BALTUR TBL 105P Manual User Instructions

TBL 85P

TBL 105P

TBL 130P

TBL 160P

TBL 210P

TBL 85P DACA

TBL 105P DACA

TBL 130P DACA

TBL 160P DACA

UK

SP

FR DE

Bedienungsanleitung

ORIGINAL INSTRUCTIONS (IT)

I

NSTRUCCIONES ORIGINALES (IT

)

I

STRUCTIONS ORIGINALES (IT)

ORIGINAL BEDIENUNGSANLEITUNG IN IT

0006081325_201210

Manual de instrucciones de uso. Manuel d’instructions pour

l’utilisation.

Manual user instructions.

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- Before using the burner for the first time please carefully read the chapter “WARNINGS NOTES FOR THE USER : HOW TO USE

THE BURNER SAFELY” in this instruction manual, which is an integral and essential part of the product. The works on the burner

and on the esystem have to be carried out only by competent people.

- Read carefully the instructions before starting the burner and service it.

- The system electric feeding must be disconnected before starting working on it.

- If the works are not carried out correctly it is possible to cause dangerous accidents.

BALTUR S.p.A.

Via Ferrarese 10 - 44042 CENTO (Ferrara) ITALIA

Tel. 051.684.37.11 Fax 051.685.75.27/28

(International Tel. ++39.051.684.37.11 - Fax ++39.051.683.06.86)

http://www.baltur.it - http://www.baltur.com - E-MAIL [email protected]

18/11/2010

Declaration of Conformity

We declare that our products

BPM...; BGN…; BT…; BTG…; BTL…; TBML...; Comist…;

GI…; GI…Mist; Minicomist…; PYR…; RiNOx…; Spark...;

Sparkgas...; TBG...;TBL...; TBML ...; TS…; IBR...; IB...

(Variant: … LX, for low NOx emissions)

Description:

forced air burners of liquid, gaseous and mixed fuels for residential and

industrial use meet the minimum requirements of the European Directives:

2009/142/CE ..............................................(D.A.G.)

2004/108/CE ...............................................(C.E.M.)

2006/95/CE .................................................(D.B.T.)

2006/42/CE ................................................(D.M.)

and conform to European Standards:

UNI EN 676:2008 (gas and combination, gas side)

UNI EN 267:2002 (diesel and combination, diesel side)

These products are therefore marked:

0085

Dr. Riccardo Fava

Managing Director / CEO

!

IMPORTANT / NOTE

i

INFORMATION

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WARNING / ATTENTION

TECHNICAL DATA ........................................................................................................................................................................................................... 6

FUEL PIPE

....................................................................................................................................................................................................................... 8

APPLICATION OF BURNER TO BOILER

........................................................................................................................................................................ 12

ELECTRICAL CONNECTIONS

........................................................................................................................................................................................ 13

DESCRIPTION OF WORKING

........................................................................................................................................................................................ 14

FIRST FILLING UP OF PIPELINES

................................................................................................................................................................................. 15

STARTING UP AND REGULATION

................................................................................................................................................................................ 15

CHECKS

........................................................................................................................................................................................................................... 16

JACK ADJUSTMENT INSTRUCTIONS

........................................................................................................................................................................... 17

MAINTENANCE

............................................................................................................................................................................................................... 20

HOW TO FIND THE CAUSES OF IMPROPER WORKING AND HOW TO RECTIFY THEM

......................................................................................... 21

DETAILS OF SUNTEC PUMP

......................................................................................................................................................................................... 23

CAMS REGULATION SERVOMOTOR SQN 72.2B4A20

................................................................................................................................................. 24

ELECTRIC DIAGRAM

...................................................................................................................................................................................................... 26

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FOREWORD

These warning notes are aimed at ensuring the safe use of the compo-

nents of heating systems for civil use and the production of hot water.

They indicate how to act to avoid the essential safety of the components

being compromised by incorrect or erroneous installation and by improper

or unreasonable use. The warning notes provided in this guide also seek

to make the consumer more aware of safety problems in general, using

necessarily technical but easily understood language. The manufacturer

is not liable contractually or extra contractually for any damage caused

by errors in installation and in use, or where there has been any failure to

follow the manufacturer’s instructions.

GENERAL WARNING NOTES

• The instruction booklet is an integral and essential part of the product

and must be given to the user. Carefully read the warnings in the bo-

oklet as they contain important information regarding safe installation,

use and maintenance. Keep the booklet to hand for consultation when

needed.

• Equipment must be installed in accordance with current regulations,

with the manufacturer’s instructions and by quali ed technicians. By

the term ‘quali ed technicians’ is meant persons that are competent in

the  eld of heating components for civil use and for the production of

hot water and, in particular, assistance centres authorised by the manu-

facturer. Incorrect installation may cause damage or injury to persons,

animals or things. The manufacturer will not in such cases be liable.

• After removing all the packaging make sure the contents are complete

and intact. If in doubt do not use the equipment and return it to the

supplier. The packaging materials (wooden crates, nails, staples, plastic

bags, expanded polystyrene, etc.) must not be left within reach of chil-

dren as they may be dangerous to them. They should also be collected

and disposed on in suitably prepared places so that they do no pollute

the environment.

• Before carrying out any cleaning or maintenance, switch off the equi-

pment at the mains supply, using the system’s switch or shut-off sy-

stems.

• If there is any fault or if the equipment is not working properly, de-ac-

tivate the equipment and do not attempt to repair it or tamper with it

directly. In such case get in touch with only quali ed technicians. Any

product repairs must only be carried out by BALTUR authorised assi-

stance centres using only original spare parts. Failure to act as above

may jeopardise the safety of the equipment. To ensure the ef ciency

and correct working of the equipment, it is essential to have periodic

maintenance carried out by quali ed technicians following the manufac-

turer’s instructions.

• If the equipment is sold or transferred to another owner or if the owner

moves and leaves the equipment, make sure that the booklet always

goes with the equipment so it can be consulted by the new owner and/

or installer.

• For all equipment with optionals or kits (including electrical), only origi-

nal accessories must be used.

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WARNING NOTES FOR THE USER HOW TO USE THE BURNER SAFELY

BURNERS

• This equipment must be used only for its expressly stated use: applied

to boilers, hot air boilers, ovens or other similar equipment and not

exposed to atmospheric agents. Any other use must be regarded as

improper use and hence dangerous.

• The burner must be installed in a suitable room that has ventilation in

accordance with current regulations and in any case suf cient to ensure

correct combustion

• Do not obstruct or reduce the size of the burner’ air intake grills or the

ventilation openings for the room where a burner or a boiler is installed

or dangerous mixtures of toxic and explosive gases may form.

• Before connecting the burner check that the details on the plate corre-

spond to those of the utility supplies (electricity, gas, light oil or other

fuel).

• Do not touch hot parts of the burner. These, normally in the areas near

to the  ame and any fuel pre-heating system, become hot when the

equipment is working and stay hot for some time after the burner has

stopped.

• If it is decided not to use the burner any more, the following actions must

be performed by quali ed technicians:

a) Switch off the electrical supply by disconnecting the power cable from

the master switch.

b) Cut off the fuel supply using the shut-off valve and remove the control

wheels from their position.

c) Render harmless any potentially dangerous parts.

Special warning notes

• Check that the person who carried out the installation of the burner  xed

it securely to the heat generator so that the  ame is generated inside

the combustion chamber of the generator itself.

• Before starting up the burner, and at least once a year, have quali ed

technicians perform the following operations:

a) Set the burner fuel capacity to the power required by the heat ge-

nerator.

b) Adjust the combustion air  ow to obtain combustion yield of at least

the minimum set by current regulations.

c) Carry out a check on combustion to ensure the production of no-

xious or polluting unburnt gases does not exceed limits permitted

by current regulations.

d) Check the adjustment and safety devices are working properly.

e) Check the ef ciency of the combustion products exhaust duct.

f) Check at the end of the adjustments that all the adjustment devices

mechanical securing systems are properly tightened.

g) Make sure that the use and maintenance manual for the burner is

in the boiler room.

• If the burner repeatedly stops in lock-out, do not keep trying to manually

reset but call a quali ed technicians to sort out the problem.

• The running and maintenance of the equipment must only be carried

out by quali ed technicians, in compliance with current regulations.

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ELECTRICAL SUPPLY

• The equipment is electrically safe only when it is correctly connected to an

ef cient ground connection carried out in accordance with current safety

regulations. It is necessary to check this essential safety requirement.

If in doubt, call for a careful electrical check by a quali ed technicians,

since the manufacturer will not be liable for any damage caused by a

poor ground connection.

• Have quali ed technicians check that the wiring is suitable for the

maximum power absorption of the equipment, as indicated in the technical

plate, making sure in particular that the diameter of cables is suf cient

for the equipment’s power absorption.

• Adapters, multiple plugs and extension cables may not be used for the

equipment’s power supply.

• An ominpolar switch in accordance with current safety regulations is

required for the mains supply connection.

• The electrical supply to the burner must have neutral to ground

connection. If the ionisation current has control with neutral not to ground

it is essential to make a connection between terminal 2 (neutral) and the

ground for the RC circuit.

• The use of any components that use electricity means that certain

fundamental rules have to followed, including the following:

- do not touch the equipment with parts of the body that are wet or damp

or with damp feet

- do not pull on electrical cables

- do not leave the equipment exposed to atmospheric agents (such as

rain or sun etc.) unless there is express provision for this.

- do not allow the equipment to be used by children or inexpert

persons.

• The power supply cable for the equipment not must be replaced by the

user. If the cable gets damaged, switch off the equipment, and call only

on quali ed technicians for its replacement.

• If you decide not to use the equipment for a while it is advisable to switch

off the electrical power supply to all components in the system that use

electricity (pumps, burner, etc.).

GAS, LIGHT OIL, OR OTHER FUEL SUPPLIES

General warning notes

• Installation of the burner must be carried out by quali ed technicians

and in compliance with current law and regulations, since incorrect

installation may cause damage to person, animals or things, for which

damage the manufacturer shall not can be held responsible.

• Before installation it is advisable to carry out careful internal cleaning

of all tubing for the fuel feed system to remove any residues that could

jeopardise the proper working of the burner.

• For  rst start up of the equipment have quali ed technicians carry out

the following checks:

• If you decide not to use the burner for a while, close the tap or taps that

supply the fuel.

Special warning notes when using gas

• Have quali ed technicians check the following:

a) that the feed line and the train comply with current law and

regulations.

b) that all the gas connections are properly sealed.

• Do not use the gas pipes to ground electrical equipment.

• Do not leave the equipment on when it is not in use and always close

the gas tap.

• If the user of is away for some time, close the main gas feed tap to the

burner.

• If you smell gas:

a) do not use any electrical switches, the telephone or any other object

that could produce a spark;

b) immediately open doors and windows to create a current of air that

will purify the room;

c) close the gas taps;

d) ask for the help of quali ed technicians.

• Do not block ventilation openings in the room where there is gas

equipment or dangerous situations may arise with the build up of toxic

and explosive mixtures.

FLUES FOR HIGH EFFICIENCY BOILERS AND SIMILAR

It should be pointed out that high ef ciency boilers and similar discharge

combustion products (fumes) at relatively low temperatures into the  ue.

In the above situation, traditional  ues (in terms of their diameter and heat

insulation) may be suitable because the signi cant cooling of the combustion

products in these permits temperatures to fall even below the condensation

point. In a  ue that works with condensation there is soot at the point the

exhaust reaches the atmosphere when burning light oil or heavy oil or the

presence of condensate water along the  ue itself when gas is being burnt

(methane, LPG, etc.). Flues connected to high ef ciency boilers and similar

must therefore be of a size (section and heat insulation) for the speci c use

to avoid such problems as those described above.

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WARNING NOTES FOR THE USER HOW TO USE THE BURNER SAFELY

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TBL TBL TBL TBL TBL

85P/ P DACA 105P/ P DACA 130P/ P DACA 160P/ P DACA 210P

BURNER FIXING FLANGE 2 2 2 2 2

ISOLATING GASKET 1 1 1 1 1

STUD BOLTS N° 4 N° 4 N° 4 N° 4 N° 4

M 12 M 12 M 12 M 12 M 12

EXAGONAL NUTS N° 4 N°4 N° 4 N° 4 N° 4

M 12 M 12 M 12 M 12 M 12

FLAT WASHERS N° 4 N° 4 N° 4 N° 4 N° 4

Ø 12 Ø 12 Ø 12 Ø 12 Ø 12

TECHNICAL DATA TBL 85P

TBL 85P

DACA

TBL 105P

DACA

TBL 130P

DACA

TBL 160P

DACA

TBL 210P

THERMIC CAPACITY MAX kW 850 1050 1300 1600 2100

MIN kW 200 320 400 500 800

OPERATION Two-stage

NOx EMMISION mg/kWh < 185 (Classe II EN 267)

MOTORE kW 1,1 1,5 2,2 2,2 3

r.p.m.

2800 2800 2800 2800

2800

ABSORBED ELECTRICAL POWER* kW 1,50 1,90 2,60 2,60 3,40

line fuse A

400 V

6 6 10 10 16

IGNITION TRANSFORMER

2 x 5 kV - 30 mA - 230 V/ 50 Hz

VOLTAGE

3N ~ 400 V ±10%- 50Hz

PROTECTION RATING

IP 40

FLAME DETECTOR

PHOTORESISTANCE

/NOISE** dBA 73 75,5 79 79 87

WEIGHT kg 82 88 92 92 95

Fuel max. viscosity (light-oil)

5,5 cst/20°C - 1,5° E / 20°C

FLOW RATE MAX kg/h 71,6 88,5 109,6 134,9 177

MIN kg/h 16,9 27 33,7 42,2 67,4

TECHNICAL DATA

*) Total absorption at start with ignition transformer on.

**) Noise levels measured by the manufacturer in the laboratory with burner running on test boiler, at maximum nominal thermal output (DACA verion burner).

STANDARD ACCESSORIES

A A1 A2 B B1 B2 C D

min

D

max

E

Ø

F

Ø

I L

min

L

max

M N

TBL 85P - P DACA

670 300 370 510 380 130 1245 175 400 161 159 260 225 300 M12 170

TBL 105P - P DACA

680 310 370 520 380 140 1250 175 400 180 178 280 250 325 M12 190

TBL 130P - P DACA

680 310 370 520 380 140 1250 175 400 180 178 280 250 325 M12 190

TBL 160P - P DACA

680 310 370 540 380 160 1280 200 450 224 219 320 280 370 M12 235

TBL 210P

680 310 370 540 380 160 1290 210 450 250 219 320 280 370 M12 255

N° 0002471141

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1) Combustion head

2) Gasket

3) Burner mounting ange

4) Burner head regulation device

5) 2° ame electrovalve

6) Safety valve

7) 1° ame electrovalve

OVERALL DIMENSIONS

10) Equipment

12) Ignition transformer

13) Motor contactor

14) Thermal relay

15) 7 pole plug

16) 4 pole plug

17) Schematic panel

ELECTRICAL BOX COMPONENTS

8) Hinge

9) Air regulation hydraulic jack

9a) Air regulation servomotor ( DACA)

10) Pump

11) Electric control panel

12) Motor

TBL 85P

TBL 85P DACA

TBL 105P

TBL 105P DACA

TBL 130P

TBL 130P DACA

TBL 160P

TBL 160P DACA

TBL 210P

TBL 210P DACA

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WORKING FIELD

The working fields are obtained from test boilers corresponding

to the standard EN267 and are indicatively for the combination

burner-boiler. For correct working of the burner the size of the

combustion chamber must correspond to current regulations; if

not the manufacturers must be consulted.

FUEL PIPE

The following description covers merely the basic requirements for

an efcient operation.

The unit is equipped with a self-suction pump, capable of sucking

oil directly from the tank also for the rst ll-up.

This statement holds only if the required conditions exist (refer to

table of distances and difference in levels). To ensure an efcient

operation, it is better to make suction and return pipes with welded

ttings and to avoid the use of threaded connections which often

cause air inltration’s interfering with the pump operation and

consequently with the burner. Where a removable tting is required,

use the welded ange method inserting a fuel resistant gasket to

obtain a positive sealing.

For systems requiring pipes with a relatively small diameter we

recommend the use of copper pipes. For unavoidable joints we

recommend the use of biconic ttings.

The annexed tables show the indicative diagrams for the different

types of systems depending on the position of the tank in respect

to the burner.

The suction pipe should run up-slope towards the burner to avoid

possible formation of gas bubbles. Where more burners are installed

in one boiler room, it is essential that every burner has its own

suction pipe. Only return pipes can lead to a single manifold pipe

with an adequate cross section leading to the tank. Never connect

the return pipe directly to the suction pipe.

It is a good practice to properly heat-insulate the suction and

return pipes to prevent cooling with would otherwise affect the unit

efciency.

Pipe diameters (to be strictly complied with are listed in the following

table.

The maximum amount of vacuum that the pump can withstand

noiselessly under normal operating conditions is 35 cm.Hg. ; if

these limit is exceeded normal pump operation will no longer be

guaranteed.

Maximum suction and return pressure = 1 bar.

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PIPES FOR LIGHT OIL BURNERS MODEL TBL 85P/ P DACA - 105P/ P DACA

GRAVITY SUPPLY SYSTEM

1 Tank

2 Feeding pipe

3 Wire-net lter

4 Pump

5 Degasier

6 Suction pipe

7 Return pipe

8 Automatic fuel interception

device at burner shut off

9 Non-return valve

DROP-TYPE SYSTEM WITH SUPPLY FROM THE TANK TOP

1 Tank

3 Wire-net lter

4 Pump

6 Suction pipe

7 Return pipe

8 Automatic fuel interception

device at burner shut off

9 One-way valve

10 Bottom valve

SUCTION - TYPE FEEDING SYSTEM

N.B. For any missing devices in the piping, follow existing regulations.

H = Difference in level between level in the tank and the pump axis.

L = Maximum length of suction pipe including the vertical lift.

For each bend or valve deduct 0,25 m.

P = 3,5 m. (max.)

H Total meters

meters meters

Ø i. 14 mm.

1 30

1,5 35

2 35

2,5 40

3 40

H Total meters

meters meters

Ø i. 14 mm.

1 30

1,5 35

2 35

2,5 40

3 40

PUMP AXIS

1 Tank

3 Wire-net lter

4 Pump

6 Suction pipe

7 Return pipe

10 Bottom valve

PUMP AXIS

H

meters

Total meters

meters

Ø i. 14

mm.

Ø i. 16

mm.

0,5 26 45

1 22 38

1,5 19 31

2 14 25

2,5

11 19

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H = Difference in level between level in the tank and the pump axis.

L = Maximum length of suction pipe including the vertical lift. For each bend or valve deduct 0,25 m.

GRAVITY SUPPLY SYSTEM

1 Tank

2 Feeding pipe

3 Wire-net lter

4 Pump

5 Degasier

6 Suction pipe

7 Return pipe

8 Automatic fuel interception

device at burner shut off

9 Non-return valve

PUMP AXIS

DROP-TYPE SYSTEM WITH SUPPLY FROM THE TANK TOP

PUMP AXIS

SUCTION - TYPE FEEDING SYSTEM

1 Tank

3 Wire-net lter

4 Pump

6 Suction pipe

7 Return pipe

10 Bottom valve

PUMP AXIS

N.B. For any missing devices in the piping, follow existing regulations.

P = 3,5 m. (max.)

PIPES FOR LIGHT OIL BURNER MODEL TBL 130P/ P DACA - 160P/ P DACA - 210P

H Total meters

meters meters

Ø i. 16 mm.

1 40

1,5 45

2 45

2,5 50

3 50

H Total meters

meters meters

Ø i. 16 mm.

1 40

1,5 45

2 45

2,5 50

3 50

1 Tank

3 Wire-net lter

4 Pump

6 Suction pipe

7 Return pipe

8 Automatic fuel interception device at

burner shut off

9 One-way valve

10 Bottom valve

H

meters

Total meters

meters

Ø i. 14 mm. Ø i. 16 mm.

0,5 36 55

1 30 48

1,5 25 41

2 20 32

2,5 15 24

3 10 15

3,5 4 7,5

Nr. 0002901470

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AUXILIARY PUMP

In some cases (excessive distance or difference in level) it is

necessary to install a “loop-type” supply system with an auxiliary

pump, which dispenses with the connection of the burner pump

directly to the tank.

In this case the auxiliary pump can be put into operation when the

burner is started up and cut-off when the latter stops.

The electric wiring of the auxiliary pump is made by connecting

the coil (230 V) which controls the pump remote control switch to

terminals “N” (equipment terminal board) and “L1” (downstream

the motor remote control switch).

It is important to comply strictly with the previsions set forth here

below:

- The auxiliary pump should be installed as near as possible to

the fuel to be sucked.

- Its head should meet the requirements of subject system.

- We recommend a delivery rate equal to at least that of the

burner pump.

- Connection pipes should be sized to cope with the delivery

rate of the auxiliary pump.

- Always avoid to electrically connect the auxiliary pump directly

to the remote control switch of the burner motor.

HYDRAULIC DIAGRAM

LEGEND

1 - Foot valve

2 - Eventual air regulation motor

3 - 2

nd

ame nozzle

4 - 1

st

ame nozzle

5 - Safety valve normally closed

6 - 12 bar pump

7 - Valve normally closed

8 - Air gate control hydraulic jack

Note Pressure loss: TBL 85P - 85P DACA = 1 bar

TBL 105P - 105P DACA = 1,5 bar

TBL 130P - 130P DACA = 1,5 bar

TBL 160P - 160P DACA = 2 bar

TBL 210P = 2,5 bar

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APPLICATION OF BURNER TO BOILER

HEAD UNIT ASSEMNLY

• Adjust the position of connector flange 5 by loosening the

screws 6 so that the combustion head penetrates the advised

amount into the combustion chamber as recommended by the

generator’s manufacturer.

• Position the seal insulation 3 on the tube unit inserting cord 2

between flange and seal.

• Fasten the Combustion Head unit 4 to the boiler 1 by means

of the stud bolts, washers and the nuts provided 7.

!

Competely seal the space between the tube unit of the burner

and the hole in the refractory panel using suitable materials

to do so.

ASSEMBLYOFVENTILATION SYSTEM

• Position the half-hinge on the burner scroll in line with those on

the combustion head assembly.

• Put the hinge pin 10 in the position considered most suitable.

• Connect the cable switch on to thecorresponding electrodes,

close the hinge, locking the burner by means of screws 11.

COMPLETING BURNER SETUP

• Remove the protective yellow caps from the connectors beneath

the combustion head and close to the solenoid valves.

• Connect the 12 light oil pipes provided with the burner to their

corresponding connectors, making sure they are properly sealed.

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ELECTRICAL CONNECTIONS

The three-phase power supply line must have a switch with fuses. The

regulations further require a switch on the burner’s power supply line,

outside the boiler room and in an easily accessed position. For the

electrical connections (line and thermostats), follow the wiring diagram

enclosed. To carry out the connection of the burner to the power supply

line proceed as follows:

• Remove the lid by unscrewing the 4 screws (1) in figure 1, without

removing the transparent door. In this way the burner’s electrical

panel can be accessed. .

• Slacken le screws (2) and, after removing the cable float (3), pass

the two 7 and 4 pole plugs through the hole (see figure

• 2). Connect the power supply cables (4) to the contactor, connect

the cable to ground (5) and close the cable holder.

• Reposition the cable float as in figure 3. Turn the cam (6) so that

the float exerts sufficient pressure on the two cables, then tightethe

screws that fasten the cable float. Finally, connect the two 7 and

4-pole plugs.

!

the housings for the cables for the 7 and 4-pole plugs are provide

respectively for cable Ø 9.5÷10 mm and Ø 8.5÷9 mm, this to

make sure the protection rating is IP 54 (standard IEC EN60529)

for the electrical panel.

• reclose the electrical panel lid, tighten the 4 screws (1) with a torque

of about 5 Nm to ensure the correct seal. At this point to be able

to access the control panel (8), unfasten the transparent door (7),

using slight touch pressure in the direction of the arrows in figure 4,

move it the short distance to separate it from the lid.

• to properly resecure the transparent door on the panel proceed

as indicated in 5:position the hooks at their hooking points and (9)

slide the door in the direction indicated by the arrow until it clicks.

It is now well sealed.

!

only qualified technicians may open the burner’s electrical panel.

Figura 1

Figura 2

Figura 3

Figura 4

Figura 5

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DESCRIPTION OF WORKING

It is not advisable to have too large a burner for the boiler for heating and

for hot water as the burner may work for long periods with a single ame,

making the boiler work at lower than required output; as a result of this

the combustion products (fumes) emerge at too low a temperature (at

about 180° C in the case of heavy oil and 130° C with light oil), causing

soot to build up at the ue. In addition, when the boiler is working at

lower output than that indicated in the technical data, it is likely that acidic

condensate and soot will form in the boiler with the result that it will quickly

corrode and get clogged up. When the two-ame burner is installed on

a hot water boiler for heating use, it must be connected so that it works

normally with both ames, completely stopping without passing to the

rst ame when the preset temperature is reached. So that it works in

this way, do not install the second ame’s thermostat, and make a direct

bridge connection between the equipment’s terminals. In this way only

the burner’s capacity to switch on at low rate is used for a gentle ignition,

which is essential for boilers with a pressurised combustion chamber and

also very useful for normal boilers with depression combustion chamber.

The boiler’s start - stop is subject to the usual running or safety

thermostats.

By switching off switch 1, if the thermostats are closed, the voltage

reaches the command and control equipment (switching on Led 2) which

starts it working. The fan motor (LED 3) and the ignition transformer (LED

4) are then switched on. The motor turns the fan that carries out an air

wash of the combustion chamber and at the same time of the fuel pump

that cause circulation in the ducts that expels any gas bubbles through

the return valve. This pre-wash stage ends with the opening of the safety

solenoid valves and the rst ame (LED 5), which allows the fuel at a

pressure of 12 bar to get to the rst ame’s nozzle and from this to enter

the combustion chamber nely atomised. As soon as the vaporized fuel

leaves the nozzle it is lit by the charge between the electrodes on the

start of the motor. During rst ame ignition the air damper is kept in

the position registered on the screw which is accessed by unscrewing

the cap on the top of the hydraulic control piston (see page 39), if the

air adjustment servo motor is used (see page 46). If the ame appears

normally, with the safety time set by the electrical equipment passed,

this switches on the solenoid valve (closed at rest) of the second ame

(LED 6) (if the air adjustment servo motor is used, see page 46). The

opening of the 2nd ame allows the light oil, at a pressure of 12 bar, to

reach the 2nd nozzle and, at the same time, the control piston for the

combustion air adjuster moves down to open the adjuster further. The

travel distance of the piston can be registered with the screw with locking

nut, the burner is thus working at full rate. From when the ame appears

in the combustion chamber the burner is controlled by the photoelectric

cell and the thermostats.

The control equipment follows the program and switches the ignition

transformer off. When the temperature or the pressure in the boiler

reaches that set by the thermostat or pressure switch, the latter stops

the burner. Subsequently, when the temperature or the pressure falls

below the closing level of that of the thermostat or pressure switch, the

burner is switched back on again. If, for any reason, during the working

of the burner the ame is lost, after just one second the photoelectric cell

reacts to cut off the power supply from that relay to automatically switch

off the solenoid valves which intercepts the nozzles ow. The switch on

stage is thus repeated and, if the ame ignites again normally, the burner

starts working again normally, if not (if the ame is irregular or fails to

light completely) the equipment goes automatically into lock-out (LED 7).

!

The LMO44 device goes into lock-out after three

repetitions of the ignition cycle.

If the program is interrupted (due to a power supply failure, manual action

or the intervention of the thermostat, etc.) during the pre-wash stage,

the programmer returns to its starting position and will automatically

repeat the whole of the burner ignition sequence.

!

It is clear from the above that the choice of nozzles, depending

on the total capacity (2 nozzles working) desired, must be

made taking into account the capacity corresponding to the

working pressure of 12 bar using light oil. It is of course

possible to vary within wide limits the relationship between

the first and the second flames by replacing the nozzles.

Bear in mid however that for good working, the fuel supply with the rst

ame should not be less than the minimum capacity (as indicated on the

plate) for the specic model. A lower capacity will make ignition difcult

and combustion with the rst ame alone may not be good.

1 Main ON-OFF switch

2 Live voltage light

3 Fan working light

4 Transformer on light

5 2

nd

stage working light

6 1

st

stage working light

7 Control box lock-out light

8 Control box release button

15 / 28

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FIRST FILLING UP OF PIPELINES

After making sure that protective plastic caps inside the pump ttings

have been removed, proceed as follows :

• Set the burner switch on “0”.This operation prevents automatic

connection of the burner.

• With a three-phase burner make sure that the motor rotates

counter-clockwise, looking at the burner from the pump end.

The direction of rotation can be determined by observing the

direction of rotation of the fan through the port-hole on rear of

the fan scroll. To start the motor, close the remote control switch

manually (pressing on the mobile part) for a few seconds and

watch the direction of the rotation of the fan. Of it is necessary

to reserve the direction of rotation, invert two phases on line

input terminals counter motor K1

!

To positively determine the direction of rotation, wait until

the fan turns very slowly because it is quite possible to

misinterpret direction of rotation.

• Disconnected, if already connected, the flexible pipes from both

suction and return lines.

• Dip the end of the suction flexible pipe into a vessel containing

either lubrification oil or fuel oil (do not use low viscosity products

such as gas-oil, light oil, kerosene. etc).

• Now press on the mobile part of the motor remote control switch

to start up the motor and the pump. Wait until the pump has

sucked in an amount of lubrificant equal 1 or 2 glasses, then

stop. This operation will prevent the pump from operating dry

and will increase the suction power.

!

Pump operating at 2800 r.p.m. must not work dry otherwise

they will jam (seizure) within a very short time.

• Now connect the flexible pipes to the suction line and open

all the gate valves fitted on this line and any other similar fuel

cut-off device.

• Now press again on the mobile part of the motor remote

control switch to start up the pump which will suck fuel from the

tank. When fuel is seen coming out of the return line (not yet

connected), stop.

!

: If the pipe is long, it may be necessary to bleed the air out

through the cap; if the pump is not fitted with a breather cap,

remove the cap from the pressure test point.

• Connect the return flexible pipe to the return line and open the

valves fitted in this pipe. Now the burner is ready for lighting up.

STARTING UP AND REGULATION

Before starting up the burner make sure that :

• Feeding line connections to thermostats or pressure switches are

made exactly according to electric diagram of the control box.

• Check if there is fuel in the tank and water in the boiler.

• All the gate valves fitted on the fuel oil suction and return pipes

should be open; the same thing applies to any other fuel cut-off

device.

• Make sure that discharge of combustion products takes place

freely (boiler and chimney gate valves open).

• Make sure that burner head project into the combustion

chamber according to the manufacturer’s directives.

For compliance with this requirement, the burner is equipped

with a boiler mounting flange, which slides in respect to the

combustion head.

• The nozzles fitted on the burner should match the boiler

capacity but, if necessary, replace them with others.

Under no circumstances should the amount of delivered fuel

be higher than the maximum amount required by the boiler and

the max. amount permitted for the burner. To start the burner

proceed as follows:

!

The burners in TBL version are provided with switch to change

from 1

st

to 2

nd

stage.

• Avoid working with the second flame: position the 1

st

and 2

nd

stage switch on the printed circuit at its 1

st

stage position for

burners.

• Slightly open the air reg ula tor and let in a n

amount of air deemed to be necessary for burner

operation with the 1

st

flame and fix it in this position:

- for adjustment of the hydraulic jack see 0002935420,

- for adjustment of the servomotor see 0002935210.

Set the air control device in an intermediate position on the

combustion head (see the chapter “Air control on the combustion

head”).

• Close the isolating switch and control box switch.

• The small motor of the cyclic relay which will start to rotate

causing the connection of the burner component devices

according to the preset program. The burner will start operation

as described in the Chapter “Description of Operation”.

• When the burner operates with the 1

st

flame, adjust the amount

of air necessary,for an efficient combustion by following the

previous description under n. 2. It is better if the amount of air

for the 1st flame is slightly reduced in order to ensure a perfect

ignition also in the most critical conditions.

• After adjusting the amount of air for the 1

st

flame, stop the

burner by cutting off the current from isolating switch, connect

the terminals on the terminal board of the 2

nd

flame thermostat

among them and settle the 1

st

and 2

nd

stage switch in 2

nd

stage

Control box specifications

Control box and relativ

programmer

Safety time

in seconds

Preventilation and washing

time in seconds

Post-starting

in seconds

`time between 1st e 2nd flame

in seconds

LMO44 5 25 5 5

16 / 28

0006081325_201210

ENGLISH

position.

• Turning the screw that limits the piston travel distance in the

case of models with hydraulic jack (see 0002935420) or use air

adjustment cam air of the 2

nd

flame for servo motor models (see

0002935210) and set the air shutter opening in the 2

nd

stage

at a position considered suitable for the desired supply of fuel.

• Now connect the burner again; it will start and automatically

switch to the 2

nd

flame according to the present program.

• With the burner operating with the 2

nd

flame, adjust the amount

of air necessary to ensure an efficient combustion with the screw

mentioned under item 7. Combustion test should be made using

appropriate instruments. Make the regulation so as to obtain a

certain amount of carbon dioxide (CO

2

) in the smoke, varying

from min. 10% to max. 13% with a smoke number not exceeding

2 (Bacharach scale).

!

When first switching on the burner, shut downs may be

experienced during the passing from 1

st

- 2

nd

flame due to

the presence of air in the jack circuit. Slightly loosen the nut

blocking the jack pipe, carry out a few operating cycles until

there is a discharge of diesel from the nut / connection of

the jack. Tighten the nut when the operation is finished.

CHECKS

After starting up the burner, check the safety devices (photoresistance,

block, thermostats).

• The photocell is the flame control device and so it should trip if

the flame extinguishes during operation (this check should be

made after at least 1 minute from lighting up).

• The burner should be capable of blocking itself and

remain so when a normal flame does not come on during

start-up cycle and within the preset on control box.

The “lock-out” causes the motor and the burner to stop

immediately and corresponding “lock-out” warning lamp lights

up.To check the function photoresistant-cell and lock-out system

proceed as follows:

- Start up the burner.

- After at least one minute, remove the photo-cell from its seat

and pull it out and simulate flame failure by covering the photo-

cell (use a rag to close the window in the photocell support).

The burner flame should go to lock-out.

- Keep the photo-cell in the dark and the burner will start again,

but the photo-cell does see the light and the burner goes to

lock-out within the time preset by control box. The control

box can be reset only manually by pressing the appropriate

push-button.

• To check the thermostat efficiency, run the burner until the water

in the boiler reaches a temperature of at least 50 °c and then turn

the thermostat control knob to reduce the temperature until an

opening click is heard and simultaneous stopping of the burner.

The thermostat should trip within a maximum tolerance of 5 to 10

°C in respect to the control thermometer (boiler thermometer);

if not, change the setting on the thermostat scale to match that

of the thermometer.

N°0002935420

17 / 28

0006081325_201210

ENGLISH

Legend:

A – Hydraulic jack body

B – Air regulation screw 1

st

ame

C1, C2 – Ring nuts for adjusting and locking of air shutter

position in 1

st

ame

D – Air regulation screw 2

nd

ame

E – Locking nut

F – Air adjustment gate

G – Air inlet

H – Support eyelet

JACK ADJUSTMENT INSTRUCTIONS

Adjustment of 1st flame air shutter position

• To increase air supply capacity, turn ring nut C1 anticlockwise;

use the counter wrench on body A of the jack to prevent too

much being exerted on the eyelet of pin H. This action lowers

body A and favours the opening of air shutter F in first stage.

To reduce the flow of air turn ring nut C2 clockwise, also in this

case use the counter wrench on the body of the jack. In this

case body A is raised and favours the closing of air shutter F.

• After adjustment of the 1

st

flame air, lock the two ring nuts C1

and C2.

Adjustment of 2nd flame air shutter position

• Slacken the locking nut E.

• To increase 2

nd

flame air flow, slacken screw D; in this way the

travel distance of the hydraulic piston will be lengthened. To

reduce air flow tighten the screw.

• After 2

nd

flame air flow adjustment, tighten nut E.

!

To avoid damaging eyelet H, carry out all the adjustment

operations with use of wrench and counter wrench.

A B C D E

TBL 85P - 85P DACA 2 ÷ 2,5 19 5 2 ÷ 3 7,5 ÷ 8,5

TBL 105P - 105P DACA 2 ÷ 2,5 19 5 2 ÷ 3 7,5 ÷ 8,5

TBL 130P - 130P DACA 2 ÷ 2,5 19 5 2 ÷ 3 7,5 ÷ 8,5

TBL 160P - 160P DACA 2 ÷ 2,5 19 5 2 ÷ 3 7,5 ÷ 8,5

TBL 210P 12 ÷ 12,5 29 15 2 ÷ 3 7,5 ÷ 8,5

N°0002935131

18 / 28

0006081325_201210

ENGLISH

Legend:

1- Diffuser

2- Deector disk

3- Nozzle holder

4- Ignition electrodes

5- Nozzle

ELECTRODES/IONISATION PROBE

ADJUSTMENT DIAGRAM

After having installed the nozzle, check the correct position of the

electrodes and disk according to the following levels. It’s adviseable

to check levels after every intervention on head.

!

To prevent damage to the support effect nozzle assembly/

disassembly tasks with the aid of a wrench and counter-

wrench.

!

The use of an ionisation angle of 45° may significantly

improve combustion values with certain applications (e.g.

narrow combustion chambers).

RECOMENDED NOZZLES

MONAMRCH tipo PLP 60° (TBL 85P)

MONARCH tipo PLP 60° (TBL 105P)

MONARCH tipo PLP 60° (TBL 130P)

STEINEN tipo SS 45° (TBL 160P)

STEINEN tipo SS 45° (TBL 210P)

19 / 28

0006081325_201210

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COMBUSTION HEAD AIR ADJUSTMENT

The combustion head has an adjustment device so that the air

passage between the disk and the combustion head is opened

or closed. You are thus able to obtain, closing the passage, high

pressure upstream of the disk even at low capacity. The high speed

and turbulence of the air provides for its greater penetration into

the fuel and therefore an excellent mixture and flame stability. It

may be necessary to have high air pressure before the disk to

prevent flame fluctuations, particularly essential when the burner

works on the combustion chamber that is pressurized and/or at a

high thermal load.

It is clear from the above that the device that closes the air to the

blast-pipe must be set at a position such as to always obtain very

high air pressure behind the disk. It is advisable to adjust in such

a way as to obtain a closure of the air at the combustion head that

will require a significant opening of the air damper that regulates

the aspiration flow from the burner fan. This must of course be

the case when the burner is working at maximum desired supply.

In practice you have to start the adjustment with the device that

closes the air at the combustion head in an intermediate position,

switching on the burner for approximate adjustment as explained

previously.

When the maximum desired supply has been reached, the position

of the device that closes the air at the combustion head is corrected,

moving it forward and backwards, until the right amount of air is

flowing to the supply, with the air damper in significantly open.

!

The above adjustments are indicative only; position the

combustion head according to the characteristics of the

combustion chamber

X= Distance between combustion head and disk; adjust the

distance X following the indications below:

a) slacken screw 1

b) turn screw 2 to position the combustion head 3, referring to

index 4.

c) adjust the distance X between minimum and maximum

according the indications in the table.

COMBUSTION HEAD ADJUSTMENT SCHEME

BURNER X Value indicated by index 4

TBL 85P - TBL 85P DACA 100 ÷ 64 1 ÷ 5

TBL 105P - TBL 105P DACA 103 ÷ 67 1 ÷ 5

TBL 130P - TBL 130P DACA 103 ÷ 67 1 ÷ 5

TBL 160P - TBL 160P DACA 127,5 ÷ 91,5 1 ÷ 5

TBL 210P 132 ÷ 96 1 ÷ 5

gura 1

figura-2

figura-4

figura-3

20 / 28

0006081325_201210

ENGLISH

MAINTENANCE

Analyse combustion gases and check that the emission values are

correct at least once a year, in compliance with current law.

Check the fuel filter: if it is dirty, replace it.

Check that all the components of the combustion head are in a

good state, not deformed by the temperature and free from im-

purities or deposits from the installation environment or by poor

combustion and check also the electrodes are working efciently.

If the combustion head needs to be cleaned, remove the compo-

nents following the procedure indicated below:

• Disconnect the light oil 1 pipes from the connectors beneath the

combustion head (be careful of drips)

• Unscrew screws 2(four) and turn the burner around pin 3 in

thehinge (figure 1).

• After pulling out the ignition cables 4 from their electrodes,

completely unscrew the locking nuts 5 (two) from mixing unit

(figure 2).

• Lift up the mixing unit 6 (figure 3) until the pipes some out and

then pull the unit out completely in the direction indicated by

the arrow 7 in figure 4.

• To complete the maintenance operations proceed with the

reassembly of the mixing unit by carrying out the above

operations in reverse order, after checking the ignition

electrodes and the deflector disk are correctly positioned ( See

0002935131).

!

On closing the burner, gently pull towards the electrical panel,

putting them slightly in tension, the two ignition cables, and

then arrange them in their places (7) as in figure 2. This will

ensure that the two cables do not get damaged by the fan

during the working of the burner.

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