MANUAL OF

- INSTALLATION
- OPERATION
- MAINTENANCE

LIGHT OIL AND BIODIESEL

BURNERS
PROGRESSIVE AND
FULLY MODULATING
VERSIONS
PG30 PG90 PG510
PG60 PG91 PG515
PG70 PG92 PG520
PG80
PG81
M03962CE Rev. 04 12/05

Documentazione Tecnica CIB Unigas - Campodarsego (PD)

 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.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SEC-
TION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1) GENERAL INTRODUCTION
z The equipment must be installed in compliance with the
regulations in force, following the manufacturer’s instruc-
tions, by qualified personnel.
z Qualified personnel means those having technical knowle-
dge in the field of components for civil or industrial heating
systems, sanitary hot water generation and particularly ser-
vice centres authorised by the manufacturer.
z Improper installation may cause injury to people and ani-
mals, or damage to property, for which the manufacturer
cannot be held liable.
z 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 devi-
ces, plastic bags, foamed polystyrene, etc), should not be left
within the reach of children, as they may prove harmful.
z 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.
z Make sure that inlet or exhaust grilles are unobstructed.
z 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 manufacturer, 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 quali-
fied personnel at regular intervals, following the manufactu-
rer’s instructions.
z When a decision is made to discontinue the use of the
equipment, those parts likely to constitute sources of dan-
ger shall be made harmless.
z 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.
z For all the units that have been modified or have options fit-
ted then original accessory equipment only shall be used.
z 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,
use and failure to comply with the instructions supplied by the
manufacturer.
2 NOTICES
2) SPECIAL INSTRUCTIONS FOR BURNERS
z The burner should be installed in a suitable room, with ven-
tilation openings complying with the requirements of the
regulations in force, and sufficient for good combustion.
z Only burners designed according to the regulations in force
should be used.
z This burner should be employed exclusively for the use for
which it was designed.
z Before connecting the burner, make sure that the unit
rating is the same as delivery mains (electricity, gas oil, or
other fuel).
z Observe caution with hot burner components. These are,
usually, near to the flame and the fuel pre-heating system,
they become hot during the unit operation and will remain
hot for some time after the burner has stopped.
When the decision is made to discontinue the use of the bur-
ner, the user shall have qualified personnel carry out the fol-
lowing operations:
a) Remove the power supply by disconnecting the power cord
from the mains.
b) Disconnect the fuel supply by means of the hand-operated
shut-off valve and remove the control handwheels from
their spindles.
Special warnings
z Make sure that the burner has, on installation, been firmly
secured to the appliance, so that the flame is generated
inside the appliance firebox.
z Before the burner is started and, thereafter, at least once a
year, have qualified personnel perform the following opera-
tions:
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.
z In case of repeated burner shut-downs, do not continue re-
setting the unit manually. Contact qualified personnel to
take care of such defects.
z The unit shall be operated and serviced by qualified per-
sonnel only, in compliance with the regulations in force.
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL
USED
3a) ELECTRICAL CONNECTION
z For safety reasons the unit must be efficiently earthed and
installed as required by current safety regulations.
z It is vital that all saftey requirements are met. In case of any
doubt, ask for an accurate inspection of electrics by quali-
fied personnel, since the manufacturer cannot be held lia-
ble for damages that may be caused by failure to correctly
earth the equipment.
z Qualified personnel must inspect the system to make sure
that it is adequate to take the maximum power used by the
equipment shown on the equipment rating plate. In particu-
lar, make sure that the system cable cross section is ade-
quate for the power absorbed by the unit.
z No adaptors, multiple outlet sockets and/or extension
cables are permitted to connect the unit to the electric
mains.
z An omnipolar switch shall be provided for connection to
mains, as required by the current safety regulations.
z The use of any power-operated component implies obser-
vance 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;
z 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.
NOTICES
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
z The burner shall be installed by qualified personnel and in
compliance 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.
z Before installation, it is recommended that all the fuel sup-
ply system pipes be carefully cleaned inside, to remove
foreign matter that might impair the burner operation.
z Before the burner is commissioned, qualified personnel
should inspect the following:
a) the fuel supply system, for proper sealing;
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 equipped with all the safety and control devi-
ces required by the regulations in force.
z 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 current regula-
tions, and in any case are sufficient for proper combustion.
z Do not use gas pipes to earth electrical equipment.
z Never leave the burner connected when not in use. Always
shut the gas valve off.
z In case of prolonged absence of the user, the main gas
delivery valve to the burner should be shut off.
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.
z 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.
3
 PART I: INSTALLATION MANUAL

SPECIFICATIONS - LIGHT OIL BURNERS

BURNERS PG30 PG60 PG70 PG80

Output min. kW 105 151 291 465
max. kW 383 791 1.047 1.570
min. kcal/h 90.000 130.000 250.000 400.000
max. kcal/h 330.000 680.000 900.000 1.350.000
Light oil rate Kg/h min. 9 13 25 40
Kg/h max. 33 68 90 135
Fuel Light oil Light oil Light oil Light oil
230V 3 ~ 230V 3 ~ 230V 3 ~
Power supply 230V 3 ~ 50Hz
400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 0.37 1.1 2.2 3
Current absorption A 3.2 - 1.9 4.8 - 2.8 8.8 - 5.1 11.2 - 6.5
Total power consumption kW 0.87 1.6 2.7 3.5
Approx. weight Kg ca. 33 58 84 84
Progressive Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating Fully modulating
Destination country * * * *

BURNERS PG81 PG90 PG91 PG92

Output min. kW 264 465 698 849
max. kW 1.900 1.512 2.093 2.558
min. kcal/h 227.000 400.000 600.000 730.000
max. kcal/h 1.634.000 1.300.000 1.800.000 2.200.000
Light oil rate Kg/h min. 22 40 60 73
Kg/h max. 160 130 180 220
Fuel Light oil Light oil Light oil Light oil
230V 3 ~ 230V 3 ~ 230V 3 ~ 230V 3 ~
Power supply 400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 3 3 4 5.5
Pump motor kW - - - -
Current absorption A 11.2 - 6.5 10.4 - 6 14.7 - 8.5 20.1 - 11.6
Total power consumption kW 3.5 3.5 4.5 6
Approx. weight Kg ca. 84 205 220 230
Progressive Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating Fully modulating
Destination country * * * *

BURNERS PG510 PG515 PG520

Output min. kW 1.314 1.628 2.326
max. kW 3.953 4.884 6.977
min. kcal/h 1.130.000 1.400.000 2.000.000
max. kcal/h 3.400.000 4.200.000 6.000.000
Light oil rate Kg/h min. 113 140 200
Kg/h max. 340 420 600
Fuel Light oil Light oil Light oil
Power supply 230V 3 ~ 230V 3 ~ 230V 3 ~
400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 7.5 11 15
Pump motor kW - - 1.5
Current absorption A 26.5 - 15.2 38.1 - 22 50.2 - 29
Total power consumption kW 8 11.5 17.5
Approx. weight Kg ca. 270 280 290
Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating
Destination country * * *

4 PART I: INSTALLATION MANUAL

SPECIFICATIONS - BIODIESEL BURNERS

BURNERS PG30 PG60 PG70 PG80

Output min. kW 105 151 291 465
max. kW 383 791 1.047 1.570
min. kcal/h 90.000 130.000 250.000 400.000
max. kcal/h 330.000 680.000 900.000 1.350.000
Light oil rate Kg/h min. 10 14 28 45
Kg/h max. 37 67 100 151
Fuel Biodiesel Biodiesel Biodiesel Biodiesel
Power supply 230V 3 ~ 230V 3 ~ 230V 3 ~ 230V 3 ~
50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 0.37 1.1 2.2 3
Current absorption A 3.2 - 1.9 4.8 - 2.8 8.8 - 5.1 11.2 - 6.5
Total power consumption kW 0.87 1.6 2.7 3.5
Approx. weight Kg ca. 33 58 84 84
Progressive Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating Fully modulating
Destination country * * * *

BURNERS PG81 PG90 PG91 PG92

Output min. kW 264 465 698 849
max. kW 1.900 1.512 2.093 2.558
min. kcal/h 227.000 400.000 600.000 730.000
max. kcal/h 1.634.000 1.300.000 1.800.000 2.200.000
Light oil rate Kg/h min. 25 45 67 82
Kg/h max. 182 145 201 246
Fuel Biodiesel Biodiesel Biodiesel Biodiesel
Power supply 230V 3 ~ 230V 3 ~ 230V 3 ~ 230V 3 ~
400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 3 3 4 5.5
Pump motor kW - - - -
Current absorption A 11.2 - 6.5 10.4 - 6 14.7 - 8.5 20.1 - 11.6
Total power consumption kW 3.5 3.5 4.5 6
Approx. weight Kg ca. 84 205 220 230
Progressive Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating Fully modulating
Destination country * * * *

BURNERS PG510 PG515 PG520

Output min. kW 1.314 1.628 2.326
max. kW 3.953 4.884 6.977
min. kcal/h 1.130.000 1.400.000 2.000.000
max. kcal/h 3.400.000 4.200.000 6.000.000
Light oil rate Kg/h min. 126 156 223
Kg/h max. 380 439 670
Fuel Biodiesel Biodiesel Biodiesel
Power supply 230V 3 ~ 230V 3 ~ 230V 3 ~
400V 3N ~ 50Hz 400V 3N ~ 50Hz 400V 3N ~ 50Hz
Electric motor (2800 rpm) kW 7.5 11 15
Pump motor kW - - 1.5
Current absorption A 26.5 - 15.2 38.1 - 22 50.2 - 29
Total power consumption kW 8 11.5 17.5
Approx. weight Kg ca. 270 280 290
Progressive Progressive Progressive
Operation Fully modulating Fully modulating Fully modulating
Destination country * * *

PART I: INSTALLATION MANUAL 5

BURNER MODEL IDENTIFICATION
Burners are identified by burner type and model. Burner model identification is described as follow.
Type PG80 Model G-. PR. S. *. A.
(1) (2) (3) (4) (5) (6)
(1) BURNER TYPE PG80
(2) FUEL G - Light oil
A - Biodiesel
(3) OPERATION Available versions
PR - Progressive
MD - Fully modulating
(4) BLAST TUBE S - Standard
L - Long
(5) DESTINATION COUNTRY * - see data plate
(6) BURNER VERSION A - Standard

6 PART I: INSTALLATION MANUAL

OVERALL DIMENSIONS (mm)

Fig. 1

H
N
P

Fig. 1a

A B BL C CL D E F G K H P M N
PG30 600 150 340 750 940 270 230 500 121 292 160 155 M10 219
PG60 760 244 442 1004 1202 270 300 570 153 290 190 190 M10 269
PG70 725 310 460 1035 1185 355 420 775 198 290 240 216÷250 M10 305÷353
PG80 825 340 490 1165 1315 355 420 775 218 290 240 216÷250 M10 305÷353
PG81 825 340 490 1165 1315 355 420 775 234 290 240 216÷250 M10 305÷353
PG90 900 290 462 1190 1362 520 485 1005 224 350 320 300 M12 423
PG91 900 300 473 1200 1375 520 485 1005 238 375 320 300 M12 423
PG92 900 294 467 1194 1373 520 485 1005 266 375 320 300 M12 423
PG510 1050 300 520 1350 1570 550 555 1105 329 450 420 390 M14 550
PG515 1050 300 520 1350 1570 550 560 1110 350 450 420 390 M14 550
PG520 1050 300 520 1350 1570 650 670 1320 370 500 460 390 M14 550

PART I: INSTALLATION MANUAL 7

PERFORMANCE CURVES

PG30 PG60
CCOMBUSTION CHAMBER mbar

6 10
5
8
BACK PRESSURE IN

4
3 6
2 4
1 Fig. 2
2
0
-1 0
-2 -2
80 120 160 200 240 280 320 360 400 440 0 100 200 300 400 500 600 700 800 900

kW kW
PG70 PG80
CCOMBUSTION CHAMBER mbar

14 14
14
BACK PRESSURE IN

9 99

4 44
Fig. 3
-1 -1-1
-6
-6 -6
200 400 600 800 1000 1200 1400 1600 1800
0 200 400 600 800 1000 1200 200 400 600 800 1000 1200 1400 1600 1800

kW kW
PG81 PG90
CCOMBUSTION CHAMBER mbar

14 18
16
12
BACK PRESSURE IN

14
10
12
8 10
6 8 Fig. 4
6
4
4
2 2
0 0
200 400 600 800 1000 1200 1400 1600 1800 2000 200 400 600 800 1000 1200 1400 1600 1800
kW kW
PG91 PG92
CCOMBUSTION CHAMBER mbar

18 18
16 16
BACK PRESSURE IN

14 14
12 12
10 10
8 8 Fig. 5
6 6
4 4
2 2
0 0
400 800 1200 1600 2000 2400 400 800 1200 1600 2000 2400 2800
kW kW
PG510 PG515
CCOMBUSTION CHAMBER mbar

24 24
20 20
BACK PRESSURE IN

16 16
12 12
Fig. 6
8 8
4 4
0 0
1000 1800 2600 3400 4200 1200 2000 2800 3600 4400 5200
kW kW

8 PART I: INSTALLATION MANUAL

 PG520
CCOMBUSTION CHAMBER mbar 24
20
BACK PRESSURE IN

16
12
Fig. 7
8
4
0
2000 2800 3600 4400 5200 6000 6800 7600

kW

PART I: INSTALLATION MANUAL 9

MOUNTINGS AND CONNECTIONS
Packing
The burners are dispatched in cardboard pakages with dimensions:
PG30 980 x 460 x 540 mm
PG60 1.200 x 560 x 570 mm
PG70 1.270 x 760 x 840 mm
PG80-81 1.270x 760 x 840 mm
Serie 90 1.720 x 1.010 x 1.270 mm
Serie 500 1.730 x 1.010 x 1.420 mm
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are placed in each packing
case.
1 burner;
2 light oil flexible hoses;
1 light oil filter;
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual.
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.

Fitting the burner to the boiler

After fitting the burner to the boiler ensure that the space between the blast
tube and the refractory lining is sealed with appropriate insulating material
(ceramic fibre cord or refractory cement).

Key
1 Burner
2 Fixing nut
3 Washer
4 Seal
5 Stud bolt
6 Sightglass cleaning tube
7 Blast tube Fig. 8

10 PART I: INSTALLATION MANUAL

Electrical connections diagram
z Remove the cover of the electrical board mounted on the burner.
z Effect the electrical connections to the power supply terminal board as shown here following, check the direction of the fan
motor (and the pump motor if fitted, see note at the end of page) and refit the cover of the electrical board.

WARNING: The burners with high-low flame operation are 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.

PG60 - 70 - 80 - 81 Probes connection

PG30 progressive serie 90 - 500 progressive

Fig. 9a Fig. 9b

PG60 - 70 - 80 - 81
PG30 fully modulating serie 90 - 500 fully modulating

Fig. 10a Fig. 10b

(**) Probes connection, Fig. 10

Fig. 10
Fan motor rotation (excludedPG30) and pump motor (PG520 only)
After completing the electrical connection of the burner, remember to check the rotation of the fan motor.
The motors must rotate in the direction indicated on their casing. In the event of incorrect rotation reverse the three-phase sup-
ply and check again the rotation of the motor.
NOTE: the burners are supplied for three-phase 400 V supply, and in the case of three-phase 230 V supply it is necessary to
modify the electrical connections inside the terminal box of the electric motor and replace the thermal cutout relay.

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.

PART I: INSTALLATION MANUAL 11

Light oil piping installation diagram

From tank

To tank

Fig. 11
Key (*) Only for installations with gravity, siphon or for-
1 Burner ced circulation feed systems. If the device installed
2 Flexible hoses (fitted) is a solenoid valve, a timer must be installed to
3 Light oil filter (fitted) delay the valve closing.
The direct connection of the device without a timer
4 Automatic interceptor (*)
may cause pump breaks.
5 One-way valve (*)
6 Gate valve
7 Quick-closing gate-valve (not in vicinity of tank or boiler)

12 PART I: INSTALLATION MANUAL

LIGHT OIL PIPING SIZING

Twin tube or syphon installation Twin tube or suction installation

Fig. 12a Fig. 12b

SUNTEC AJ6/J6 SUNTEC E7 DELTA VM3 LR2

H (m) L (m) H (m) L (m) H (m) L (m)
ø10 ø12 ø14 ø16 ø10 ø12 ø14 ø16 ø8 ø10 ø12
0 5 13 27 47 0 2 7 16 29 0 11 25 50
Fig. 12a 0,5 6 15 3 52 0,5 2 8 18 33 0,5 9 23 43
1 7 17 33 58 1 3 10 20 37 1 8 22 40
2 9 21 40 70 2 4 12 25 44 2 7 16 35
3 10 24 47 80 3 5 14 29 52 3 - 11 23
4 12 28 53 92 4 6 17 33 59 4 - 7 13

SUNTEC AJ6/J6 SUNTEC E7 DELTA VM3 LR2

H (m) L (m) H (m) L (m) H (m) L (m)
ø10 ø12 ø14 ø16 ø10 ø12 ø14 ø16 ø8 ø10 ø12
0 5 13 27 47 0 7 16 29 76 0 10 25 50
Fig. 12b 0,5 4 12 23 41 0,5 6 14 26 67 0.5 11 26 55
1 3 10 20 36 1 5 12 22 58 1 12 29 60
2 2 6 13 24 2 2 7 14 40 2 13 32 62
3 0 3 7 13 3 0 3 7 21
4 0 0 0 2 4 0 0 0 3

L= piping lenght in meters

Single pipe system

The burners leave the factory ready for a 2 pipes supply system.
It is however possible to transform them for a single pipe supply system (advisable in the case of a gravity feed system).
See appendix for details about operations to be carried out.

PART I: INSTALLATION MANUAL 13

HYDRAULIC DIAGRAMS FOR LIGHT OIL FEEDING CIRCUITS

Fig. 13a
Gravity circuit

Fig. 13b
Ring circuit

Fig. 13c
Suction circuit

14 PART I: INSTALLATION MANUAL

ADJUSTMENTS
Starting the pump
Before carrying out the adjustment it is necessary to start up the light oil pump, proceeding as follows:

Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
z Start the burner, light up the photoresistance after the opening of the solenoid valve and let the air escape from the pres-
sure gauge connection.
Fuel rate setting
The fuel rate is regulate choosing a properly dimensioned nozzle (reflux type) and adjusting the inlet and return pressure fol-
lowing the directions on Tab. 1.

Tab. 1

INLET MAX. RETURN MIN. RETURN

NOZZLE PRESSURE PRESSURE PRESSURE MIN.-MAX.
RATIO
bar bar bar
BERGONZO A3/A4 20 13 - 19 5 1:3
BERGONZO A4 20 13 - 19 5 1:4
FLUIDICS WR2 25 20 9 1:3

V
To set the suction pressure working on
the regulation screw on the pump, see
Page 17. Further informations about
light oil pumps are available in the
appendix.
To set the return pressure, adjust the
cam on the adjustable cam by means
of the screw V, as shown in figure.

Fig. 14

Key
2
1 Light oil pump
3
1 2 Light oil solenoid valve
3 Nozzle
5 4 Adjustable cam
5 Manometer
6 Pressure regulator
7 Check valve
4

7 6

Fig. 15a

PART I: INSTALLATION MANUAL 15

 3
2

1
Fig. 15b
Pre-purge
5
4

8
7
6

3
2

1
1
Fig. 15c
Low flame
5
4

8
7
6

3
2

1
Fig. 15d
High flame

8
7 4
6

Key
1 Light oil pump
2 Light oil solenoid valve
3 Nozzle
4 Servocontrol
5 Adjustable cam
6 Manometer
7 Pressure regulator
8 Check valve

16 PART I: INSTALLATION MANUAL

LIGHT OIL PUMPS

Delta V3LR2
Oil viscosity 2 ÷ 50 cSt (1,1 ÷ 6,5°E)
Oil temperature 60°C (140°F) max.
Suction height 0,5 bar (15 inHg) max.
Suction pressure 0,7 bar (10 psi) max.
Return pressure 1,5 bar (21 psi) max.
Rated speed 3500 rpm max.
Fig. 16

Suntec AJ6 CC
Viscosity 2,8 - 75 cSt
Oil temperature 60°C max. in the pump
Inlet pressure 2 bar max.
Return pressure 2 bar max.
Suction height 0,45 bar max. to avoid air separation
from oil
Rated speed 3600 rpm max.
Fig. 17

Pump Suntec J6 CCC - J7 CCC

Viscosity range 2,8 - 200 cSt
Oil temperature 0 - 90°C into the pump.
Inlet pressure 1,5 bar max.
Return pressure 1,5 bar max.
Suction height 0,45 bar max. vacuum to prevent air
separation from oil .
Rated speed 3600 rpm max.
Fig. 18

Pump Suntec TA
Viscosity range 4 - 450 cSt
Oil tenperature 0 - 140°C max. into the pump
Inlet pressure 5 bar max.
Return pressure 5 bar max.
Rated speed 3600 rpm max.

Fig. 19

Key
1 Pressure regulation
2 Manometer
3 Vacuometer
5 Nozzle
7 Suction
8 Return

PART I: INSTALLATION MANUAL 17

Danfoss KSM
Oil viscosity4 ÷ 450 cSt
Oil temperature 10 ÷ 60 °C max.
Suction vacuum 0,5 bar max.
Suction pressure 4 bar max.
Return pressure 4 bar max.
Rated speed 1400 ÷ 3450 rpm max

Fig. 20

Key
1 Pressure regulation
2 Manometer
3 Vacuometer
5 Nozzle
7 Suction
8 Return

18 PART I: INSTALLATION MANUAL

AIR AND FUEL RATE SETTING
Burners PG30 - PG60
Pump priming
Before carrying out the adjustment it is necessary to start up the light oil pump, proceeding as follows.

Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.

Start the burner and light the photoresistor after the opening of the solenoid valve, then breath the air through the pressure
gauge.
During the test in the factory, the air damper in the low flame operation mode, the light oil regulator and the servocontrol are set
to their intermediate positions. To change the settings in the plant follow this procedure.
1 Turn on the burner and verify the operation. If the ignition is correct jump to step 3, else follow the directions on step 2.
2 To set the air rate during ignition (same position as low flame) work on the cam ST1 on the servocontrol (Fig. 23); to incre-
ase the air rate increase the opening angle of the servocontrol.
To set the light oil rate during ignition, work on the screw V (Fig. 22 - Fig. 27). Rotate clockwise to increase the oil rate or coun-
terclockwise to decrease it.
After the completion of such adjustments, turn off the burner and turn it on again, verifiyng the operation: if all regulations are
satisfactory, proceed with point 3, else repeat the previous operations.
3 Drive the burner to the high flame. Set the light oil rate to the requested value by means of the screw V, corresponding to
the 90° position on the servocontrol . To adjust the air flow rate, unscrew the screw RA (Fig. 21) and rotate the screw VRA
(Fig. 27) until the desired rate is obtained; clockwise rotation increases the air rate, counterclockwise rotation decreases it.
4 Turn off the burner, turn it on again and check its operation; if the light oil rate or the air rate need further adjustments,
repeat the procedure described in step 2.
Note: At the end of settings remember to tight the lock screw RA.

RA

MV
ST2

ST1

ST0

Fig. 21 Fig. 22 Fig. 23

PART I: INSTALLATION MANUAL 19

AIR AND FUEL RATE SETTING
Burners PG70 - 80 - 81, 90 and 500 serie
Pump priming
Before carrying out the adjustment it is necessary to start up the light oil pump, proceeding as follows.

Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.

Start the burner and light the photoresistor after the opening of the solenoid valve, then breath the air through the pressure
gauge.
During the test in the factory, the air damper in the low flame operation mode, the light oil regulator and the servocontrol are set
to their intermediate positions. To change the settings in the plant follow this procedure.
1 Start the operation of the burner and wait until the flame appears; keep the burner in the ignition phase by means of the
AUTO-MAN selector on the servocontrol (Fig. 26, ignition position =0).
2 To set the air flow rate of the ignition stage, rotate the cam AB on the servocontrol (Fig. 24) following these directions:
z remove the plastic lock B;
z keep completely pushed the green lever G;
z manually drive the air damper to the desired position and release the lever G.
z To set the light oil rate of the ignition phase, work on the screw V (Fig. 26); rotate clockwise to increase the light oil rate or
counterclockwise to decrease it.
3 Turn off the burner, select the AUTO position on the servocontrol by means of the AUTO-MAN selector and turn on the bur-
ner. If the settings are correct jump to step 4, otherwise repeats the previous steps.
4 Turn on the burner, select the MAN position on the servocontrol and if necessary adjust the ignition light oil rate working on
the screws V, as shown in Fig. 26 and Fig. 27.
5 With the servocontrol still in the MAN position, drive the servocontrol towards the high flame position (servocontrol position
= 90°)
WARNING: rotate slowly by hand the servocontrol, having care the burner doesn’t operate with insufficient air flow.
Drive the servocontrol to the AUTO position and adjust the light oil rate working on the screws V (Fig. 26 - Fig. 27).
To set the air rate slacken the screw RA (Fig. 27) and rotare the screw VRA (Fig. 27; clockwise rotation increases the air rate,
counterclockwise rotation decreases it), until the desired rate is obtained.
6 Drive the burner to low flame, check the combustion and if necessary adjust the light oil rate working on the screws V (Fig.
26 - Fig. 27).
At the end of settings remember to tight the screw VRA and refit the plastic lock B.

V
BF

AB

Fig. 24 Fig. 25 Fig. 26

20 PART I: INSTALLATION MANUAL

 Fig. 27

On PG520 only
V

RA
VRA

PART I: INSTALLATION MANUAL 21

COMBUSTION HEAD ADJUSTMENT
The burner is adjusted in the factory with the combustion head at the "MAX" position, corresponding to the maximum output.
For operation at reduced power, move back the combustion head towards the "MIN" position turning the screw "VRT" clockwise.

Burners PG30 - PG60

Fig. 28

Burners PG70 ÷ PG520

Slacken the screw VB before proceed with settings; the combustion head position is set turning the knob VRT.

VB VRT

Fig. 29

22 PART I: INSTALLATION MANUAL

 PART II: OPERATION 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 FUNCTIO-
NING OF THE BURNER.

THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLA-
TION OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNEC-
TION, EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF
THE BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION
ALSO FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.

IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RESET 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

z Set to the ON position the switch A on the control panel of the burner.
z Check the flame control device is not in the stop position (light B must be off); in such a case reset it with the reset pushbut-
ton C.
z Check the serie of thermostats or pressure switches gives the consent to operate the burner.
z The startup sequence begins: the flame control device starts the fan motor and meanwhile energizes the ignition trans-
former (signalled by the light H on the control panel of the burner).
z At the end of the pre-purge stage, the light oil solenoid valve EV1 is energized (signalled by the lamp G on the control
panel) and the burner is on.
z The ignition transformer remains energized for any seconds after the ignition of the flame (post-ignition time) and at the end
of this time is de-energized (light H off).
Burners PG30 and PG60
z The burner is now in operation in the low flame stage (light G on); after 5 ÷ 15 sec. (depending by the flame controller
installed) the 2 stages operation begins and the burner automatically switches to high flame or remains in low flame,
depending on the plant demand.
Burners PG70 ÷ PG520
z After the ignition the servocontrol opens for 5 - 15 sec. After this time the operation begins and the burner switches to high
flame or to low flame, depending on the plant demand.

Operation in high or low flame is signalled by the signalling lamp F (on or off) on the control panel.

PART II: OPERATION MANUAL 23

BURNER CONTROL PANEL
PG30 - PG60 - PG70 -PG80 - PG81

F G H
E

C D

A J

Fig. 30a
PG90 - PG91 - PG92

F G H E B

A Q

Fig. 30b

Key
A Main switch ON-OFF
B Lockout signalling lamp
C Flame controller release pushbutton (burners PG70 - PG80)
D Light oil solenoid valve opening signalling lamp
E Thermal cutout intervention signalling lamp
F High flame operation signalling lamp
G Low flame operation signalling lamp
H Ignition transformer operation signalling lamp
P Landis modulator
Q Manual operation mode switch

24 PART II: OPERATION MANUAL

PG510 - PG515 - PG520 - PG520

F G H E

C P

Q A

Fig. 30c Fig. 31

Key
A Main switch ON-OFF
B Lockout signalling lamp
C Flame controller release pushbutton (burners PG70 - PG80)
D Light oil solenoid valve opening signalling lamp
E Thermal cutout intervention signalling lamp
F High flame operation signalling lamp
G Low flame operation signalling lamp
H Ignition transformer operation signalling lamp
P Landis modulator
Q Manual operation mode switch

PART II: OPERATION MANUAL 25

 PART III: MAINTENANCE MANUAL

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to
carry out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out
every 6 months.

WARNING: All operations on the burner must be carried out with the mains disconnected!

PERIODICAL OPERATIONS
z check and clean the cartdrige of the fuel filter, replace it if necessary;
z carefully check for leaks, the fuel flexible hoses;
z check and clean the filter on the fuel pump (see appendix for details on fuel pumps);
z dismantle, check and clean the combustion head (see Fig. 32) and reassembling respect the measures suggested in Tab. 2
carefully;
z check the ignition electrodes and their ceramic insulators, clean, adjust and replace if necessary;
z dismantle and clean the oil nozzles (IMPORTANT: don’t clean the nozzles using metallic or sharp utensils, use only sol-
vents or steam); at the end of maintenance operations, refit the burner, turn it on and check the combustion. If in doubt,
replace the defective nozzle/s. In case of intensive use of the burner, the nozzles must be replaced at the end of the
working season;
z check and carefully clean the flame detection photoresistor, if necessary replace it and, if in doubt, check the ionisation cur-
rent following the scheme in Fig. 36;
z clean and grease levers and rotating parts.

Removing the combustion head

Burners PG30 - PG60
z Remove the cap C;
z Pull the photoelectric cell out of its housing; C
AR
z Unscrew the connectors from the 2 oil pipes (E in
Fig. 33) using 2 spanners to avoid loosening the
connections attached to the distributor block;
z Loosen the screw VRT to free the threaded rod
VRT
AR, then screw out the 2 screws V holding the
washer R and the screw VRT in position;
R
z Remove the entire assembly as shown in Fig. 32.

Note: To re-assemble reverse the order of proce-

dure described above.

Fig. 32

E
Fig. 33

26 PART III: MAINTENANCE MANUAL

Removing the oil lance PG70 ÷ PG520
z Unscrew the connectors from the 2 oil pipes (E in VB
Fig. 33) using 2 spanners to avoid loosening the
connections attached to the distributor block);
z Loosen the screw .0VB
z Remove the lance with the light oil nozzle sup-
port.

Note: To re-assemble reverse the order of proce- E

dure described above.

Fig. 34

Correct position of electrodes and combustion head

Tab. 2
A B C D
8 mm 4 mm 5,5-6,5 mm 8-10 mm

Fig. 35

PART III: MAINTENANCE MANUAL 27

Check the detection current
To measure the detection signal follow the diagram in Fig. 36. TERMINAL BLOCK MC

If the signal is not in the advised range, verify the electrical con- 34 35
tacts, the cleaning of the combustion head, the position of the
photoresistor and if necessary replace it.

Minimum current intensity with flame

SCALE µA DC
LOA24-44, LMO24-44: 65 µA
LAL25: 8µA

Fig. 36
TROUBLESHOOTING

CYCLE DURING OPE-

NOISY FUEL PUMP

THE BURNER STOPS

DOESN’T SWITCH

AND REPEATS THE

DOESN’T START
DOESN’T START

TO HIGH FLAME

STOPS DURING
REPEATS PRE-
THE BURNER

THE BURNER

THE BURNER

THE BURNER

THE BURNER

THE BURNER
STARTS AND

OPERATION
AND STOPS
PURGE

RATION
STOPS
MAIN SWITCH OPEN ●
LINE FUSE INTERVENTION ●
MAX. PRESSURE SWITCH FAULT ● ●
FAN THERMAL CUTOUT INTERVENTION ●
AUXILIARY RELAIS FUSES INTERVENTION ●
FLAME CONTROL DEVICE FAULT ● ● ● ● ●
SERVOCONTROL FAULT ●
SMOKEY FLAME ● ●
IGNITION TRANSFORMER FAULT ●
IGNITION ELECTRODE DIRTY OR BADLY
POSITIONED
●
DIRTY NOZZLE ● ●
FUEL SOLENOID VALVE DEFECTIVE ● ●
PHOTORESISTOR DIRTY OR DEFECTIVE ● ●
HI-LO FLAME THERMOSTAT DEFECTIVE ●
WRONG POSITION OF SERVOCONTROL
CAMS
●
FUEL PRESSURE TOO LOW ●
DIRTY FUEL FILTERS ● ● ●

28 PART III: MAINTENANCE MANUAL

WIRING DIAGRAMS - Complete key
BP Coil on light oil motor contactor
BV Fan motor contactor coil
CAV Auxiliary contacts on fan motor contactor
CMF Operation manual switch
0) stop - 1) high flame - 2) low flame - 3) automatic
CO Time counter (optional)
CP Contacts on light oil pump contactor
CR1 Auxiliary relay contacts
CR1÷CR2 Auxiliary relay contacts
CRT Time relay contacts
CTP Contacts on pump motor thermal cutout
CTV Contacts on fan motor thermal cutout
CV Contacts on fan motor contactor
ER Flame detection electrode
EVG Light oil solenoid valve
F Fuses
F÷F1 Fuses
F÷F2 Fuses
F÷F3 Fuses
F÷F4 Fuses
FR Photoresistor
IG Main switch
IL Main switch
L Phase
LAF Burner in high flame signalling lamp
LAL2.25 LANDIS flame controller
LB Flame lockout signalling lamp
LBF Burner in low flame signalling lamp
LEV1 EV1 opening signalling lamp
LEV2 EV2 opening signalling lamp
LEVG EVG opening signalling lamp
LGB22.33 LANDIS flame controller
LOA24/BHO64 LANDIS or BERGER flame controller
LOA24/LMO24 LANDIS flame controller
LOA44/LMO44 LANDIS flame controller
LPG MIN Gas in the network signalling lamp
LT Thermal cutout intervention signalling lamp
LTA Ignition transformer signalling lamp
MA Burner power supply terminal board
MC Components connection board
MP Light oil pump motor
MV Fan motor
N Neutral
PA Air pressure switch
PGMAX Maximum gas pressure switch (optional, if fitted remove the connection between terminal 6 and 7 on ter-
minal board MA
PGMIN Minimum gas pressure switch
PS Flame controller release pushbutton
PS (*) Flame release pushbutton (only with LMO24)
Pt100 3 wires temperature probe Pt100
R1 Auxiliary relay
R1÷R2 Auxiliary relais
RT Time relay
RWF40.000 ** LANDIS modulator
SD-0/4÷20mA Probe connection with signal 0÷20mA / 4÷20mA
SD-0÷10V Probe connection with signal 0÷10V
SD-PRESS. 3 wires pressure probe (LANDIS QBE620p..)
SD-TEMP. 2 wires temperature probe (Pt1000 - LANDIS QAE2..,QAC2..)
SQL33 Air damper servocontrol LANDIS
SQN../STA.. Air damper servocontrol LANDIS or BERGER
SQN30.251 Air damper servocontrol LANDIS (alternate)
ST Thermostats or pressure switches serie
STA12B3.41/63N21L Air damper servocontrol BERGER

PART III: MAINTENANCE MANUAL 29

STA15B3.41/83N21L Air damper servocontrol BERGER (alternate)
TA Ignition transformer
TAB High-low flame thermostat (if fitted remove the connection between terminals 6 and 7 on terminal block
MA)
TC Thermocoupling connection
TP Pump motor thermal cutout
TV Fan motor thermal cutout

SERVOCONTROL CAMS
LANDIS BERGER
I ST2 High flame
II ST0 Stop
III ST1 Low flame
V MV Startup consent

Y1 High flame
Y2 Startup and ignition
3 Low flame
* The modulator includes a limit switch (terminals Q13 and Q14), it stops the burner if the work parameter overcomes set diffe-
rential.

ATTENTION:
1 - Electric supply 400V 50Hz 3N a.c.
2 - Don't reverse phase and neutral
3 - Make sure that the burner is properly hearted

30 PART III: MAINTENANCE MANUAL

Wiring diagram 04-619 Rev. 2 - Burners PG30 progressive

Wiring diagram 04-625 Rev. 3 - Burners PG30 fully modulating

PART III: MAINTENANCE MANUAL 31

Wiring diagram 05-556 Rev. 3 - Burners PG60 progressive

Wiring diagram 05-617 Rev. 3 - Burners PG60 fully modulating

32 PART III: MAINTENANCE MANUAL

Wiring diagram 07-352 Rev. 2 - Burners PG70 - 80 - 81 - 90 - 91 - 92 progressive

Wiring diagram 07-401 Rev. 3 - Burners PG70 - 80 - 81 - 90 - 91 - 92 fully modulating

PART III: MAINTENANCE MANUAL 33

Wiring diagram 11-270 Rev. 1 - Burners PG510 - PG515 progressive

Wiring diagram 11-272 - Burners PG520 progressive

34 PART III: MAINTENANCE MANUAL

Wiring diagram 11-292 Rev. 2 - Burners PG60 - 70 - 80 - 81 - 90 - 91 - 92 - 510 - 515 fully modulating

PART III: MAINTENANCE MANUAL 35

Wiring diagram 11-293 - Burners PG520 fully modulating

36 PART III: MAINTENANCE MANUAL

 APPENDIX: COMPONENTS CHARACTERISTICS

LANDIS OIL BURNERS AUTOMATIC CONTROLLER LMO24 - LMO44 38

LANDIS OIL BURNERS AUTOMATIC CONTROLLER LOA44 41
FLAME CONTROL DEVICE FOR OIL BURNERS LAL.. 43
SUNTEC PUMP AJ6 46
SUNTE PUMPS J6 - J7 47
PUMP SUNTEC TA 48
SUNTEC PUMPS E6 - E7 NC1001 49
PUMP DANFOSS KSM 50
NOTES FOR USE AND MAINTENANCE OF FUEL PUMPS 51

APPENDIX: COMPONENTS CHARACTERISTICS 37

LANDIS OIL BURNERS AUTOMATIC CONTROLLER LMO24 - Operation
LMO44 Lock-out reset button «EK...» is the key operating element for
The LMO... burner controls are designed for the start-up and supervi- EK resetting the burner control and for activating / deactivating
sion of single- or 2-stage forced draught oil burners in intermittent the diagnostic functions.
operation. Yellow-burning flames are supervised with photoresistive
detectors QRB..., blue-burning flames with blue-flame detectors The multicolour «LED» is the key indicating element for both
QRC... visual diagnosis and interface diagnosis.
In terms of housing dimensions, electrical connections and flame
detectors, the LMO... are identical to the LOA... oil burner controls.
Preconditions for startup
▲ Red
z Burner control is reset
● Yellow
z All contacts in the line are closed
❏ Green
z No undervoltage
z Flame detector is darkened, no extraneous light
Colour code table
Undervoltage Status Colour code Colour
z Safety shut-down in the operating position takes place should the Oil pre-heater heats,
mains voltage drop below about AC 165 V ●●●●●●●●●●● Yellow
waiting time «tw»
z Restart is initiated when the mains voltage exceeds about Ignition phase, ignition
AC 175 V ●❍●❍●❍●❍●❍● Yellow-off
controlled
Time supervision oil pre-heater Operation, flame o.k. ❏❏❏❏❏❏❏❏❏❏❏❏ Green
If the oil pre-heater’s release contact does not close within 10 minu- Operation, flame not o.k. ❏❍❏❍❏❍❏❍❏❍❏ Green-off
tes, the burner control will initiate lock-out. Undervoltage ●▲●▲●▲●▲●▲● Yellow-red
Controlled intermittent operation Fault, alarm ▲▲▲▲▲▲▲▲▲▲▲ Red
After no more than 24 hours of continuous operation, the burner con- Output of fault code (refer
trol will initiate an automatic safety shut-down followed by a restart. ▲❍▲❍▲❍▲❍▲❍ Red-off
to Fault code table)
Control sequence in the event of fault Extraneous light prior to
❏▲❏▲❏▲❏▲❏▲❏ Green-red
If lock-out occurs, the outputs for the fuel valves and the ignition will burner start-up
immediately be deactivated (< 1 second). Interface diagnosis ▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Red flicker light

Cause Response Key

❍ Off
After a mains failure Restart
● Yellow
After voltage has fallen below the ❏ Green
Restart
undervoltage threshold ▲ Red

In the event of a premature, faulty Diagnosis of cause of fault

Lock-out at the end of «t1»
flame signal during «t1»
After lock-out, the red fault signal lamp remains steady on.
Prevention of start-up, lock- In that condition, the visual diagnosis of the cause of fault according
In the event of a premature, faulty to the error code table can be activated by pressing the lock-out reset
out after no more than 40
flame signal during «tw» button for more than 3 seconds.
seconds

If the burner does not ignite during Error code table

Lock-out at the end of TSA
«TSA»
Blink code Possible cause
In the event the flame is lost during Max. 3 repetitions, followed
operation by lock-out 2 blinks ** No establishment of flame at the end of TSA
z Faulty or soiled fuel valves
Oil pre-heater’s release contact does
Lock-out z Faulty or soiled flame detector
not close within 10 min.
z Poor adjustment of burner, no fuel
z Faulty ignition
Lock-out
3 blinks *** Free
In the event of lock-out, the LMO... remains locked (lock-out cannot
be changed), and the red signal lamp will light up. This status is also
4 blinks **** Extraneous light on burner startup
maintained in the case of a mains failure.
Resetting the burner 5 blinks ***** Free
Whenever lock-out occurs, the burner control can immediately be
reset. To do this, keep control the lock-out reset button depressed 6 blinks ****** Free
for about 1 second (< 3 seconds).
Ignition program with LMO24.113A2 7 blinks ******* Too manny losses of fleme during operation
(limitattion og the number of repetitions)
If the flame is lost during «TSA», the burner will be reignited, but not
later than at the end of «TSAmax.». This means that several ignition z Faulty or soiled fuel valves
attempts can be made during TSA (refer to «Program sequence»). z Faulty or soiled flame detector
Limitation of repetitions z Poor adjustment of burner
If the flame is lost during operation, a maximum of 3 repetitions can
be made. If the flame is lost for the 4th time during operation, the bur- 8 blinks ******** Time supervision oil pre-heater
ner will initiate lock-out. The repetition count is restarted each time
controlled switching on by «R-W-SB» takes place. 9 blinks ********* Free

10 blinks ********** Wiring error or internal error, output contacts

38 APPENDIX: COMPONENTS CHARACTERISTICS

During the time the cause of fault is diagnosed, the control outputs
are deactivated. Key
z Burner remains shut down
AL Alarm device
z Fault status signal «AL» at terminal 10 is activated
kbr... Cable link (required only when no oil pre-heater is used)
The diagnosis of the cause of fault is quit and the burner switched on BV... Fuel valve
again by resetting the burner control.
EK1 Lock-out reset button
Press lock-out reset button for about 1 second (< 3 seconds).
EK2 Remote lock-out reset button
FS Flame signal
Connection diagram and internal diagram
FSV Flame signal amplifier
K... Contacts of control relay
LED 3-colour signal lamps
EK1 µC 1 µC control µC 2
M Burner motor
LED OW Release contact of oil pre-heater
K2 t1 Pre-purge time
K1 FSV
t3 Pre-ignition time
K3 K4 t3n Post-ignition time
A´ Beginning of start-up sequence with burners using an oil pre-
1 2 10 8 3 6 7 4 5 9 11 12
kbr heater
SB A Beginning of start-up sequence with burners using no oil pre-
8 3
R
heater
OW Q RB
EK2
Controller output signals
W OH BV2 Required input signals
AL
N OH Oil pre-heater
Q RC
Si 1 bl sw
QRB Photoresistive detector
L M Z BV1 br

N QRC Blue-flame detector

7130a02e/0700
bl = blue
br = brown
Control sequence
sw = black
R A´ A B C D R Control thermostat or pressurestat
W 1
SB tw
SB Safety limit thermostat
OH 8 Si External primary fuse
W Limit thermostat or pressure switch
OW 3 Z Ignition transformer
M 3
t4 Interval from flame signal to release «BV2»
TSA Ignition safety time
BV1 4 tw Waiting time for oil pre-heating
B Time of flame establishment
BV2 5
t1 t3n C Operating position
Z 6 D Controlled shut-down by «R»
t3 TSA
11 µC1 Microcontroller 1
FS
12 µC2 Microcontroller 2

t3n t3n
Z 6

11
FS
7130d03e/0700 12

APPENDIX: COMPONENTS CHARACTERISTICS 39

General unit data
Mains voltage AC 230 V +10 % / -15 %
AC 110 V +10 % / -15 %
Mains frequency 50...60 Hz ±6 %
External primary fuse (Si) 5 A (slow)
Power consumption 12 VA
Mounting orientation optional
Weight approx. 200 g
Degree of protection IP 40
Perm. cable lengths max. 3 m at a line capacitance of 100
pF/m
Detector cable laid separately 20 m
Remote reset 20m
Max perm. amperage at cosϕ≥ 0.6
Terminal 1 5A
Terminals 3 and 8 5A
Terminals 4, 5, 6 and 10 1A
Flame supervision with QRB and QRC
QRB
QRC
Min. detector current required (with flame) 45 µA
70 µA
Min detector current permitted (without flame) 5.5 µA
5.5 µA
Max. possible with flame (tipically) 100 µA
100 µA

Measurement circuit for detector current

11 12 LMO... 11 12 1 LMO...
7130v01/0700
bl sw bl sw br 7130v02/0700
+ +

µA DC µA DC

QRB... QRC1...

Key
µA DC DC microamperometer with an inter-
nal resistance of 5 kΩ max.
bl Blue
sw Black
br Brown

40 APPENDIX: COMPONENTS CHARACTERISTICS

LANDIS OIL BURNERS AUTOMATIC CONTROLLER LOA44
OPERATION
Burners without fuel pre-heater
Start-up, thermostat and pressure switches R, burner motor G and
ignition transformer Z are all controlled at the same time.
After about 25 seconds the solenoid is energised (in this period the
flame amplifier is at maximum sensitivity). The command to the first
solenoid BV1 marks the start of the safety time during which, either
there is no flame in the burner and the controller locks it out, or after 5
seconds the stage 2 solenoid BV2 is energised and this ends the bur-
ner start-up programme.
Burners with fuel pre-heater
(Operational all-clear from contact OW which short circuits terminals
3 and 8). The burner start-up programme is exactly the same as
above except that it is initiated by the closing of the OW contact of the
preheater OH.
When the flame lights the flame relay contact (fr2) is short circuited
and should the contact OW open that does not cause a lockout but a
repetition of the cycle.
Commands in the event of operational interference
Premature ignition / Flame present during pre-purge: Lockout and
termination of pre-purge
Defective components in controller or electronic programmer:
Lockout
No flame signal at the end of safety time: Lockout
No flame during post-ignition: Lockout
No flame during normal operation: Repetition of start-up pro-
gramme
Power cut during start-up programme or operation: Automatic
repetition of programme when power restored.
Lack of sufficient power (~160V): Solenoid BV1 de-energised, sole-
noid BV2 de-energised when flame goes out
Lockout which occurs within less than 1 second, cuts off power to ter-
minals 3-8 and 12; terminal 10 still remains live in order to activate the
optical lockout indicator. The controller can be reset 2 seconds after a
lockout.
Important: when external wiring is replaced ensure that it is switched
on at the same phase of terminal 2 (so that terminal 9 is connected up
to neutral).
Electrical connections and programmer's layout
A’ burner start-up
B Flame signal with oil pre-heater present
C End of programme-start of normal operation Key - Internal diagram
A burner start-up
AL alarm device
C-D normal operation without oil pre- heater
AR main relay with contacts
D normal stop
BV.. fuel valve
Programme or command cycle
BR lockout relay
tw fuel pre-heating time acc. to system EK.. lockout reset button
tl pre-purge time, ~25secs. FS flame signal
t3 pre-ignition time, ~25secs. M burner motor
t2 safety time max.5 secs. HR auxiliary relay with contacts hr
t3n post-ignition time, ~2 secs. OH oil pre-heater
t4 interval between BV1 and BV2 commands, ~5 secs* - lockout OW release contact of oil pre-heater
from absence of flame, <1 sec.
QRB photoresistive detector
* In relation to the moment when the flame occurs.
R control pressostat or pressure switch
V flame signal amplifer
W limit thermostat or pressure switch
Z ignition transformer

APPENDIX: COMPONENTS CHARACTERISTICS 41

Technical characteristics
Voltage 220V-15%..240V+10% or
100V-15%..110V+10%
Frequency 50...60Hz _6%
External fuse max.10 A, slow action
Contact flow:
terminal 1 max. 5A
terminal 3 5A (incl. consumed cap. of motor and
pre-heater)
terminals 4,5& 6 max.2A
terminal 8 max. 5A
terminal 10 max.1A
Permitted temperature
operation -20...+60°C
storage and transport -50...+40°C
Protection IP40
Mass (weight) controller/socket 140g/80g,
AGK accessories ~12g

Key to internal diagram

AL Remote optical lockout indicator
AR Main relay with contacts ar...
BV.. Fuel solenoid
BR Lockout relay with contacts br..
EK Reset button
FR Flame relay with contacts fr...
FS Flame present signal
G Burner motor
HR Auxiliary relay with contacts hr..
L Lockout LED incorporated in the reset button
OH Fuel pre-heater
OW All-clear contact for pre-heater
QRB Photo resistor (flame detector)
R Normal thermostat or pressure switch
V Flame signal amplifier
W Safety thermostat or pressure switch
Z Safety transformer

Internal diagram

42 APPENDIX: COMPONENTS CHARACTERISTICS

FLAME CONTROL DEVICE FOR OIL BURNERS LAL.. t3’ Long preignition time: «Z» connected to terminal 15.
Use t3n Postignition time:
z Control and supervision of oil atomization burners - «Z» must be connected to terminal 15
z For burners of medium to high capacity - With short preignition, «Z» remains on until «TSA» has elapsed
connection to terminal 16.
z For intermittent operation (at least one controlled shutdown every
24 hours) t4 Interval «BV1 – BV2» or «BV1 - LR»: On completion of «t4»,
voltage is present at terminal 19. The voltage is required to power
z Universally applicable for multistage or modulating burners
«BV2» connected to auxiliary switch «v» in the actuator.
Housing and plug-in base t5 Interval: On completion of «t5», terminal 20 receives power. At
z Made of impact-proof and heat-resistance black plastic the same time, control outputs 9 to 11 and input 8 are galvanically
z Lockout reset button with viewing window; located behind it: separated from the LAL...’s control section.
z Lockout warning lamp LAL... is now protected against reverse voltages from the load control
z Lockout indicator coupled to the spindle of the sequence switch circuit. With the release of «LR» at terminal 20, the startup sequence
and visible in the transparent lockout reset button of the LAL... ends. After a few idle steps (steps with no contact posi-
tion changes), the sequence switch switches itself off.
z uses easy-to-remember symbols to indicate the type of fault and
the point in time lockout occurred B Operating position of the burner
Base and plug-in section of the LAL... are designed such that only B-C Burner operation: during burner operation, «LR» drives the air
burner controls of the LAL... family can be plugged in. damper to the nominal load or low-fire position, depending on heat
demand; the release of the nominal load takes place via auxiliary
z 24 connection terminals
switch «v» in the actuator and in the event of loss of flame during ope-
z Auxiliary terminals «31» and «32» ration, the LAL... will initiate lockout. For automatic start repetition, the
z 3 earth terminals terminating in a lug for earthing the burner clearly marked wire link «B» on the plugin section of the LAL... must
z 3 neutral conductor terminals prewired to terminal 2 be cut away.
z 14 knockout holes for cable entry by means of cable glands C Controlled shutdown: in the case of controlled shutdown,
z 8 at the side «BV...» will immediately be closed. At the same time, the sequence
switch is started to program «t6»
z 6 in the bottom of the base
C-D Sequence switch travels to start position «A»
z 6 lateral threaded knockout holes for cable entry glands Pg11 or
M20 t6 Postpurge time: fan «M2» connected to terminal 7. Shortly after
the start of «t6», terminal 10 receives power and the air damper is dri-
Operation ven to the MIN position. Full closing of the air damper starts only shor-
Flame detector and flame simulation test are made automatically tly before «t6» has elapsed initiated by the control signal at terminal
during burner off times and the prepurge time «t1». If loss of flame 11. During the following burner off time, terminal 11 is live.
occurs during operation, the burner control will initiate lockout. If auto- t13 Permissible afterburn time: during «t13», the flame signal input
matic repetition of the startup sequence is required, the clearly may still receive a flame signal.
marked wire link on the plug-in section of the LAL... must be cut away. D-A End of control program: start position
As soon as the sequence switch has reached the start position –
Pre-conditions for burner startup having thereby switched itself off – the flame detector and flame simu-
z Burner control is not in the lockout position lation test will start again.
z Sequence switch is in its start position (with LAL2 voltage is pre- During burner off times, the flame supervision circuit is live.
sent at terminals 11 and 12.
z Air damper is closed; end switch «z» for the CLOSED position
must feed power from terminal 11 to terminal8.
z Contact of the limit thermostat or pressure switch «W» and the
contacts of any other switching devices in the control loop
between terminals 4 and 5 must be closed e.g. a control contact
for the oil preheater’s temperature
z Normally closed contact of the air pressure switch must be closed.
Startup sequence
Start command by «R»:
«R» closes the start control loop between terminals 4 and 5
z The sequence switch starts to run
z Only prepurging, fan motor at terminal 6 receives power
z Pre- and postpurging, fan motor or flue gas fan at terminal 7 recei-
ves power on completion of «t7»
z On completion of «t16», the control command for opening the air
damper is delivered via terminal 9
z Terminal 8 receives no power during the positioning time
z The sequence switch continues to run only after the air damper
has fully closed.
t1 Prepurge time with air damper fully open:
z The correct functioning of the flame supervision circuit is checked
during «t1»
z The burner control will initiate lockout if correct functioning is not
ensured.
With LAL2:
Shortly after the beginning of «t1», the air pressure switch must
change over from terminal 13 to terminal 14 otherwise, the burner
control will initiate lockout start of the air pressure check.
t3 Short preignition time:
«Z» must be connected to terminal 16, release of fuel via terminal 18.

APPENDIX: COMPONENTS CHARACTERISTICS 43

Lockout and indication of the stop position Lockout indication
Whenever a fault occurs, the sequence switch stops and with it the
lockout indicator. The symbol appearing above the reading mark indi-
cates the type of fault:
No start. One of the contacts is not closed (also refer to «Pre-
conditions for burner startup»):
Extraneous light:
Lockout during or after completion of the control program
Examples: nonextinguished flame, leaking fuel valves faulty flame
supervision circuit.
Interruption of startup. No OPEN signal at terminal 8 from the
changeover end switch «a». Terminals 6, 7 and 15 are live until a-b Startup sequence
fault has been corrected b-b’ Idle step (with no contact confirmation)
P Lockout. No air pressure indication at the beginning of the air b(b’)-a Postpurge program
pressure check. Air pressure failure after the air pressure check.
Defect in the flame supervision circuit.
Burner control can immediately be reset after lockout:
Interruption of the startup sequence. No positioning signal at
Do not press the lockout reset button for more than 10 seconds
terminal 8 from the auxiliary switch «m» for the low-fire position.
Terminals 6, 7 and 15 are live until fault has been corrected. The sequence switch always travels to the start position first
1 Lockout. No flame signal at the end of the safety time. After resetting
| Flame signa has been lost during operation. After rectification of a fault that led to shutdown
A Consenso all’avviamento (ad esempio tramite il termostato After each power failure
o il pressostato R dell’impianto During this period of time, power is only fed to terminals 7 and 9...11.
B Operating position of the burner Then, the LAL.... will program a new burner startup sequence
B-C Burner operation: during burner operation, «LR» drives the air Specifications
damper to the nominal load or low-fire position, depending on heat Power supply AC 230 V -15 / +10 %
demand; the release of the nominal load takes place via auxiliary for LAL2... on request AC 100 V -15 %...AC 110 V +10 %
switch «v» in the actuator and in the event of loss of flame during ope- Frequency 50 Hz -6 %...60 Hz +6 %
ration, the LAL... will initiate lockout. For automatic start repetition, the Absorption AC 3.5 VA
clearly marked wire link «B» on the plugin section of the LAL... must Mounting position optional
be cut away. Protection IP 40
C Controlled shutdown: in the case of controlled shutdown, Perm. input current at terminal 1
«BV...» will immediately be closed. At the same time, the sequence AC 5 A max., 20 A peak
switch is started to program «t6»
Perm. current rating of control terminals 3, 6, 7, 9...11, 15...20
C-D Sequence switch travels to start position «A».
4 A max., 20 A peak
Internal fuse T6,3H250V according to IEC 127
During burner off times, the flame supervision circuit is live. External fuse max. 10 A
Weight Device 1000 g
Plug-in base 165 g

L S Q R C 1 ...
H
bl sw br
SB
22 23 1
1
AS

b r1
a b
I
Q R B 1 ...
a b
ar1 a r2 22 23 24
4 6 7 V

W
FR
M1 M2
R a b
B N
X IV
5 a b
fr1 fr2
V II
a b a b
IX
a r3

XI X III X II IV II X V III V VI III

b a a b b aa b a b a b a b

EK1* AR
SM
b r2
L1 M M
E
BR
A

20
3 21 2 15 16 18 17 19 9 11 1 0 8
1 (3 ) LR
SA
H
AL v a
M
z m
LK
EK2*
Z BV1 BV2
N 7 1 5 3 a 0 7 /0 4 9 6

44 APPENDIX: COMPONENTS CHARACTERISTICS

Sequence diagram

Control output at terminal

A B C t6 D
t11 t1 t12
a 4 12 *
I b t7 7
t4
a 19
II b 16
a 10
III b 9
t3
IV 15
t3" t3 n
a 9
V b 11
t1 6 t5
VI 20

a
V II b 8
t20
a 17
V III b

IX t2
a 18
X b
a
XI b
a
X II b *
t10* t13
a
X III b
a
X IV b
t8

Lockout position indication

Key
t1 Prepurge time with air damper fully open
t2 Safety time
t3 Preignition time, short («Z» connected to terminal 16)
T3’ Preignition time, long («Z» connected to terminal 15)
t3n Postignition time («Z» connected to terminal 15)
t4 Interval between voltage at terminals 18 and 19 («BV1-
BV2»)
t5 Interval between voltage at terminals 19 and 20 («BV2»
load controller)
t6 Postpurge time (with «M2»)
t7 Interval between start command and voltage at terminal 7
(start delay time for «M2»)
t8 Duration of startup sequence (excluding «t11» and «t12»)
t10 Interval from startup to the beginning of the air pressure
check
t11 Air damper running time to the OPEN position
t12 Air damper running time to the low-fire position (MIN)
t13 Permissible afterburn time
t16 Interval to the OPEN command for the air damper
t20 For self-shutdown of the sequence switch

APPENDIX: COMPONENTS CHARACTERISTICS 45

SUNTEC PUMP AJ6
Operating principle
The gear set draws oil from the tank through the built-in filter and transfers it to the valve that regulates the oil pressure to the nozzle line. All oil
which does not go through the nozzle line will be dumped through the valve back to the return line, in two pipe installation or, if it is a one-pipe
installation, back to the suction port in the gear-set (in that case, the by-pass plug must be removed from the vacuum gauge port, and the return
port sealed by steel plug and washer).
The valve also has a cut-off function* as follows:
During starting period when the gear-set speed is increasing, all the oil passes through a bleed slot in the piston, back to the return. Once the
speed reaches a certain value and the flow can no longer pass through this bleed slot, then the pressure increases rapidly overcoming the valve
spring force and opens the valve. During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is
lower than the bleed slot flow. The cut-on and cut-off speeds depend on the gear-set size, and set pressure.
Bleed
Bleeding in two pipe operation is automatic, but it could be accelerated by loosening the plug in a pressure gauge port. In one pipe operation, a
pressure port must be opened to bleed the system.
* Owing to the presence of the nozzle by-pass hole, AJ 1002 models have no cut-off function. Cut-off must be provided by an external solenoid
valve.

Technical data Hydraulic data

Mounting Flange according to European Stan- Nozzle pressure range C: 10 - 20 bars
dard EN 225 E: 10 - 30 bars
Connection threads Cylindrical according to ISO 228/1 Delivery pressure setting 12 bar
Inlet and return G 1/4" Operating viscosity 2,8 - 75 cSt
Nozzle outlet G 1/8" Oil temperature 60°C max. in the pump
Pressure gauge port G 1/8" Inlet pressure 2 bar max.
Vacuum gauge port G 1/8" Return pressure 2 bar max.
Valve function Pressure regulating and cut-off (except Suction height 0,45 bars max. vacuum to prevent air
for 1002 models) separation from oil
Strainer Open area 30 cm2 Rated speed 3600 rpm max.
Opening size 120 x 150 mm2 Starting torque 0,30 N.m
Shaft AJ 1000/1002 Ø 11mm (7/16")
AJ 1003 Ø 8 mm according to European Stan-
dard EN 225
By-pass plug Inserted in vacuum gauge port for 2
pipe system; to be removed with a 4
mm Allen key for 1 pipe system
Weight 1,7 kg

Key
A Oil under suction
B Oil under pressure
C By-passed oil returned to tank or to suction
1 Pressure regulator
2 Pressure gauge
3 To nozzle
4 Gear
5 Shaft seal
6 Return
7 Return to suction
8 Vacuum gauge
9 Inserted by-pass plug
10 By-pass plug removed
11 Suction
12 Closed return

Single tube installation Twin tube installation

46 APPENDIX: COMPONENTS CHARACTERISTICS

SUNTE PUMPS J6 - J7
Operating principle
The gear set draws oil from the tank through the built-in filter and transfers it to the valve that regulates the oil pressure to the nozzle line. All oil
that does not go through the nozzle line will be dumped through the valve back to the return line in two pipe installation or, if it is a one-pipe
installation, back to the suction port in the gear-set. In that case, the by-pass plug must be removed from the return port and the return port sea-
led by steel plug and washer. The valve also has a cut-off function* as follows:
During starting period when the gear-set speed is increasing, all the oil passes through a special flat on the piston, back to the return. Once the
speed reaches
a certain value and the flow can no longer pass through this flat, then the pressure increases rapidly overcoming the valve spring force and
opens the valve. During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is lower than the
flat flow. The cut-on and cut-off speeds depend on the gear-set size and set pressure.
Bleed
Bleeding in two pipe operation is automatic, but it may be accelerated by loosening the plug in a pressure gauge port. In one pipe operation, a
pressure port must be opened to bleed the system.
* Owing to the presence of the nozzle by-pass hole, J 1002 models have no cutoff function. Cut-off must be provided by an external solenoid
valve.

Technical data Hydraulic data

Nozzle pressure range 10 - 21 bar
Mounting Flange mounting according to EN 225. Delivery pressure setting 12 bar
Operating viscosity 2,8 - 200 cSt
Model 1000 1001/1002 Oil temperature 0 - 90°C in the pump.
Cylindrical (according to
Connection threads Conical Inlet pressure 1,5 bar max.
ISO 228/1)
Inlet and return 1/4"NPTF G 1/2" Return pressure 1,5 bar max.
Nozzle outlet 1/8"NPTF G 1/4" Suction height 0,45 bar max. vacuum to prevent air
Pressure gauge port 1/8"NPSF G 1/8" separation from oil.
Vacuum gauge port 1/4"NPTF G 1/2"
Rated speed 3600rpm max.
Valve function Pressure regulating and cut-off (except Torque (@ 45 rpm) 0,30 N.m
for 1002 models).
Strainer Open area: 45 cm²
Opening size: 170 µm
Shaft Ø 11mm according to EN 225.
By-pass plug Inserted in return port for 2 pipe
system; to be removed with a 3/16"
Allen key for 1 pipe system.
Weight 4 kg

Key
1 Inlet
2 Vacuum gauge A 1 2
3 gear
4 Shaft seal B 3
5 Pressure regulation
6 To nozzle C
7 Pressure gauge
8 Return 4
9 Inserted by-pass plug
9a Removed by-pass plug 10
10 Return to suction 5 6
A Oil under suction
B Oil under pressure 7
C By-passed oil returned to tank or to suction 9a 9

8
Single pipe installation Twin pipe installation

APPENDIX: COMPONENTS CHARACTERISTICS 47

PUMP SUNTEC TA
The SUNTEC TA oil pump is specially designed for industrial heating applications using light or heavy oils. It is fitted with a preheater location to
render cold starting easier.
Operating principle
The gear set draws oil from the tank and transfers it to the valve that regulates the oil pressure to the nozzle line. All oil which does not go
through the nozzle line will be dumped through the valve back to the return line in two pipe installation or, if it is a one-pipe installation, back to
the gear-set.
Bleed
The plug of the pressure gauge port must be loosened until the air is evacuated from the system.
Note
All TA models are delivered for two-pipe system (by-pass plug fitted in vacuum gauge port). For one-pipe system, the by-pass plug must be
removed and the return port sealed by steel plug and washer.
PRE-HEATING FACILITY
Care should be taken to avoid starting pump with high viscosity cold oil leading to pump and coupling damage. For this reason, the TA pump
body includes a drilling to accept an electric preheater. This drilling has been located to give maximum heat transfer from the heater to the oil in
the pump without there being direct contact between the heater cartridge and the oil. Heaters should be connected for a period of time prior to
starting the pump. When the right temperature is reached, they can be switched off or left permanently switched on to maintain fluid oil in the
pump during the periodic burner shut-downs. The oil supply, pipes and filters must be separately heated.

TECHNICAL DATA Hydraulic data

Mounting Flange mounting Nozzle pressure ranges 30 : 7 - 30 bar
Connection threads Cylindrical according to ISO 228/1 40 : 7 - 40 bar
Shaft Ø 12 mm Delivery pressure setting 30 bar
By-pass plug Inserted in vacuum gauge port for 2 pipe system; to Operating viscosity 4 - 450 cSt
be removed with a 3/16" Allen key for 1 pipe systemOil temperature 0 - 140°C max. in the
Weight 5,4 kg (TA2) - 5,7 kg (TA3) pump
6 kg (TA4) - 6,4 kg (TA5) Inlet pressure 5 bar max.
Return pressure 5 bar max.
Rated speed 3600 rpm max.
Starting torque 0,3 N.m

Key
1 Vacuum port
2 Pressure port
3 Suction
4 Nozzle
5 Return
6 Pressure regulator
7 Inserted by-pass plug
8 Suction
9 Removed by-pass plug
10 Closed return

Twin pipe installation Single pipe installation

48 APPENDIX: COMPONENTS CHARACTERISTICS

SUNTEC PUMPS E6 - E7 NC1001
Operating principle
The gear set draws oil from the tank through the built-in filter and transfers it to the valve that regulates the oil pressure to the nozzle line. All oil
that does not go through the nozzle line will be dumped through the valve back to the return line in two pipe installation or, if it is a one-pipe
installation, back to the suction port in the gear-set. In that case, the by-pass plug must be removed from the return port and the return port sea-
led by steel plug and washer.
The valve also has a cut-off function as follows.
During starting period when the gear-set speed is increasing, all the oil passes through a special flat on the piston, back to the return. Once the
speed reaches a certain value and the flow can no longer pass through this flat, then the pressure increases rapidly overcoming the valve spring
force and opens the valve.
During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is lower than the flat flow. The cut-
on and cut-off speeds depend on the gear-set size and set pressure.
Bleed
Bleeding in two pipe operation is automatic, but it may be accelerated by loosening the plug in a pressure gauge port.
In one pipe operation, a pressure port must be opened to bleed the system.

Technical data Hydraulic data

Mounting Flange mounting according to EN Nozzle pressure range 14 - 30 bar
225. Delivery pressure setting 20 bar
Connection threads Cylindrical according to ISO 228/1 Operating viscosity 2,8 - 450 cSt
Inlet and return G 1/2" Oil temperature 0 - 90°C in the pump.
Nozzle outlet G 1/4" Inlet pressure 1,5 bar max.
Pressure gauge port G 1/8" Return pressure 1,5 bar max.
Vacuum gauge port G 1/2" Suction height 0,45 bar max. vacuum to prevent air sepa-
Valve function Pressure regulating and cut-off. ration from oil.
Strainer Open area 45 cm² Rated speed 3600 rpm max.
Opening size C = 170 µm Torque (@ 45 rpm) 0,30 N.m
N = 550 µm
Shaft Ø 11mm according to EN 225.
By-pass plug Inserted in return port for 2 pipe
system; to be removed with a
3/16" Allen key for 1 pipe system.
Weight 4 kg

Key
A Oil under suction
B Oil under pressure
C By-passed oil returned to tank or to suction
1 Suction
2 Vacuum gauge port
3 Gear set
4 Shaft seal
5 Pressure adjustment
6 By-pass plug inserted
7 Return
8 Pressure gauge port
9 To nozzle
10 Back to suction
11 Return plugged
12 Removed by-pass pug

Single pipe installation Twin pipe installation

APPENDIX: COMPONENTS CHARACTERISTICS 49

PUMP DANFOSS KSM
This pump is designed for use on burners with fuel rate up to 1400 l/h.
Operation
From the suction S the oil is transferred to the gear set where increases its pressure. The pressure is kept constant to the value set by means of
the screw P1, the piston B and the pressure governor.
Single tube and twin tube installation
In single tube systems with the return port R closed and the by-pass screw removed, the fuel in excess is put off to the gear set (see picture).
KSM umps don’t carry out the cut-off function and are suitable for burners where a solenoid valve or a pre-heater on the nozzle line is fitted.
Drain
In twin tube installations, the pump primes itself automatically, thet is the drain is carried out through the pressure regulation port T, thowards
the return R; in the single tube systems with the return closed R and the by-pass screw A removed,the drain is carried out through the port P or
the pressure gauge Pn.

A B

A - Clockwise rotation: Key

single tube, screw removed P1 Pressure regulation
twin tube, screw installed S Suction
R Return
B - Counterclockwise rotation: P To nozzle
single tube, screw removed Pn Presure port
twin tube, screw installed Ps Vacuum port

50 APPENDIX: COMPONENTS CHARACTERISTICS

NOTES FOR USE AND MAINTENANCE OF FUEL PUMPS

z Make sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and
damage to the pump and burner motor could result.
z Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear
teeth, thus obstructing them.
z After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of
the tank, thus avoiding the possibility that they might be sucked into the pump.
z On initial commissioning a "dry" operation is foreseen for a considerable length of time (for example, when there is a long
suction line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet.
z Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on
the joint, noise and overloading the gears.
z Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal
junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The num-
ber of junctions should be kept to a minimum as they are a possible source of leakage.
z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could
deposit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium
gaskets) junctions if possible.
z Filter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit. To remove the filter,
unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted with the feet toward the pump
body. If the gasket between cover and pump housing should be damaged, it must be replaced. An external filter should
always be installed in the suction line upstream of the fuel unit.

APPENDIX: COMPONENTS CHARACTERISTICS 51