide CT as desired. This will cause the damper S to move and required air delivery will be obtained.
Low flame adjustment is attained by loosening the screw VB and manually adjusting the damper S to the
desired set-point.
NOTE: after adjustment, make sure the screw RA and lockscrew VB are tight.
LOW FLAME SETTING SQL 33
The low fire air regulation can be adjusted between 45 & 100%.
To adjust move red cam with a screwdriver as illustrated.
- downwards to decrease
- upwards to increase
The low fire and ignition point must never coincide and for this reason the low fire must be 5_ higher than the
ignition cam.
Fig. 15
Fig. 16
INSTALLATION MANUAL
14
OIL FIRING
OiI Line FiIIing
It is advisable to adopt gravity feed of the burner, as shown by the installation diagram, Fig. 7.
Oil in the pre-heater is to be kept at 40_ C approx.
Before starting the burner, set the regulating and oil temperature control thermostats at 100_ C and 75_ C
respectively. These values apply to fuel oil with viscosity ranging from 3.5_ to 7_ E at 50_ C.
To fill the oil line (pre-heater, oil suction, feed to and return the nozzle) proceed as follows:
1- Cut off oil electric heaters via the line switch (off the control panel).
2 - Correct terminal 48 to terminal 49.
3 - Open the valve on the vent pipe of the pre-heater
4 - Turn control switch to position 1 .
At this point the burner performs a complete start-up cycle.
As soon as oil flows out of the vent pipe, throw the line switch to the ON position and close the valve.
If at the end of the first cycle, when burner goes to lockout and stops, oil has not filled the line yet, push reset
control button to repeat the cycle.
The line is full up when pressure gauge on the pump indicateds about 25 bar, which is the pressure required
for the proper burner operation.
To obtain that reading, loosen or tighten the screw 4, Fig. 20-21.
A few minutes' time is required to fill the oil line, but a longer time could damage the pump seals.
If the line is not filling it is necessary to check the suction pipe.
Upon completion of filling, disconnect terminal 48 from 49 and connect start-up thermostat there.
FUEL OIL THERMOSTATS
ADJUSTMENT PROCEDURE
1 -Remove the cover which encloses the safety thermostat (TRS) and interlock switch thermostat (TCN).
The pointer (TRS) controls the safety thermostat setting while the pointer (TCN) controls the interlock
switch thermostat.
2 - The thermostat pointer (2) should be at 190" C and then raised or lowered as required.
3 - The cold oil interlock switch-thermostat is controlled by the pointer (TCN). This is set to prevent the burner
from starting until a minimum oil temperature is reached and should be set 20-25" below the oil
temperature setting on the Heater Control Thermostat (see fig.19).
CAUTION: Don not set the cold oil interlock higher than the oil temperature.
4 - Replace the cover which encloses the thermostat and interlock switch-thermostat.
Fig. 17
INSTALLATION MANUAL
15
HEATER CONTROL THERMOSTAT
To regulate the thermostat use a screwdriver on RT screw (Fig. 19). The temperature to be set can be
determined from viscosity diagram (see Fig. 35 pag. 26). We suggest the actual oil temperature be set
precisely with the burner working using a mercury thermometer in the pocket.
OIL PUMPS
Pompa Suntec TA2 - TA3 - TA4 - TA5
Suction: max. 0.5 bar - maximum
recommended depression to
avoid formation of air
bubbles: 0,35 mbar
Velocity: max. 3600 rpm
Operational viscosity: 4 - 800 cSt
Intake & back pressure:
Fig. 18
Fig. 19
Key:
1) Suction 4) Pressure regulator
2) Feedback 5) Vacuum gauge connection
3) Delivery to nozzle 6) Pressure gauge connection
7) Electric heater 80W
INSTALLATION MANUAL
16
START-UP SEQUENCE
Check that the burner flame safeguard unit is not in the lockout position.
If so reset.
Ensure the temperature and pressure controls are in the made position.
When the oil has reached its correct operating temperature the fan motor starts and pre-purging begins.
As pre-purging is carried out at the maximum air position the control circuitry drives the servocontrol motor
to the fully open position within 30 seconds. When the servocontrol motor is fully open an auxiliary switch
signals to the flame safeguard unit and the full air purge is carried out for 30 secs.
During this period hot oil is circulated around the nozzle to ensure good ignition.
After pre-purging the servocontrol returns to the low flame position for ignition.
Simultaneously the ignition transformer is energised and after 3 seconds (pre-ignition) the 3 way oil valve is
actuated. This allows oil to flow to the atomizing nozzle and ignite under the control of the pressure regulator.
Two seconds after the oil valve is actuated the ignition transformer is de-energised.
The burner is now operating at the low fire rate (about 30% of the maw firing rate).
If the temperature controller is calling for maximum the servocontrol drives the burner to high flame position.
The atomizing nozzle is fed at max pressure by the regulator 8 which has been fully closed by the cam C.
Irrespective of burner position the flame safeguard continues its programme to the end and returns to its start
position for the next cycle which will be carried out once the burner has been stopped by a temperature or
limit switch.
Fig. 20
INSTALLATION MANUAL
17
Fig. 21
Fig. 22
INSTALLATION MANUAL
18
OIL DELIVERY ADJUSTMENT
The diagram illustrates the fuel flow system for this type of burner, incorporating a by-pass nozzle with oil flow
regulation in the return line.
The oil flowto the nozzle is altered by varying the pressure in the return line which is controlled bythe regulator
position.
Max oil supply is reached when the pressure in the flow line is about 25 bar and the return line is fully closed.
Min oil supply when the return line is fully open.
Relevant pressure readings in the return line are as follows:
Max oil supply : 25 bar
Min. oil supply : 9-10 bar
Turndown ratio : 3:1
START FLAME SETTING
Start flame size is a function of the nozzle size and oil pressure measured at the regulator (Fig. 26).
Select a nozzle for the application so that during the oil firing rate is about one third of the maximum one.
When valve 3 (Fig. 23) opens the pressure measured on the gauge fitted to the regulator must be between
9-10 bar to give min oil supply to the nozzle.
To obtain this pressure adjust the cam (Fig. 26) coupled with the air servocontrol.
During the setting of the start flame it is advisable to interrupt the burner operating cycle.
HIGH FLAME ADJUSTMENT
Disconnect terminal 5 and connect terminals 6 and 7 together.
The servocontrol turns the air damper and simultaneously, via the cam, closes the pressure regulator causing
an increase in pressure in the nozzle return line thereby developing maximum firing rate.
If it is necessary to adjust the oil pressure this can be done with the cam which can be adjusted until the correct
combustion readings are obtained.
LOW FLAME ADJUSTMENT
Oil supply regulation is carried out by rotating the cam that controls the oil return pressure regulator (Fig. 26)
until the pressure reading corresponds to the correct quantity of oil required for the air delivered at low flame
rating.
OIL SUPPLY PRESSURE SETTING
This is carried out during pre-purge time by tightening or loosening the socket headed screw RP on the oil
pump. For proper burner operation, the pressure reading indicated by the pressure gauge M must be 25 bar
approx.
Fig. 23
INSTALLATION MANUAL
19
OIL PRESSURE REGULATOR SETTING
The shape given to the blade in the oil sector determines the oil supply to the nozzle. The figure shows two
possible shapes:
L1: blade shape before start flame setting
L2: final shape after setting.
OIL PIPE CONNECTIONS
Fig. 24
Fig. 25
Legend
1 Flow
2 Return
3 Needle operating port
INSTALLATION MANUAL
20
INSTALLATION MANUAL
VB
LANCE REGULATION
The main feature is the capability to adjust the head to obtain maximum results from different types of plants.
Positioning the head T is carried out by releasing VR screw and turning the knurled nut to obtain the correct
setting. This head setting as well as regulating burner output also varies the velocity of combustion air accross
the head and enables the flame to be shaped according to the appliance.
Fig. 26
Fig. 27
21
PART II: OPERATIONS MANUAL
OPERATIONS MANUAL
LIMITATIONS OF USE
THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING
CORRECTLY CONNECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE,
ETC.), ANY OTHER USE IS TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.
THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE
INSTALLATION OF IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT
CARRIED OUT BY A SERVICE CENTRE AUTHORISED BY THE COMPANY MANUFACTURING THE
BURNER. A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE
GENERATOR'S CONTROL AND SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH
GUARANTEES CORRECT AND SAFE FUNCTIONING OF THE BURNER.
THEREFORE ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE
INSTALLATION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE
(E.G. DISCONNECTION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR,
DISMANTLING OF PART OF THE BURNER).
DO NOT EVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.
OPERATE ONLY THE MAIN SWITCH ("ON-OFF" SEE FIG. XX), WHICH THROUGH ITS EASY ACCESSIBILITY
AND RAPIDITY OF OPERATION ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RE-SET
BUTTON.
IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RE-SET BUTTON AND CONTACT
QUALIFIED PERSONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION.
WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR
(COUPLING FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT.
OPERATION
- Turn switch A on the burner control panel to position 1.
N.B. Make sure than the interceptor valves on the feed and return tubes are turned on.
- Check that the mechanism is not blocked (LED B lights up), if it is reactivate it by pressing the reset button C.
- Check that the series of thermostats (or pressostats) gives the all clear for operating the burner.
- Begin the burner start-up cycle: the controller activates the burner fan and at the same time switches on the ignition transformer
(indicated by LED 1 on the front panel); pre-purge lasts 13-25 seconds, depending on the burner controller.
- At the end of the pre-purge stage the oil solenoid (first stage EVG1) is energised, indicated by LED E on the display panel,
and the burner lights.
- The ignition transformer remains on for some seconds after the flame is lit (post-ignition time) after which time it is cut out
of the circuit and the LED goes out.
- As soon as the flame ignites the burner control circuit moves the automatic controller towards the high flame position; after
about 5 seconds the high/low flame thermostat takes over and the apparatus goes into 2-stage mode. High or low flame is
indicated by whether LED G on the display panel is on (high flame) or off (low flame)
22 OPERATIONS MANUAL
Front panel
A
B
C
D
E
F
G H
I
L
M
Key:
A: Main on/off switch
B: LED indicating burner blocked
C: LED indicating oil heater on
D: LED indicating oil thermostat blocked
E: LED indicating oil valve on
F: LED indicating thermal rely on
G: LED indicating ignition transformer working
H: LED indicating low flame operation
I: LED indicating high flame operation
L: LANDIS & GYR RWF32 (only on fully modulating models)
M: Automatic-Manual control of burner CAPACITY (only on fully modulating models)
N: Re-set button for burner monitor
Fig. 28
N
23
PART III: MAINTENANCE MANUAL
MAINTENANCE MANUAL
At least once a year carry out the following maintenance procedures. Where servicing is on a seasonal basis it is recopmmended
for the end of the heating season; routine servicing should be carried out every 6 months.
N.B. AII work on the burners shouId be carried out with the mains eIectricity switched off.
PERIODICAL SERVICING
- Clean and examine the oil filter cartridge and replace if necessary;
- Examine the condition of the oil flexible pipe-work and check for possible leaks;
- Clean and examine the filter inside the oil pump (see instructions in the Appendix);
- Cleaning of oil heater filter, if necessary substitution.
Note: (N.D. version only) Periodically turn filter knob to clean oil filter (see fig.XX)
- Cleaning of the heater element bundle aand ssludge removal from the shell casing in which the heater is located. Periodically
(depending on frequency of use and oil conditions) it is reccomended that the heater flange bolts be removed and the heater
withdrawn and the sdluge deposit be removed from the elements with solvent or steam.
CAUTION: do not get steam or solvent into the electrical terminals of the heater.
On flanged heaters it is recommended that a new packing be installed at each ccleaning. It issuggested periodic inspections
be made to determine the appropriate frequency of cleaning.
- Dismantle, examine and clean the combustion head (see Fig.27) and when reassembling pay scrupulous attention to the steps
shown in Figs.24/25;
- Examine the ignition electrodes and their ceramic insulators, adjust and replace if necessary (see Fig.23);
- Dismantle and clean the oil nozzle (Important: use solvents for cleaning and not metal utensils), and at the end of the
maintenance procedures replace the burner, light it and check the shape of the flame and if in doubt replace the faulty nozzle;
where the burner is used intensively it is recommended that nozzles be replaced at the start of the operating season;
- Examine and carefully clean the flame detector photoelectric cell and replace if neceessary. If in doubt light the burner and
then check the detector circuit following the procedure illustrated in Fig.24;
How to remove Iance
- Unscrew the oil fittings E
- Remove cover H (see above)
- Draw the lance C out
Fig. 29
24
How to remove Iance (NozzIe HoIder)
NozzIe positioning
- Unscrew the oil fittings E
- Loosen the screw VB
- Draw the lance (Nozzle Holder) out
To position the nozzle in relation to the head unscrew VB and move the drewer
to the required position.
Check ignition electrodes once this has been completed.
Fig. 30
Fig. 31
MAINTENANCE MANUAL
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