ACV BMR 33 Assembly instructions

EN • 1
ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
662Y0500 • B
Installation, operating
andmaintenance instructions
BMR 33

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
662Y0500 • B
INDEX
SAFETY PRECAUTIONS 3
STANDARDS AND REGULATIONS 3
Standards and directives 3
Exhaust gas system and effective heat requirement 3
Nozzle selection 3
GENERAL 4
The flame makes the difference 4
Energy saving 4
The mixing unit and recirculation principle 4
INSTALLATION 5
Specification 5
Dimensions 6
Recirculation 6
Installation instructions 6
System check 6
Burner assembly 6
Special applications 6
COMMISSIONING 7
Commissioning and Adjustment 7
Pump pressure adjustment 7
Changing the burner capacity 7
Fan compression 7
Air intake nozzle adjustment 8
Air intake nozzle 8
Air circulation 8
VIEWS, GASKET 8
MAINTENANCE 9
Maintenance 9
Flame monitoring 9
TROUBLESHOOTING 10
Fault causes and solutions 10
TECHNICAL DOCUMENTATION 12
Technical data and electrical supply 12
Output table 12
Oil line dimensions 12
BMR 33 wiring diagram 12
BMR 33 operating range 13
Dimensions 13
Guarantee 13
Oil tank and oil lines 13
Spare parts 13
SPARE PARTS WWW.ACV.COM
DECLARATION OF CONFORMITY 8/1/2004 - BE
We hereby declare that the following appliance series complies
with the type described in the EC Declaration of Conformity and
that it is manufactured and placed on the market in conformity
with the requirements of the declaration of conformity of
8January 2004.
Model: BMR 33
Product type with: Forced draught oil burner
Inspection authority: TÜV Rheinland
Product ID number: CE 0035BS107
Measured values: NOx : 84 mg/kWh
CO : 3 mg/kWh
Certified quality system ISO 9001

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
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Safety precautions
Please read these installation instructions carefully before commencing any installation work.
Liability and warranty claims will not be accepted for damage caused by failure to observe these
installation instructions!
Faulty installation may result in injuries or property damage!
Working on the heating system: - Installation, commissioning, maintenance and repairs
to the burner should be carried out only by an
authorized specialist heating company.
When working on the burner and boiler: - Switch off the heating emergency shut-off switch
andensure that it cannot be switched on again.
- Shut off the oil supply line and ensure that it cannot
be accidently opened.
STANDARDS
AND DIRECTIVES
The burner must be installed and
operated in accordance with the
following standards and directives.
HEIZAnIV
The German Heating Installations
Ordinance
EN 303, Part 1 and Part 2
Heating boilers with forced draught
burners
EN 60335, Part 1
Household and similar electrical
appliances - Safety
DIN EN 267
Atomizing oil burners – Definitions,
requirements, construction and testing
DIN 4755
Oil firing installations – Construction,
design, safety requirements
DIN 51603, Part 1
Extra-light heating oils
Please observe regional building
regulations.
EXHAUST GAS SYSTEM
AND EFFECTIVE HEAT
REQUIREMENT
Boiler, burner and exhaust gas system
(chimney) form one operational unit.
In the event of a power reduction,
allowances must be made for low
exhaust gas temperatures.
The system must be designed to avoid
damage caused by condensate created
when exhaust gas temperatures fall
below 160°C.
We recommend installing a draught
limiter (secondary air device) to obtain
consistent combustion values and
minimize potential humidity.
Ideally, this should be installed in the
chimney to avoid any noise in the flue
tube.
NOZZLE
SELECTION
Please note that a correct, low-emission
burn can be achieved only with nozzles
that match the burner. The nozzles listed
on page 13 are approved for use with
the BMR burner.
All data on page 13 is recorded at
maximum excess pressure.
STANDARDS AND REGULATIONS

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
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GENERAL
ENERGY SAVING
By purchasing this burner, you will be able to make significant
savings in terms of costs, oil and above all, energy!
We recommend that the heating system is regularly inspected
and serviced by a qualified heating engineer in accordance with
DIN 4755.
An indication of the combustion quality and oil consumption can be
obtained by checking the exhaust gas temperature and the burner
running times.
THE MIXING UNIT AND RECIRCULATION
PRINCIPLE
A. Air
B. Ignition electrode
C. Gasket
D. Recirculation
E. Oil
F. Inspection glass for flame detector
THE FLAME MAKES THE DIFFERENCE
Thanks to many years’ experience of developing blue burners,
we have been able to develop a product that not only meets, but
far exceeds the sophisticated requirements of modern heating
technology. In the design and development phase we took an
innovative route; by combining a new housing with a high-powered
fan which creates a pressure of 9 - 16 mbar behind the nozzle,
we have managed to develop a highly efficient oil gasification
system. This system provides a totally blue flame and an optimum
soot-free burn, whilst running extremely quietly and is a further
step towards green technology.
• Exhaust gas temperature
The exhaust gas temperature is measured using a thermometer
which can be purchased from a specialist shop. The chimney
sweep’s inspection hole is the ideal measuring point. If the exhaust
gas temperature appears to increase by more than 30°C, it
must be assumed that a coating has formed in the combustion
chamber, which will cause the heating system to run inefficiently.
If this occurs, clean the boiler and check the burner immediately.
When comparing with reference measurements, make sure that
the burner running times are the same.
• Operating hours meter
An operating hours meter which records the opening time
of the solenoid valve can be used to monitor oil consumption.
The system is connected to the electrical supply via the B4
terminal of the connection plug.
When comparing with reference measurements, allow for the
respective outside temperature of the year in question.
• Flue gas shut-off valve
Flue gas shut-off valves are occasionally used to prevent excess
cooling during shut-down. When the system is fully shut down,
condensation can form in the boiler and the chimney due to
the interrupted air flow. In addition, hot boiler components may
reflect back onto the nozzle (carbonization). However, the use
of a draught limiter or secondary air device can prevent the
satisfactory ventilation of the chimney and excessive cooling of
the boiler.
F
DB C
A
E

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
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INSTALLATION
SPECIFICATION
Single-step switch with preheating and pre-purge, approved for
intermittent operation in cast iron and steel boilers.
Burner components:
• Spiral housing (injection-molded)
• Burner pipe (high-temperature resistant steel)
• Sound-proofed combustion system with thermodynamic fuel-air
mixing
• Electric motor with operating capacitor
• Oil pump with built-in solenoid valve
• Automatic oil firing unit for intermittent operation
• Flame monitoring
• Ignition transformer
• Ignition electrodes
• Nozzle assembly
• Oil preheater with release thermostat and drip stop
• Cover
• Connection plug
• Oil hoses with swivel nut
• Clamping flange
• Burner gasket and connection screws
The burner is heat-tested.
The combustion quality is guaranteed by certified test
certificates.
The burner is inserted into the boiler through the sliding flange

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INSTALLATION
DIMENSIONS
When the burner is mounted to a boiler, the following dimensions
must be observed:
- Bolt circle: Ø 150 mm ± 1.5 mm
- Boiler door bore: min Ø 91 mm
INSTALLATION INSTRUCTIONS
When installing the oil hoses and connection wire, make sure that
the connection is strain-relieved and that the burner can be easily
placed in the service mounting bracket.
To commission the oil supply system, it must be vented via the
manometer connection of the oil pump.
Make sure that there are no leaks in the oil supply system!
Failure to do so can lead to combustion problems and dripping.
Replace the oil filter unit at the same time as replacing the burner!
Do not reverse phase and Mp!
Make sure that the protective earth conductor is properly
connected!
SYSTEM CHECK
Correct installation by a specialist company should include the
following:
1. Correct installation of oil lines and filter, leak testing and filling
with oil.
2. Compliance with relevant provisions of the Federal Water Act
(Wasserhaushaltsgesetz, WHG) relating to the laying of oil
lines and the anti-siphoning device.
3. Electrical connections must be installed in compliance with
local regulations. Use flexible cable for the burner connection.
4. The temperature of the oil in the storage tank and the oil lines
must be at least +5 degrees C.
5. Make sure that cold outside air cannot be drawn in.
BURNER ASSEMBLY
The BMR blue burner is particularly suitable for installing in
standard boilers (intermittent operation) for providing domestic
heating and hot water. Our design and development and test
conditions are precisely matched to these operating conditions.
SPECIAL APPLICATIONS
Special requirements and operating conditions must be observed
for the following fields of application:
• Dark radiators
• Ovens
• Drying chambers
• Annealing furnaces
• Industrial applications
Please seek our approval before using the burner in these applications!
It is advisable to consult ACV in the event of increased load in the
combustion chamber or increased thermal load.
Do not allow contaminated combustion air to enter the
burner!
This can be prevented by taking appropriate precautions,
particularly in areas contaminated with halohydrocarbons (printing
shops, hair salons, dry cleaners, laboratories).If in doubt, please
contact us.
Avoid excessive dust accumulation when the burner is
operating!
Avoid high air humidity and frost!
Good ventilation is essential!
We accept no liability for non-compliance with these
recommendations!
RECIRCULATION
The recirculation slots must on no account be covered by the door
cladding. Chamfer the door cladding as shown in the diagram if
necessary.
M 8
150
91
Flange adjustment
Chamfered door cladding
This recirculation opening must be kept clear
This mounting bracket must not be damaged

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COMMISSIONING
COMMISSIONING AND ADJUSTMENT
Adjustment by a qualified technician is essential to obtain a
permanently high combustion quality and operational safety.
When the oil pre-heater is switched on, the burner starts up once
the required temperature has been reached.
Ignition and oil release occur automatically via the automatic oil
firing device.
With some pumps, the oil pressure is displayed only
when the solenoid valve has opened.
If no oil is delivered when it is suctioned for the first time, discontinue
after 3 minutes at the most to avoid damaging the pump. Operating
status is reached when the oil filter is filled with oil.
With oil-air ratio regulators, the oil pressure must be readjusted
to the inherent boiler and chimney ratios (see diag.).
The chimney draught should not exceed – 0.1 mbar.
When the boiler is at operating temperature, check the
combustion values, starting with the CO2value. This value
determines the degree to which the oil flow rate must be modified
for a predetermined air volume:
CO2< 13.5%: the oil pressure can be increased
CO2> 13.5%: the oil pressure must be reduced.
Check the CO value when the CO2value has been adjusted to
13-14%. A CO reading of over 40 mg/kWh indicates that the
CO2 value has been distorted by an air leak in the boiler or flue
pipe connection. Seal up any leakages in the boiler and repeat
the measurement. Poor combustion can also be caused by an
unsatisfactory nozzle spray action. The oil pressure may also be
too high.
Note: The CO values in boiler systems can be affected by
combustion residues.
To correctly measure the CO2value the boiler must be
sealed and there must be a flue gas connection, since
any air leaks will falsify the reading!
PUMP PRESSURE ADJUSTMENT
Use the pressure regulator to adjust the pump pressure.
To the right: pressure increases; to the left: pressure decreases.
Do not turn the pressure regulator before venting the
pump!
CHANGING THE BURNER CAPACITY
The burner is preset as shown in the diagram and can be
adjusted by ± 8 %.
FAN COMPRESSION
For adjustment control, the fan compression must be measured
by loosening the screw.
1
3
2
5
4
1. Vacuum gauge connection
2. Pressure regulator
3. Manometer connection
4. Pump return
5. Pump flow
Do not turn the
adjustable screw on
the nozzle assembly!
Measurement port for determining
the fan compression.
Switch off power supply when
working on the burner!

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
662Y0500 • B
COMMISSIONING
AIR INTAKE NOZZLE ADJUSTMENT
The air flow is preset. To change the air flow, unscrew theretaining
screw on the air intake nozzle. Adjust the position of the air intake
nozzle to increase or reduce the fan pressure (see table p. 14).
If capacity is reduced, make sure that the oil pressure does not
fall below 10 bar.
(The oil pressure at burner start-up is higher)
AIR INTAKE NOZZLE
The air intake nozzle is preset.
If the burner capacity needs to be significantly changed (forexample,
due to the size of the mixing system), proceed as follows:
1. Remove the burner from the heating boiler.
2. Loosen the retaining screw on the air intake nozzle and adjust
the air intake nozzle. Retighten the retaining screw.
3. Re-mount the burner on the heating boiler.
Use the air damper to fine tune.
AIR CIRCULATION
The recirculation openings must be kept clear, see illustration on p.6.
Air intake silencer with cover and suction nozzle
for ambient air-independent operation
VIEWS, GASKET
Burner in service position for BMR 33
Right view of burner
Air intake nozzle
BMR 33 flame tube neck
with fixed recirculation
Alloy tube for BMR 33 with bayonet lock.
The lock must engage, check during installation!
Inspection opening for the flame
detector. Do not obstruct.
Gasket on the air intake sleeve

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
662Y0500 • B
MAINTENANCE
MAINTENANCE
It is advisable to have the oil firing system serviced annually by a
competent engineer, if only to comply with statutory requirements.
Cleaning the burner:
Fan, mixing system, ignition device. Change the nozzle and drip
stop if necessary, and the gasket on the mixing system. Then take
measurements to check.
When changing the nozzle, use only the replacement nozzles
listed in the table on p.13.
FLAME MONITORING
Checking the flame detector. Use the test socket with an
ammeter or multimeter.
The signal flow should not exceed 5.5 A during the pre-purge
phase. If it does, check the position of the ignition electrodes.
During operation the measurement signal must lie in the range
of > 90 A. Otherwise lockouts may occur. To ensure correct
functioning of the flame detector, it should be activated and
obscured so that the flame is extinguished. The automatic oil
firing device repeats and goes into error mode.
Service position for carrying out maintenance work
onthemixing system
Air sleeve in detailService mounting bracket

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
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TROUBLESHOOTING
Fault Cause Solution
The burner starts, but there is
no ame; It goes from running
mode to fault mode
Solenoid valve will not open Check electrical connections; replace solenoid
valve coil if necessary
Oil line blocked; nozzle blocked;
oilhosesblocked
Check specied components for blockages
(lters etc.)
Oil tank empty, oil pump defective Check oil pump and oil tank and replace
orllas required
Suction lines leaking Check suction lines and tighten screw
connections if necessary
Suction lines have not been vented Vent suction lines at the pump manometer
connection
Dirty mixing device Check mixing device and clean if necessary
Ignition electrode burnt down on one side Replace ignition electrode
Ignition electrodes incorrectly adjusted to
nozzle
Adjust as indicated in the manual
Incorrect burner settings Check burner settings and readjust if
necessary
Burner starts and has ame,
butthe ame goes out
Dirty or defective ame detector Clean or replace ame detector as required
Electrical connection from the automatic
ringdevice to the ame detector is
interrupted
Check electrical connection and replace
ifnecessary
Automatic ring device defective Replace automatic ring device
Burner vibrates when
inoperation
Firing resistance is too high Increase compression
After-spray or afterburn
whenthe burner has been
switched off
Insufcient venting of the oil line Vent the oil lines
Deposition on the tips
oftheignition electrodes
Temperatures are too high Eliminate source of air leak
Nozzle may be defective Replace nozzle
Burner will not start Voltage drop Restore voltage
Control switched off Switch on control (STB; KTR; automatic)
Burner in fault mode Dejam the ring device on the burner

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
662Y0500 • B
TROUBLESHOOTING
Fault Cause Solution
Burner starts, but here is no
ame (lockout) and the inspection
glass in the oil lter is only half
full or empty
Sealing plugs not removed during initial
commissioning
Remove sealing plugs
Oil line not lled with oil during initial
commissioning.
Several minutes may elapse before
theoilisdrawn in though the inlet.
Fill oil line with oil during initial commissioning
CAUTION:
Do not allow oil pump to run for more than
3min. without oil
No fuel in tank Fill tank
Oil pump not working Check electrical connection, replace oil
pumpifnecessary
Defective coupling between motor
andoilpump
Replace coupling
Kink in oil line Check oil line and replace if necessary
External valve to tank system, if present,
maybe shut
Check the external valve
Solenoid valve will not open Check electrical connections
andreplacesolenoid if necessary
Burner starts, but there is no
ignition. Oil inspection glass is
lled with oil. Lockout occurs!
Ignition transformer or ignition wiring
damagedor not connected.
Check primary connection wire from the
ignition transformer and replace if necessary
Ignition electrode burnt down on one side Replace ignition electrode
Ignition electrode incorrectly set Adjust ignition electrode
The ame detector has detected
extraneouslight
Eliminate extraneous light source
orreplaceame detector if necessary
Automatic ring device defective Replace automatic ring device

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ENGLISHFRANCAISNEDERLANDSESpAñoLITALIANoDEuTSCH
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TECHNICAL DOCUMENTATIONTECHNICAL DOCUMENTATION
TECHNICAL DATA AND ELECTRICAL SUPPLY
Mains connection : 230V/50Hz
Max. recorded output : 185 W (BMR 33)
Motor output : 90 W (BMR 33
Max. CO2: 13.5 %
Weight : 12 kg
BMR 33 WIRING DIAGRAM
OUTPUT TABLE BMR 33
Power kW 22.5
Nozzle 0.50 - 80°S
Nozzle manufacturer Steinen
Oil pressure bar 16
Air sleeve Ø mm 19
Flame tube (A) mm 90 x 2 x 193
Flame tube (B) mm 86 x 1 x 166.7
Air intake nozzle 4
Air damper 4
T2 S3T1NL1 B4
1 2 8 3 7 4 5 10 11 12
MT
CF
VM1 VM2 AL
NPF
LOA 14
LOA 14 : Automatic oil firing device
N : Neutral
M : Burner motor
T : Ignition transformer
VM 1 : Solenoid valve 1
VM 2 : Solenoid valve 2
AL : Warning light
CF : Flame detector
PF : Oil preheater
OIL LINE DIMENSIONS
Suction line length, 2-pipe system, tank higher Flow 0 bar (W/H) 60
Pipe diameter Ø mm Ø 6 mm Ø 8 mm
E
H
E max. = 20 m
(E - H) max. = 4,5 m
Static pressure H (m) Max. pipe length (m)
014 49
0.5 16 55
118 61
2 22 73
3 25 85
429 96
Suction line length, 2-pipe system, tank lower Flow 0 bar (W/H) 60
Pipe diameter Ø mm Ø 6 mm Ø 8 mm
H
H max. = 4,5 m
Static pressure H (m) Max. pipe length (m)
014 49
0.5 12 44
110 38
2 7 26
3 3 13
40 1
Note: The line lengths indicated do not allow for local pressure losses caused by bends, fittings, accessories etc.

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G
A
B
F
D
A
C E
TECHNICAL DOCUMENTATION
DIMENSIONS A
mm
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
Kg
BMR 33 292.5 280 193 85 152 230 255 12
BMR 33 OPERATING RANGE
GUARANTEE
The oil burner will function correctly when installed and
commissioned by a competent technician provided that EL heating
oil compliant with DIN 51 603, Part 1 is used.
Our warranty is valid for 24 months after commissioning, but
no longer than 27 months after purchasing and is limited to the
replacement of defective parts.
Further details can be found in the device certificate.
Incorrect use of fuel additives may invalidate the warranty.
OIL TANK AND OIL LINES
Switch off the burner before filling the tank and leave it switched
off for approx. 3 hours to allow any sediment to settle.
If the oil lines are not air-tight and the tank is running empty,
deflagration may occur as a result of air bubble formation.
Do not ignore any oil leakages! Fire hazard!
Soot-free combustion can be achieved without the addition of
combustion improvers. There are no objections to the use of ash-
free heating oil additives such as flow improvers.
SPARE PARTS
Use only original ACV replacement parts:
Some components, such as flame detectors, oil pumps,
preheaters etc. are designed and manufactured specifically for
ACV burners.
Please state the burner number when ordering spare parts!
1,5 1,7 1,9 2,1 2,3 2,5 2,7 2,9 3,1 3,3 3,5
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
- 0,
1
- 0,
2
BMR 33
Oil flow: from 1.65 kg/h — 3.37 kg/h
Combustion chamber
pressure mbar

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