baltur BT 180 DSG User manual

• - The works on the burner and on the system have to be carried out only by competent people.
- Read carefully the instructions before starting the burner and service it.
- The system electric feeding must be disconnected before starting working on it.
- If the works are not carried out correctly it is possible to cause dangerous accidents.
en
2001/05
Edizione/Edition/Ediciòn
Cod. 0006080365
INSTRUCTION FOR BURNERS MODEL
HINGED EXECUTION
BT 250 DSG
BT 300 DSG
BT 350 DSG

2
L'Amministratoredelegato
Dott. Riccardo Fava
Dichiarazione del Costruttore
Dichiariamo che i bruciatori di gas, gasolio, olio combustibile e misti (gas/gasolio oppure gas/olio combustibile)
sono da noi prodotti a regola d’arte in conformitàalle Norme CE - CEI - UNI vigenti al momento della costruzione.
•La BALTUR garantisce la certificazione “CE”sul prodotto solo se il bruciatore viene installato con la rampa gas
“CE”fornita dalla BALTUR e con accessori di linea gas certificati “CE”(forniti su richiesta).
NOTA:lapresente dichiarazionenonèvalida, relativamenteallaNormaCEoppureUNI,peribruciatoridigaseperlaparte
gasdei bruciatori misti(gas/gasolio oppure gas/oliocombustibile) quando, glistessi, ci vengonoordinati non conformialla
NormaCE oppureUNI,perchédestinatiad usospeciale,nonprevistonellenormesopra indicate.
Manufacturer’s declaration
We hereby declare that our gas, light oil, heavy oil, and combination (gas/light oil or gas/heavy oil) burners are
manufacturedinconformancewithcurrent CE, CEI and UNI standards.
•BALTUR guarantees the “CE”certification provided that the burner is coupled to the “CE”gas train supplied by
BALTUR and the “CE”gas line accessories (on request).
NOTE:this declaration is notvalidwith regard to ECor UNI Standards forgasburners or the gaspartof duel-fuel burn-
ers(gas/lightoil or gas/heavy oil) whensuchburnershave been ordered in non-compliancewiththeEC Standard or
ItalianUNIStandardbecause they are to be used forspecialpurposesnotprovided for in the above-mentioned stand-
ards.
Declaración del fabricante
Declaramosque la empresa fabrica los quemadores de gas, gasóleo, fuel ymixtos (gas/gasóleo o
gas/fuel)ajustándose a lasNormas CE - CEI- UNI vigentesen el momento desu fabricación.
•Lafirma “BALTUR”garantiza lacertificación“CE”sombre el producto sólosiel quemador viene instaladoconla
rampa gas “CE”suministrada por la “BALTUR”misma y con los accesorios de linea gas certificados “CE”
(suministrablesapedido).
NOTA: la presente declaración no tiene validez, respecto a la Norma CE o UNI, para los quemadores de gas y para la
parte de gas de los quemadores mixtos (gas/gasóleo o gas/fuel) cuando, los mismos, se piden no conformes a la
Norma CE o a la norma italiana UNI, porque están destinados a un uso especial, no previsto en las normas arriba
mencionadas.
Déclaration du constructeur
Nous déclarons que les brûleurs àgaz, fioul, fioul lourd et mixtes (gaz/fioul ou gaz/fioul lourd) sont produits selon
lesrègles de l’art, conformémentaux Normes CE –CEI–UNI en vigueur aumomentde la fabrication.
•La BALTUR garantit la certification “CE”seulement si les brûleur sont installéavec les rampes de gaz “CE”
produites par la BALTUR et les accessoires de ligne gaz “CE”(fournis sur demande).
NOTE:la présente déclaration n’est pasvalable,correspondante àla Norme CEoubien UNI, pour lesbrûleursàgaz
et pour la partie gaz des brûleurs mixtes (gaz/fioul ou bien gaz/fioul lourd) lorsque, ces derniers, nous sont
commandés sans être conformes àla Norme CE ou bien àla norme italienne UNI, parce qu’ils sont destinés àune
utilisation spéciale qui n’est pas prévue par les normes indiquées ci-dessus.
Herstellererklärung
Wirerklären,dassdie Gas-, Heizöl-, Schweröl- und Wechselbrenner(Gas/HeizöloderGas/Schweröl)von uns
fachgerechtundin Übereinstimmung mit den zum Zeitpunkt derFertigunggeltendenNormen CE - CEI - UNI
hergestelltwurden.
•Die“CE”-ZertifizierungdervonBALTURhergestelltenProdukteistnurinVerbindungmiteinervonBALTURgelieferten
CE-Gasarmaturund unterVerwendungvon CE-zertifiziertenBauteilen in der Gaszufürhrung gültig.
HINWEIS:DievorliegendeErklärungimHinblickaufdieEU- oder UNI-Normen ist nicht gültig für Gasbrenner und für
denGasteilvon Wechselbrennern (Gas/Öl oder Gas/Schweröl), wennsolchebeiuns ohne Konformität mit den EU-
Normenoder mit der italienischen NormUNIbestellt werden, weil sieeinefür spezielle Verwendung bestimmt sind,
dievondenobengenanntenNormennichtvorgesehenist.
0006080197Rev.1

3
INDEX PAGE
- Technicalspecifications .....................................................................................................................“4
- Conditionsforgoodinstallation -Fasteningtheburnerto the boiler - Fuel pipeline...............................“6
- Auxiliarypump -Descriptionofoperation ............................................................................................“9
- Controlbox specifications - Firstfilling up of pipelines .........................................................................“10
- Startingupandregulation ..................................................................................................................“11
- Cecks - Air regulation on the combustion head - Regulating the distance between the disck
andthe nozzle ...................................................................................................................................“12
- Usingof theburner-Maintenance-Descriptionofoperation oftwo-flameburners .................................“13
- Hydraulicdiagram..............................................................................................................................“14
- Generaldiagramairregulation ............................................................................................................“15
- Layout diagram of nozzle - electrodes - disk .......................................................................................“16
- Detailsof pump .................................................................................................................................“18
- Nozzleflow-ratetable.........................................................................................................................“19
- AirregulationservomotorSQN30.111A3500 ......................................................................................“20
- ConnectronairmotorLKS300regulation............................................................................................“21
- Electricdiagrams...............................................................................................................................“23
- Irregularity-cause-remedy...............................................................................................................“27

4
CARATTERISTICHE TECNICHE /TECHNICAL SPECIFICATIONS
BT 180 - 250 - 300 - 350 DSG
WHIT HINGE N°0002270350
REV. 11/10/95
TECNICAL DATA MODEL
CARATTERISTICHE TECNICHE MODELLO
BT 180 DSG BT 250 DSG BT 300 DSG BT 350 DSG
FLOW RATE MIN kg/h 60 90 110 115
PORTATA MAX kg/h 180 280 325 350
BURNER OUTPUT MIN kW 712 1067 1304 1364
POTENZA TERMICA MAX kW 2135 3320 3854 4151
FUEL 1,5°E at 20°C1,5°E at 20°C1,5°E at 20°C1,5°E at 20°C
COMBUSTIBILE
FAN MOTOR 3kW-11,5/6,6A 7,5kW-26,8/15,5A 7,5kW-26,8/15,5A 9Kw-18,5A
MOTORE VENTOLA 2870 r.p.m. 2870r.p.m. 2870r.p.m. 2900 r.p.m.
TRANSFORMER 14kV - 30 mA 14kV - 30 mA 14kV - 30 mA 14kV - 30 mA
TRASFORMATORE
VOLTAGE 230/400v 230/400v 230/400v 230/400v
ALIMENTAZIONE ELETTRICA
STANDARD ACCESSORIES MODEL
MATERIALE A CORREDO MODELLO
BT 180 DSG BT 250 DSG BT 300 DSG BT 350 DSG
INSULATING GASKET N°1N°1N°2N°2
GUARNIZIONE ISOLANTE
STUD BOLTS N°4 - M16 N°4 - M16 N°4 - M18 N°4 - M18
PRIGIONIERI
HEXAGONAL NUTS N°4 - M16 N°4 - M16 N°4 - M18 N°4 - M18
DADI ESAGONALI
FLATWASHERS N°4 - M16 N°4 - M16 N°4 - M18 N°4 - M18
RONDELLE PIANE
FLEXIBLE PIPE N°2N°2N°2N°2
TUBI FLESSIBILI 1" 1" 1" 1/4 1" 1/4
NIPPLES N°2N°2 - - - -
NIPPLI 1" x 1" 1" x 1"
LIGHT OIL FILTER 1" 1" 1" 1/4 1" 1/4
FILTRO GASOLIO
50Hz
LIGHT OIL
GASOLIO
50Hz
230v - 50Hz
LEGEND
1 -COMBUSTION HEAD
2 -ISOLATINGGASKET
3 - HINGE
4 -1st FLAMEELECTROVALVE
5 -PUMP
6 - 1st FLAME PRESSURE REGULATOR
7 -2nd FLAMEELECTROVALVE
8 - ELECTRIC BOARD
9 -FAN MOTOR
10 -AIR REGULATINGSERVOMOTOR
LEGENDA
1 -TESTADI COMBUSTIONE
2 -GUARNIZIONE ISOLANTE
3 - CERNIERA
4 -ELETTROVALVOLA1°FIAMMA
5 -POMPA
6 -REGOLATOREDIPRESSIONE 1°FIAMMA
7 -ELETTROVALVOLA2°FIAMMA
8 -QUADRO ELETTRICO
9 -MOTOREPOMPA
10 -SERVOMOTORE REGOLAZIONEARIA

5
BT 180 - 250 - 300 - 350 DSG
WITH HINGE
N°0002200350
REV. 11/10/95
CARATTERISTICHE TECNICHE /TECHNICAL SPECIFICATIONS
MODELLO DIMENSIONI DI INGOMBRO
MODEL OVERAL DIMENSIONS
A A1 A2 B B1 B2 C D E ØF ØHILMN
BT 180 DSG 820 400 420 760 580 180 930 265 260 225 940 395 280 M16 275
BT 250 DSG 840 420 420 760 580 180 930 265 260 225 940 395 280 M16 275
BT 300 DSG 840 420 485 760 580 180 930 385 355 280 960 510 360 M16 370
BT 350 DSG 1055 530 525 885 660 225 1110 420 355 280 1155 510 360 M16 370
CAMPO DI LAVORO / WORKING FIELD

6
CONDITION FOR A GOOD INSTALLATION
Beforeproceeding with installation, checkthat:
1) The chimney (cross section and height) complies with the boiler manufacturer’s instructions and local
standards.
2) When it is necessary to make a refractory lining for the combustion chamber (if the type of boiler requires it),
then it must be made according to the specific instructions of the boiler manufacturer.
3) The electric powersupplyline for the burnershouldbe according to our diagramandthe electrical connections
on the burner should match the voltage of the electric power supply line.
4) Fuel pipelines shouldbemade according to ourdiagram.
5) The nozzle(s) fitted on the burner should be suitable for the boiler capacity; replace them with others if
necessary.
In no case should the quantity of fuel delivered exceed the maximum amount required by the boiler and the
maximumamountpermitted for the boiler.
Rememberthat the combustionhead has beendesigned for nozzleswith a 45°spray angle.
Onlyinspecialcasescannozzleswithadifferent sprayangle be fitted; in these cases, however,makesurethat
the nozzle with a different spray angle will not cause problems (flame separation, disk or combustion head
fouling,violentignition, etc.).
6) When removing the protective plastic cap from the nozzle seat be careful because if the sealing surface is
indented (a slight scoring would be enough) it will cause fuel dripping.
7) Before connecting theflexible pipes, remove the plasticprotective caps from thepumpfittings.
FASTENING THE BURNER TO THE BOILER
The burner must be applied to the boiler’s iron plate, where the stud bolts given as standard accessories have already
been fitted in accordance with the plate drilling.
Itisadvisable to electrically weldthestud bolts to the internalpartof the plate to avoidextractingthem together with the
unit’s locking nuts, should the burner be disassembled.
Theinsulatingflange must be placed betweentheburner and the boiler plate.
Therelativenutsandwashersrequiredfor connecting the burner to the boiler have been suppliedasstandardaccesso-
ries. Theunitisequippedwithacylindricalcombustionhead; itisadvisabletofastentheboiler’siron plate first and then
theburner. When the boiler door is not fitted with heat insulation,itisnecessarytoinsertaninsulatingprotectionatleast
10mm.thickbetweentheplateandthe boiler. Theboilerplateshouldbeaccording to our drawing and have a minimum
thicknessof 10 mm. inorder to avoid possibledeformation.
FUEL PIPELINE (LIGHT OIL)
Thefollowingdescriptioncoversthe basic requirements to ensure efficient operations.
The unit is equipped with a self-suction pump capable of sucking oil directly from the cistern also for the first fill-up.
This statement is only valid if the required conditions exist (refer to the table of distances and differences in levels).
Toensureefficientoperations,it is preferable to makesuction and return pipes withweldedfittings and to avoidtheuse
ofthreaded connections which oftencauseair infiltration’s and disturbpump operations and consequentlythoseof the
burner. Where a removable fitting is required, use the welded flange method with a fuel resistant gasket inserted to
ensure a perfect sealing. For systems requiring pipes with a relatively small diameter, we recommend the use of
copper pipes. For unavoidable connections we recommend the use of biconic fittings.
Theattached tables show diagrams ofthe different types of systemsdepending on the positionofthe tank with respect
totheburner. The suction pipe should run up-slope towards the burner to avoid the possibleformationofgasbubbles.
Where more than one boiler is installed in one boiler room, it is essential that each burner has its own suction pipe.
Only return pipes can lead to a single manifold pipe with an adequate cross section leading to the cistern.
Never connect the return pipe directly to the suction pipe.
Itisadvisabletoproperlyinsulatethesuctionand return pipes to prevent cooling which would effecttheunit’s efficiency.
Pipe diameters (to be strictly complied with) are listed in the following tables.
Themaximum amount of vacuum that the pump canwithstand when operating regularly and silently is 35cm. of Hg; if
thislimit is exceeded,normal pump operationscan no longer be guaranteed.
Maximum suction and return pressure = 1 bar.

7
GRAVITY SUPPLY SYSTEM
1 Tank
2 Feeding pipe
3 Wire-net filter
4 Pump
5 Degasifier
7 Return pipe
8 Automatic fuel interception
device at burner shut off
9 Non-return valve
DROP-TYPE SYSTEM WITH SUPPLY FROM THE TANK TOP
1 Tank
3 Wire-net filter
4 Pump
6 Suction pipe
7 Return pipe
8 Automatic fuel interception
device at burner shut off
9 One-way valve
10 Bottom valve
SUCTION - TYPE FEEDING SYSTEM
1 Tank
3 Wire-net filter
4 Pump
6 Suction pipe
7 Return pipe
10 Bottom valve
N.B. For any missing devices in the piping,
follow existing regulations.
HTotal meters
meters meters
Øi. 16 mm. Øi. 18 mm.
0,5 21 34
11829
1,5 15 24
2 11,5 19
2,5 8,5 14
3 5,5 9
3,5 - 3,5
H = Difference in level between level in the tank and the pump axis.
L = Maximum length of suction pipe including the vertical lift.
For each bend or valve deduct 0,25 m.
P = 3,5 m. (max.)
PIPES FOR LIGHT OIL BURNER
MODEL BT 250 DSG
HTotal meters
meters meters
Øi. 16 mm. Øi. 18 mm.
13040
1,5 35 45
23545
2,5 40 50
34050
HTotal meters
meters meters
Øi. 16 mm. Øi. 18 mm.
13040
1,5 35 45
23545
2,5 40 50
34050
6 Suction pipe

8
PIPES FOR LIGHT OIL BURNER
MODEL BT 300 - 350 DSG
GRAVITY SUPPLY SYSTEM
1 Tank
2 Feeding pipe
3 Wire-net filter
4 Pump
5 Degasifier
6 Suction pipe
7 Return pipe
8 Automatic fuel interception
device at burner shut off
9 Non-return valve
HTotal meters
meters meters
Øi. = 3/4”Øi. 20 mm.
14040
1,5 45 45
24545
2,5 50 50
35050
HTotal meters
meters meters
Øi. = 3/4”Øi. 20 mm.
14040
1,5 45 45
24545
2,5 50 50
35050
DROP-TYPE SYSTEM WITH SUPPLY FROM THE TANK TOP
1 Tank
3 Wire-net filter
4 Pump
6 Suction pipe
7 Return pipe
8 Automatic fuel interception
device at burner shut off
9 One-way valve
10 Bottom valve
P = 3,5 m. (max.)
SUCTION - TYPE FEEDING SYSTEM
1 Tank
3 Wire-net filter
4 Pump
6 Suction pipe
7 Return pipe
10 Bottom valve
HTotal meters
meters meters
Øi. = 3/4”Øi. 20 mm.
0,5 34 34
12929
1,5 24 24
21919
2,5 14 14
399
3,5 3,5 3,5
N.B. For any missing devices in the piping,
follow existing regulations.
H = Difference in level between level in the tank and the pump axis.
L = Maximum length of suction pipe including the vertical lift.
For each bend or valve deduct 0,25 m.

9
ANCILLARY PUMP (see BT 8666/2)
In some cases (excessive distance or difference in level) it is necessary to install a “loop-type”supply system with an
ancillary pump, which dispenses with the connection of the burner pump directly to the tank.
In this case the ancillary pump can be put into operation when the burner is started up and cut-off when the latter
stops.
The electric wiring of the ancillary pump is made by connecting the coil (220 V) which controls the pump remote
controlswitch to terminals “N”(equipment terminal board)and“L1”(downstream the motor remotecontrolswitch).
It is important to comply strictly with the previsions set forth here below:
- The ancillary pump should be installed as near as possible to the fuel to be sucked.
- Its head should meet the requirements of subject system.
- We recommend a delivery rate equal to at least that of the burner pump.
- Connection pipes should be sized to cope with the delivery rate of the ancillary pump.
- Always avoid to electrically connect the ancillary pump directly to the remote control switch of the burner motor.
DESCRIPTION OF OPERATIONS (see diagram)
Byclosingtheswitchontheburner,andifthethermostats(controlandsafety)allowit,currentflowtothecontrolboxand
activatethemotorand the ignition transformer.
Themotorwillstartupthe fan which will carry out a pre-ventilationwithairfromthecombustionchamber and simultane-
ously the pump which will drive oil through the pipes and expel any gas bubbles through the return pipe.
Duringthepre-ventilation phase the combustion air shutterisactivatedby its motor and opens inthe2ndflame position
(pre-ventilation with air open). Subsequently, the air shutter returns to the 1st flame position for ignition.
This“pre-washing”caseswhenelectrovalveno.1closes(openintherestposition)andthisinterruptsthefreedischarge
of oil towards the cistern. When electrovalve no. 1 closes, an increase in pressure in the delivery pipes follows.
Whenthe light oil pressure reaches7 bar,themechanical valve which canbefound in the atomizerunitopens allowing
oil to reach the 1st flame nozzle and come out of it into the combustion chamber finely atomized. The pressure
stabilises at about 10 bar because the 1st flame pressure regulator has been set at this value. As soon as atomized
oilcomesoutofthenozzle, it is ignited by the spark betweenelectrodeswhichhasbeenpresentsince the motor started
up. If the flame appears regularly, the programmer passes over the “shut down”position and inserts the motor which
activates the combustion air shutter and puts it in the 2nd flame position.
While this is happening, an adjustable cam activated by the same motor, closes the electrical contact which takes
voltage to electrovalve no. 2 which intercepts the flow of oil through the 1st flame pressure regulator. The 1st flame
pressure regulator is excluded in this way and the pressure increase until it reaches the value at which the pressure
regulator incorporated in the pump has been set (16 bar). The 16 bar pressure also acts on the mechanical valve
which,uptoapressurevalueof13bar, prevents the fuel from flowing to the second nozzle. Thisvalveisopenedinthis
waybythe pressure, and thesecondnozzle also starts operating. The 16bar, pressurenowacts on the two nozzles.
When the unit is working at a pressure of 16 bar, it is operating at maximum capacity.
Note: From the above outline it is evident that the choice of nozzles with respect to the desired total
burneroutput(2nozzlesin operation) should be madetakingintoaccountthedeliveryratescorrespondingtothe
lightoil16bar, operating pressure. It should benoted,however, that when the burner operates onlywiththe1st
flame,the delivery rate of thefirst nozzle corresponds to thevalues given in the10bar,pressuretable because
thepressureregulatorforthe1stflameissetatthisvalue. Obviously, it is possible to changetheratiobetween
the1st and 2nd flame withinawide range by replacingthenozzles. However,it should be rememberedthatfor
efficientoperations the fuel supply for the 1stflame should not beless than theminimum burner output (shown
onthe name-plate) for eachspecificmodel. A smaller output couldmake ignition difficult, andcombustion with
the1stflame only might not be satisfactory. Fromthemomentthe flame appears in thecombustionchamber,
theburneriscontrolled and monitored by the photoresistant cellandthermostats,theprogrammer continues its
cycle and disconnects the ignition transformer; consequently the burner is “on”and operating at full rating. If
theprogrammeisinterrupted (voltage failure, manualoperation,thermostattripping,etc.)duringthepre-washing
phase, the programmer will return to its original position and automatically repeat the whole burner start-up
cycle. When the temperature or pressure reaches the value preset on the thermostat or operating pressure
switch, its tripping will cause the burner to stop. The burner will resume its operation automatically when the
temperature or pressure value falls by the required amount. In case of flame failure during operations, the
photoresistant cell will trip immediately (1 second) and stop current to the relay which then opens and conse-
quentlydisconnects the washing electrovalve. Thisinturn rapidly discharges theexisting pressure and thejet
ofatomizedoiliscutoffbytheautomaticclosureof the atomizing unit valve as soon as the pressure drops below
7bar. In this case,thestart-upcycleisrepeatedautomaticallyandiftheflameignitesnormallyagain,theburner
will also resume its normal operations. If there is a poor flame or no flame at all, the unit goes automatically to
“shut down”.

10
CONTROL BOX SPECIFICATIONS
Controlbox
&relatire
programmer
LAL1.25
cyclic relay
FIRST FILLING UP OF PIPELINES
Afterhavingchecked that the protectiveplasticcaps inside the pump fittingshavebeen removed, proceed as follows:
1) Put the switchontheburnerin the “0”position. This operation prevents the automatic connection oftheburner.
2) If the burner is there-phase, make sure that the motor rotates in an anti-clockwise direction, by
observingtheburnerfromthepumpside.
Thiscan be controlled bylooking at thesense of rotation ofthe fan through thespy hole situatedon the back of
the scroll. To start up the motor, close manually the relay (by pressing on the mobile part) for a few seconds
and watch the sense of rotation of the fan.
It is necessary to change the sense of rotation, invert two phases of the line input terminals (L1 - L2 - L3).
Note: Wait until the fan is moving very slowly before trying to ascertain the sense of direction;
it is possible to misinterpret it.
3) Detach, if already attached, the flexible pipes from the suction and return pipelines.
4) Emerge the end of the flexible suction pipe in a tin containing either lubrification oil or fuel oil (do not use low
viscosity products such as light oil, crude oil, petrol, kerosene, etc.).
5) Now press on the mobile part of the motor’s relay in order to start up the motor and thereby the pump.
Wait until the pump has sucked in an amount of lubrificant equal to 1 or 2 glassfuls.
Thisoperationwill prevent the pump fromoperatingdryand will increase the suction power.
Note: Pumps operating at 2800 RPM must not work dry otherwise they will jam (seizure) within a short time.
6) Now attach the flexible pipe to the suction pipeline and open any gate valves or any other type
offuelcut-off device fitted on thispipeline.
7) Press again on the mobile part of the motor’s relay to start the pump which will suck fuel from the cistern.
When fuel is seen coming out of the return pipe (not yet connected), stop.
Note: If the pipeline is long, it may be necessary to bleed air from the air bleed plug.
If the pump is not fitted with one, remove the plug from the manometer connection point and bleed air
throughit.
8) Connect the flexiblereturn pipe to the pipelineand open any gatevalvesfitted on this pipeline.
The burner is now ready to start up.
Safety time
in seconds
5
Pre-ventilation
&pre-washing
time in seconds
22,5
Post-ignition
time in seconds
15
Timebetween
1stand 2nd flame
in seconds
7,5

11
STARTING UP AND REGULATION (see Bt 8653/1 and BT 8608/3)
Before starting up, make sure that:
a) Connections to the supply line, to thermostats or pressure switches, have been made exactly according to the
electrical diagram of the control box.
b) There is fuel oil in the cistern and water in the boiler.
c) Allthegatevalvesfittedonthefueloilsuctionand return pipelines are open as are any other fuel cut-off devices.
d) Thedischarge of combustion products can take place freely (boiler and chimneylock-gates should be open).
d) The nozzles applied to the burner match the boiler’s capacity but, if necessary, substitute them with others.
Undernocircumstancesshouldthe quantity of fueldeliveredexceedthemaximumamountrequiredbythe boiler
andthemaximum amount permitted for theburner.
Remember that the combustion head is designed for nozzles with a 45°spray angle.
Note: For good ignition and good combustion with the 1st flame only, fuel delivery must not
be considerably lower than the minimum output (indicated on the nameplate) of the specific burner
employed.
Note: The burner is equipped with a switch to change from the 1st to the 2nd stage.
For ignition proceed as follows:
1) Remove the thermostatconnection, if there isone,in order to avoidinsertion of the 2ndflame.
2) Openslightly the air regulator (seeBT8653/1) to allow a flowofair presumed adequate for burneroperations
with the 1st flame and block it in this position. Set the air regulation device on the combustion head in an
intermediateposition(seeChapter“AirRegulationontheCombustion Head”).
3) Connect the main switch and the control box switch.
4) The control box will start functioning and will connect the burner component devices according to its
pre-established programme. The unit starts up in this way, as described in the Chapter “Description of Opera-
tions”.
5) When the burnerisoperating with the 1stflame,proceed with regulating theamountof air required forgood
combustion(seeBT 8653/1). It is preferable that thequantityofair for the 1st flameisslightlyreduced, in order
to ensure soft ignition even in the most critical conditions.
6) Afterregulating air for the 1stflamestopthe burner,bydisconnectingthe main switch, connect the terminalsof
the terminal board for the 2nd flame thermostat and settle the 1st and 2nd stage switch in 2nd stage position.
7) Regulate the combustionairfor the 2nd flame (seeBT8653/1).
8) Now turn on the unit again. It should start up and pass automatically to the 2nd flame according to its
pre-establishedprogramme.
9) With the burneroperatingat 2nd flame, proceedwithregulating (see BT 8653/1) theamountof air required to
guaranteegoodcombustion.
A control of the combustion should be made with the appropriate instruments.
Iftheappropriate instruments are notavailable,judgement can be based onthecolour of the flame.
We advise regulating in such a way as to obtain a soft flame, bright orange in colour.
Avoid a red flame with smoke presence or a white flame with an exaggerated excess of air.
Theair regulator should be insuch a position that thepercentage of Carbon Dioxide(CO2) in the smoke should
varyfroma minimumof10%toa maximumof13%,andthe smokenumbershouldnotexceed2 oftheBacharach
Scale. Itshouldberememberedthatit is preferable to limit the quantity ofairnecessaryforthe1stflame to the
minimum indispensable in order to ensure ignition even in the most critical conditions.

12
CHECKS
After starting up the burner, check the safety devices (photoresistant cell, shut down system, thermostats).
1) The photoresistant cellisthe flame control deviceand,if the flame should beextinguishedduring operations, it
must be capable of intervening (this check should be made at least one minute after start up).
2) The burner shouldbecapableofblockingitself(shut down), and remaining so, when theflamedoesnotappear
regularly during the starting phase within the time limit pre-set on the control box. The shut down causes the
immediate arrest of the motor and therefore the burner and the red warning light is turned on. To check the
efficiency of the photoresistant cell and of the shut down system, proceed as follows:
a) Start up theburner.
b) About one minute after ignition, extract the photoresistant cell by pulling it out of its seat and simulate
flame failure (using a rag to close the window in the photoresistant cell support). The burner flame
shouldbeextinguished.
c) Keep the photoresistant cell in the dark and the burner will start up again but, as the
photoresistant cell does not see the light, the burner will go to shut down within the time pre-set by the
programmer.
Thecontrol box can onlybeunblocked by pressing manuallyonthe appropriate push-button.
Check the shut down efficiency at least twice.
3) To check thermostat efficiency, run the burner until the water in the tank reaches a
temperature of at least 50 °C. Then turn the thermostat control knob, to lower the water temperature, until an
opening click is heard which causes the burner to stop.
The thermostat should trip within a maximum tolerance of 5 to 10 °C in respect to the control thermostat (boiler
thermostat); if not, change the setting on the thermostat scale to match that of the thermometer.
AIR REGULATION ON THE COMBUSTION HEAD (see BT 8608/3)
Thecombustionhead is fitted with aregulatingdevicewhich closes (by moving forwards)andopens
(bymoving backwards) the airpassagebetween the disk andthehead.
By closing the passage it is possible to achieve high pressure upstream the disk for low outputs as well. High velocity
and air turbulence ensure a better penetration in the fuel, an optimum mixture and good flame stability. It might be
necessarytohavehigh air pressure upstream the diskinordertoavoid flame pulsation’s and it isconsideredpractically
indispensablewhentheburner is operating with a pressurizedfurnaceand/orhigh thermal load.
Itisevidentfromtheabove,that the device which closes the air on the combustion headshouldbeputinsuchaposition
as to always obtain a decidedly high air pressure value behind the disk.
Itisadvisabletoregulateinsuchawayastoachieveaclosingoftheaironthehead; thiswillnecessitateaconsiderable
opening of the air shutter which regulates the flow to the burner’s fan suction. Obviously these adjustments should be
carriedoutwhen the burner is operating atmaximumdeliverydesired. In practice, start regulating by puttingthedevice
whichclosesthe air on thecombustionhead in an intermediate position,startup the burner and maketrialadjustments
aspreviouslydescribed.
Whenmaximumdeliveryrequiredhasbeenreached,proceedwithcorrectingthepositionofthedevicewhichclosesthe
aironthecombustionhead; moveit backwards or forwards in such awayastoobtainanairflowsuitableforthe delivery,
with the air regulation shutter in suction considerably open.
When reducing the air passage on the combustion head, avoid closing it completely.
Proceed with perfect centering with respect to the disk. It must be pointed out that, if perfect centering with respect to
the disk is not obtained, bad combustion and excessive heating of the head could occur which would result in its rapid
deterioration.
A control can be carried out by looking through the spy hole situated at the back of the burner.
Note: Checkthatignition occurs regularly,becausewhenthe device has been movedforwards,it
could occur that the air velocity in exit is so high as to render ignition difficult.
If this happens, move it backwards, gradually, until it reaches the correct position and ignition occurs regularly.
Thispositionshouldbedefinitive.
SETTING THE DISTANCE BETWEEN THE DISK AND THE NOZZLE
Burners are fitted with a device which permits to change the distance between the disk and the nozzle.
Thedistancebetweenthediskandthenozzleissetinthefactory,anditshouldbereducedonlyiftheatomizedfuelcone
coming out of the nozzle wets the disk and fouls it up.

13
USE OF THE BURNER
The burner is a fully automatic burner; it is activated by closing the isolating switch and the control box switch; Burner
operationis controlled by controlandmonitoring devices as statedinthe chapter “Description ofoperation”.
The“lock-out”positionisasafetypositionautomaticallytakenup by the burner when a burner component ortheelectric
equipmentis inefficient; before connecting the “released”burneragain,it is good practice tomake sure that no defects
existinheating plant. The burner can remaininalock-out”positionwithout any time limit. Toresettheburner,pressthe
appropriatepush-button.“Lock-out”canbecausedalsobytransientflaws (a little water in the fuel,airinthepipes, etc.);
if reset, the burnerwill start up normally. When “lock-out”occurrepeatedlydonottry to start, firstcheckif there is fuelin
the tank and then call the local service to repair the defect.
MAINTENANCE
Theburnerrequiresno special maintenance, but it is goodpracticetoperformthe following operation at least attheend
ofheatingseason:
1) Removeandthroughly wash with solvents(petrol,trichoethylene, oil) the filters, thenozzles,theturbolatordisk and
the ignition electrodes. When cleaning the nozzle, avoid using metal tools (use wood or plastic).
2) Clean the photoresistant-cell.
3) Have the boiler cleaned and also the chimney if necessary.
Remarks: Thenozzleor nozzles should be replaced atleasteverytwo heating season. It maybenecessaryto perform
suchoperationmorefrequently.
DESCRIPTION OF HOW THE TWO FLAME BURNERS OPERATE
The two stage burner always ignites with a limited amount of air and fuel (1st flame) and, subsequently, after a few
seconds, it will switch to full air and fuel operation (2nd flame). The ignition of the 2nd flame is subject to the consent of
the control box and control device (pressure switch or thermostat). When the burner works at full rating it will remain in
thispositionuntil itreachesthepressureortemperature limitpre-setonthecontrol device(pressureswitchorthermostat).
Thecontroldevicetrips,disconnectingthe2nd flame (fuel and air), when the limit towhichithasbeenpre-setisreached.
Then the burner works only with the 1st flame. Normally the 1st flame alone is not sufficient to keep the temperature or
the pressure at the desired limit, and so it will decrease until it reaches the limit to which the control device of the 2nd
flame(pressureswitch or thermostat) reactivates the totalfuelandair delivery rate. If the burner operatesonlywiththe
1stflamewill stop completely whenthepressure or the temperature reachesthetripping point set on thecontroldevice
(pressureswitchorthermostat). Theburner starts up automatically again when thepressureortemperaturefallsbelow
the limit to which the pressure switch or thermostat has been pre-set.
Remarks: When a two stage burner is installed on a boiler for heating purposes, it should be connected so that it will
normally operate with both flames and stop completely, without switching to the 1st flame, when the pre-set
temperatureis reached. If the burneroperates(sometimes for long periodsof time) with oneflameonly and the
boiler is insufficiently loaded, consequently combustion products come out at a very low temperature (less than
180°C)andfoul up the chimney outlet withsoot.Whenthe boiler is insufficiently loaded, acidcondenseandsoot
arelikelytobuildupin the boiler resulting in fast clog-up and corrosion ofthesame.Forthis specific operation, do
notfitthethermostatforthe2ndflameandmakeadirectconnection(bridge)betweentherespectiveterminalson
theelectricequipment. This uses only theburnercapacity to ignite at areducedoutput which ensures a smooth
lightingup,anessentialconditionforboilershavinganover pressure combustion chamber,yetveryusefulalsoin
normal boilers (vacuum combustion chamber). The burner control is subject to the usual operating and safety
thermostats.

14
DIAGRAM OF PIPES OF FEED SYSTEM FOR
LIGHT OIL BURNERS OR HEAVY OIL BURNERS WITH
MAXIMUMNOMINAL VISCOSITY (5 °E AT 50 °C)
BT8666/2
rev.
SCHEMA IDRAULICO DI PRINCIPIO ALIMENTAZIONE
PER PIÙ’ BRUCIATORI DI GASOLIO OPPURE OLIO
COMBUSTIBILE CON VISCOSITÀ’ NOMINALE MASSIMA
(5 °E A 50 °C)
ESQUEMA HIDRÁULICO PARA LA ALIMENTACIÓN
DE MÁS DE UN QUEMADOR DE GASÓLEO O DE PETRÓLEO
PESADO CON UNA VISCOSIDAD NOMINAL MÁXIMA DE 5°E 50°C
HYDRAULIC DIAGRAM N°BT 8502
I serbatoi di recupero olio (diametro ~150 - altezza ~400)
devono essere installati il piùvicino possibile al bruciatore
ad una quota superiore di almeno 0,5 m. rispetto alla pompa
dello stesso.
The light oil recovery tanks (diameter ~150 - height ~400)
should be installed as near as possible to the burner and
should be about 0,5 m. higher with respect to the burner’s pump.
Los depósitos de recuperación de gasóleo
(diámetro ~150 altura ~400) tienen que instalarse lo más
cerca posible del quemador a una cota superior de
aproximadamente 0,5 m. con respecto a la bomba del mismo.
Tubi flessibili
Flexible pipes
Tubos flexibles
Tubi flessibili
Flexible pipes
Tubos flexibles
Pompabruciatore
Burnerpump
Bombaquemador
Pompabruciatore
Burnerpump
Bombaquemador Pompe di circolazione
Circulating pumps
Bombas de circulación
1 - Cisterna principale / Main cistern / Tanque principal
2 - Filtro / Filter / Filtro
3 - Recupero combustibile e degasatore / Fuel recobery and degasifier /
Recuperación combustible y desgasificador
4 - Valvola unidirezionale / One-way valve / Válvula unidireccional
5 - Filtro / Filter / Filtro
6 - By-pass (normalmente chiuso) / By-pass (usually closed) /
By-pass (normalmente cerrado)
1 - Foot valve
2 - Eventual air regulation motor
3 - 2nd flame nozzles
4 - 1st flame nozzle
5 - Valve normally open
6 - Pump (16 bar)
7 - Valve normally open
8 - Hydraulic jack for air shutter control
9 - 1st flame pressure regulator (10 bar)
10 - Valve 7 bar
11 - Valve 13 bar
12 - Suction
13 - Return

15
GENERAL DIAGRAM AIR REGULATION N°8608/3

16
INDICATIVE DIAGRAM SHIWING THE NOZZLE POSITION
ELECTRODES - FLAME DISK AND REGULATION OF THE “D”
HEAD-DISK DISTANCE IN HINGED LIGHT OIL TWO STAGES
“DSG”BURNERS
N°0002930070

17
N°BT 8605/1
PARTICOLARI BRUCIATORI
BURNERS DETAILS
1 - Vite bloccaggio volantino
Handwhell clamp screw
2 - Volantino di comando
serranda aria.
Regolazione
aria per la 1°fiamma.
Air damper control
handweel.
1st flame air regula-
tion.
3 - Dado di bloccaggio
Lock nut
4 - Vite regolazione aria
per la 2°fiamma
Air control screw for
2nd flame
5 - Tappo di accesso alla vite di regolazione
pressione combustibile per la 1°fiamma.
Plug for access to screw regulating fuel
pressure for the 1st flame

18
POMPA BALTUR MODELLO BT....
BALTUR PUMP MODEL BT....
BOMBA BALTUR MODELO BT.... N°0002900580

19
Ugello
Nozzle
Boquilla
Gicleur
Düse
Ugello
Nozzle
Boquilla
Gicleur
Düse
G.P.H. 7 8 9 10111213141516171819 20 21 G.P.H.
0,40 1,27 1,36 1,44 1,52 1,59 1,67 1,73 1,80 1,86 1,92 1,98 2,04 2,10 2,15 2,20 0,40
0,50 1,59 1,70 1,80 1,90 1,99 2,08 2,17 2,25 2,33 2,40 2,48 2,55 2,62 2,69 2,75 0,50
0,60 1,91 2,04 2,16 2,28 2,39 2,50 2,60 2,70 2,79 2,88 2,97 3,06 3,14 3,22 3,30 0,60
0,65 2,07 2,21 2,34 2,47 2,59 2,71 2,82 2,92 3,03 3,12 3,22 3,31 3,41 3,49 3,58 0,65
0,75 2,38 2,55 2,70 2,85 2,99 3,12 3,25 3,37 3,49 3,61 3,72 3,82 3,93 4,03 4,13 0,75
0,85 2,70 2,89 3,06 3,23 3,39 3,54 3,68 3,82 3,96 4,09 4,21 4,33 4,45 4,57 4,68 0,85
1,00 3,18 3,40 3,61 3,80 3,99 4,16 4,33 4,50 4,65 4,81 4,96 5,10 5,24 5,37 5,51 1,00
1,10 3,50 3,74 3,97 4,18 4,38 4,58 4,77 4,95 5,12 5,29 5,45 5,61 5,76 5,91 6,06 1,10
1,20 3,82 4,08 4,33 4,56 4,78 5,00 5,20 5,40 5,59 5,77 5,95 6,12 6,29 6,45 6,61 1,20
1,25 3,97 4,25 4,50 4,75 5,00 5,20 5,40 5,60 5,80 6,00 6,20 6,35 6,55 6,70 6,85 1,25
1,35 4,29 4,59 4,87 5,13 5,38 5,62 5,85 6,07 6,28 6,49 6,69 6,88 7,07 7,26 7,44 1,35
1,50 4,77 5,10 5,41 5,70 5,90 6,24 6,50 6,75 6,98 7,21 7,43 7,65 7,86 8,06 8,26 1,50
1,65 5,25 5,61 5,95 6,27 6,58 6,87 7,15 7,42 7,68 7,93 8,18 8,41 8,64 8,87 9,09 1,65
1,75 5,56 5,95 6,31 6,65 6,98 7,29 7,58 7,87 8,15 8,41 8,67 8,92 9,17 9,41 9,64 1,75
2,00 6,30 6,80 7,21 7,60 7,97 8,33 8,67 8,99 9,31 9,61 9,91 10,20 10,48 10,75 11,01 2,00
2,25 7,15 7,65 8,15 8,55 8,97 9,37 9,75 10,12 10,47 10,85 11,15 11,47 11,79 12,09 12,39 2,25
2,50 7,95 8,50 9,01 9,50 9,97 10,41 10,83 11,24 11,64 12,02 12,39 12,75 13,10 13,44 13,77 2,50
3,00 9,54 10,20 10,82 11,40 11,96 12,49 13,00 13,49 13,96 14,02 14,87 15,30 15,72 16,12 16,52 3,00
3,50 11,13 11,90 12,62 13,30 13,95 14,57 15,17 15,74 16,29 16,83 17,34 17,85 18,34 18,81 19,28 3,50
4,00 12,72 13,60 14,42 15,20 15,94 16,65 17,33 17,99 18,62 19,23 19,82 20,40 20,95 21,50 22,03 4,00
4,50 14,31 15,30 16,22 17,10 17,94 18,73 19,50 20,24 20,95 21,63 22,30 22,95 23,57 24,19 24,78 4,50
5,00 15,90 17,00 18,03 19,00 19,93 20,82 21,67 22,48 23,27 24,04 24,78 25,49 26,19 26,87 27,54 5,00
5,50 17,49 18,70 19,83 20,90 21,92 22,90 23,83 24,73 25,60 26,44 27,25 28,04 28,81 29,56 30,29 5,50
6,00 19,00 20,40 21,63 22,80 23,92 24,98 26,00 26,98 27,93 28,84 29,73 30,59 31,43 32,25 33,04 6,00
6,50 20,67 22,10 23,44 23,70 25,91 27,06 28,17 29,23 30,26 31,25 32,21 33,14 34,05 34,94 35,80 6,50
7,00 22,26 23,79 25,24 26,60 27,90 29,14 30,33 31,48 32,58 33,65 34,69 35,69 36,67 37,62 38,55 7,00
7,50 23,85 25,49 27,04 28,50 29,90 31,22 32,50 33,73 34,91 36,05 37,16 38,24 39,29 40,31 41,31 7,50
8,30 26,39 28,21 29,93 31,54 33,08 34,55 35,97 37,32 38,63 39,90 41,13 42,32 43,48 44,61 45,71 8,30
9,50 30,21 32,29 34,25 36,10 37,87 39,55 41,17 42,72 44,22 45,67 47,07 48,44 49,77 51,06 52,32 9,50
10,50 33,39 35,69 37,86 40,06 41,73 43,74 45,41 47,20 48,90 50,50 52,00 53,50 55,00 56,40 57,80 10,50
12,00 38,20 40,80 43,30 45,60 47,80 50,00 52,00 54,00 55,90 57,70 59,50 61,20 62,90 64,50 66,10 12,00
13,80 43,90 46,90 49,80 52,40 55,00 57,50 59,80 62,10 64,20 66,30 68,40 70,40 72,30 74,30 76,00 13,80
15,30 48,60 52,00 55,20 58,10 61,00 63,70 66,30 68,80 71,10 73,60 75,80 78,00 80,20 82,20 84,30 15,30
17,50 55,60 59,50 63,10 66,50 69,80 72,90 75,80 78,70 81,50 84,10 86,70 89,20 91,70 94,10 96,40 17,50
19,50 62,00 66,30 70,30 74,10 77,70 81,20 84,50 87,70 90,80 93,70 96,60 99,40 102,20 104,80 107,40 19,50
21,50 68,40 73,10 77,50 81,70 85,70 89,50 93,20 96,70 100,10 103,40 106,50 109,60 112,60 115,60 118,40 21,50
24,00 76,30 81,60 86,50 91,20 95,70 99,90 104,00 107,90 111,70 115,40 118,90 122,40 125,70 129,00 132,20 24,00
28,00 89,00 95,20 101,00 106,40 111,60 116,60 121,30 125,90 130,30 134,60 138,70 142,80 146,70 150,50 154,20 28,00
30,00 95,40 102,00 108,20 114,00 119,60 124,90 130,00 134,90 139,60 144,20 148,70 153,00 157,20 161,20 165,20 30,00
G.P.H. G.P.H.
Pressione pompa /Pump pressure /Presión bomba / Pression de la pompe / DruckPumpe
bar
Portata all'uscita dell'ugello / Nozzle output flow-rate / Caudal a la salida de la boquilla /
Pression a la sortie du gicleur / Durchsatz bei Austritt aus der Düse
bar
1 mbar= 10 mmC.A.≅100 Pa
1 kW= 860 kcal
Densitàdel gasolio / light oil density / Densidad del gasóleo............................................= 0,820 / 0,830 PCI = 10150
Densitàdello special / Special heating oil density / Densidad del especial ......................= 0,900 PCI = 9920
Densitàdel domestico (3,5°E) / Domestic (3,5°E) heating oil density /..............................= 0,940 PCI = 9700
Densidad del doméstico (3,5°E)
Densitàdel denso (7,9°E) / Heavy oil density (7,9°E) / Densidad del denso (7,9°E) .........= 0,970 / 0,980 PCI = 9650
PCI = Potere Calorifico Inferiore / Minimum calorific value / Poder calorifico inferior
TABELLA PORTATA UGELLI PER GASOLIO
NOZZLE FLOW-RATE TABLE FOR LIGHT OIL
TABLA CAUDAL BOQUILLAS PARA GASÓLEO

20
8653-1
SQN 30.111 A3500
- PREVENTILAZIONE CON ARIA APERTA (POSIZIONE 2°FIAMMA) ARIA CHIUSA CON BRUCIATORE FERMO
- PREVENTILATION WITH AIR OPEN (2nd FLAME POSITION) AIR CLOSED WITH BURNER IN STOP POSITION
- PREBARRIDO CON AIRE ABIERTO (POSICION 2aLLAMA) AIRE CERRADO CON QUEMADOR PARADO
Permodificarelaregolazionedellecammessiagiscesuirispettivi anellidicolorerosso. Spingendoconforzasufficiente,
nelsenso voluto ognianello rosso puòruotare rispetto alla scala diriferimento. L'indice dell'anellorosso indica sulla
rispettivascala di riferimentol'angolo di rotazioneimpostato per ognicamma.
In order to modify the cams regulation it's necessary to intervene on the relative red rings. Pushing by sufficient
strength,in the sens one desires, each red ring can turn in respect to the reffering scale. The pointer of the red ring
indicates on the respective reffering scale the rotation angle set for each cam.
Paramodificar la regulaciónde las levas,manipule las correspondientesruedas rojas.
Empujeconfuerza en el sentido queUd.deseey la rueda se desplazarárespecto alaescala de referencia. El índice
dela rueda rojaindica el ángulode rotación establecido para cada leva enla correspondiente escalade referencia.
1- CAMMA inserzione valvola 2°fiamma (deve essere regolata in posizione intermedia tra la camma di 1°e quella di 2°
fiamma)
- 2nd Flame valve connection cam (must be adjusted in a position between the 1st flame and the 2nd flame cam)
- LEVA conexión válvula 2allama (es preciso regularla a una posición intermedia entre la leva de 1allama y la de 2a)
2- CAMMA regolazione aria 1°fiamma
- Air regulation cam 1°flame
- LEVA regulación aire 1a llama
3- CAMMA serranda aria chiusa con bruciatore fermo
- Close air shutter cam with burner in stop position
- LEVA clapeta aire cerrada con quemador parado
4- CAMMA regolazione aria 2°fiamma
- Air regulation cam 2nd flame
- LEVA regulación aire 2allama
2
341
Perno di esclusione accoppiamento motore-albero cammes.
Premendo si ottiene la disinserzione del collegamento
motore e albero.
Motor-cam shaft coupling cutting out pin.
The switching-off of the motor and shaft connection can be
obtained by pushing.
Perno de exclusión acoplamiento motor- árbol levas.
Si aprieta este perno se desconecta la unión motor y árbol.