baltur BT 75 DSNM-D User manual

en
BT 180 DSNM-/D
BT 250 DSNM-/D
BT 300 DSNM-/D
BT 350 DSNM-/D
2004/11
Cod. 0006080092
BT 75 DSNM-/D
BT 100 DSNM-/D
BT 120 DSNM-/D
- Instruction for burners model
Edition

2
Manufacturer’s declaration
We hereby declare that our gas, light oil, heavy oil, and combination (gas/light oil or gas/heavy oil)
burners are manufactured in conformance with current 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 not valid with regard to EC or UNI Standards for gas burners or the gas part of
duel-fuel burners (gas/light oil or gas/heavy oil) when such burners have been ordered in non-compliance
with the EC Standard or Italian UNI Standard because they are to be used for special purposes not provided
for in the above-mentioned standards.
L' Amministratore delegato
Dott. Riccardo Fava
· Read carefully the instructions before starting the burner and service it.
· The works on the burner and on the system have to be carried out only by competent people.
· The system electric feeding must be disconnected before starting working on it.
· If the woeks are not carried out correctly it is possible to cause dangerous accidents.
INDEX PAGE
- Technical data ........................................................................................................................................“ 3
- Fuel feed plant .......................................................................................................................................“ 8
- Application of the burner to boiler ..........................................................................................................“ 10
- Electric connections - Description of operation......................................................................................“ 11
- Ignition and regulation............................................................................................................................“ 16
- Combustion head setting - Setting the distance between disk and nozzle.............................................“ 17
- How to use the burner - Maintenance....................................................................................................“ 18
- Two - flame burner operation .................................................................................................................“ 19
- Variants for burners provided qith steam pre-heater to heat the fuel oil ................................................“ 20
- Air regulation servomotor SQN 30... -Air servomotor Conectron LKS 160... .......................................“ 23
- Oil burner control devices ......................................................................................................................“ 24
- Instruction for adjusting the electronic timer relay mod. “YDAV”............................................................“ 32
- Electric wiring diagram...........................................................................................................................“ 33

3
N° 0002370013
n° 1 di 4
CARATTERISTICHETECNICHE/
TECHNICALDATA/
CARACTERISTICASTECNICAS
CARATTERISTICHE TECNICHE MODELLI / MODELS / MODELO
TECHNICAL DATA BT 75 BT 100 BT 120 BT 180
DSNM -D DSNM -D DSNM -D DSNM -D
PORTATA MIN Kg/h 40 50 60 65
FL
O
W RATE
Caudal MAX Kg/h 75 100 130 180
POTENZATERMICA MIN kW 446 558 669 725
THERMIC CAPACITY
Potencia térmica MAX kW 837 1116 1451 2009
VISCOSITA’ COMBUSTIBILE OLIO DENSO 20°E 20°E 50°E 50°E
FUEL VISCOSITY
Viscosidad combustible Petróleo
pesado a/at 50°C a/at 50°C a/at 50°C a/at 50°C
MOTORE VENTOLA kW 1,1 kW 1,5 kW 2,2 kW 3 kW
FAN MOTOR
Motor impulsor 2800 r.p.m. 2810 r.p.m. 2825 r.p.m. 2870 r.p.m.
MOTORE POMPA kW 0,55 kW 0,55 kW 1,1 kW 1,1 kW
PUMP MOTOR / motor bomba 1420 r.p.m. 1420 r.p.m. 1410 r.p.m. 1410 r.p.m.
TRASFORMATORE / VOLT 10 kV-30mA 12 kV-30mA 12 kV-30mA 14 kV-30mA
TRANSFORMER /Transformador voltios
TENSIONE TRIFASE 220/380V 220/380V 220/380V 220/380V
VOLTAGE
Tensión THREE PHASE
trifásica 50 Hz 50 Hz 50 Hz 50 Hz
RESISTENZAPRERISCALDATORE kW 10,5 kW 10,5 kW 10,5 kW 15 kW
PRE-HEATER RESISTANCES
resistencia precalentador
CC SSO CO O / S
ACCESSORIES /
Accesorios que se suministranconel
FLANGIAATTACCO BRUCIATORE
BURNER FIXING FLANGE
Brida de unión quemador N° 2 N° 2 N° 2 N° 2
COLLARE ELASTICO / ELASTIC COLLAR
Collar (acoplamiento) elástico N° 1 N° 1 N° 1 N° 1
N° 1 N° 1 N° 1 N° 1
PRIGIONIERI /STUD BOLTS /Pernos sin cabeza N° 4 - M12 N° 4 - M16 N° 4 - M16 N° 4 - M16
N° 8 - M12 N° 8 - M16 N° 8 - M16 N° 8 - M16
ROSETTE PIANE / FLAT WASHERS
Arandelas planas N° 8 - M12 N° 8 - M16 N° 8 - M16 N° 8 - M16
TUBI FLESSIBILI / FLEXIBLE PIPES N°2 N°2 N°2 N°2
Latiguillos 1"1/4 x 1"1/4 1"1/4 x 1"1/4 1"1/4 x 1"1/4 1"1/4 x 1"1/4
NIPPLI / NIPPLES / Contrarroscas N°1 - 1"1/4x2" N°1 - 1"1/4x2" N°1 - 1"1/4x2" N°1 - 1"1/4x2"
FILTRO / FILTER / Filtro 2" 2" 2" 2"
CARACTERISTICAS TECNICAS
GUARNIZIONE ISOLANTE /ISOLATING GASKET
Junta aislante
DADI ESAGONALI - HEXAGONAL NUTS
Tuercas hexagonales

4
CARATTERISTICHETECNICHE/
TECHNICALDATA/
CARACTERISTICASTECNICAS
N° 0002370013
n° 2 di 4
MOD.
TECHNICAL DATA BT 250 BT 300 BT 350
DSNM -D DSNM -D DSNM -D
PORTATA MIN Kg/h 84 110 115
FL
O
W RATE
Caudal MAX Kg/h 284 310 350
POTENZATERMICA MIN kW 1004 1227 1284
THERMIC CAPACITY
Potencia térmica MAX kW 3127 3627 3907
VISCOSITA’ COMBUSTIBILE OLIO DENSO 50°E 50°E 50°E
FUEL VISCOSITY
Viscosidad combustible HEAVY OIL
Petróleo pesado a/at 50°C a/at 50°C a/at 50°C
MOTORE VENTOLA kW 7,5 kW 7,5 kW 9 kW
FAN MOTOR
Motor impulsor 2870 r.p.m. 2870 r.p.m. 2900 r.p.m.
MOTORE POMPA kW 1,1 kW 2,2 kW 2,2 kW
PUMP MOTOR
motorbomba 1410 r.p.m. 1430 r.p.m. 1430 r.p.m.
TRASFORMATORE VOLT 14 kV-30mA 14 kV-30mA 14 kV-30mA
TRANSFORMER
Transformador voltios
TENSIONE TRIFASE 220/380V 220/380V 220/380V
VOLTAGE
Tensión THREE PHAS
E
trifásica 50 Hz 50 Hz 50 Hz
RESISTENZAPRERISCALDATORE kW 18 kW 25,5 kW 28,5 kW
PRE-HEATER RESISTANCES
resistencia precalentador
FLANGIA ATTACCO BRUCIATORE
BURNER FIXINGFLANGE
Brida de unión quemador N°2N°1N°1
COLLARE ELASTICO/ELASTIC COLLAR
Collar (acoplamiento) elástico N° 1 - - - -
N° 1 N°2 N° 2
PRIGIONIERI / STUD BOLTS / Pernos sin cabeza N° 4 - M16 N° 3 - M20 N° 3 - M20
N° 8 - M16 N° 3 - M20 N° 3 - M20
ROSETTE PIANE / FLAT WASHERS
Arandelas planas N° 8 - M16 N° 3 - M20 N° 3 - M20
TUBI FLESSIBILI / FLEXIBLE PIPES N°2 N°2 N°2
Latiguillos 1"1/4 x 1"1/4 1"1/4 x 1"1/4 1"1/4 x 1"1/4
NIPPLI / NIPPLES / Contrarroscas N°1 - 1"1/4x2" N°1 - 1"1/4x2" N°1 - 1"1/4x2"
FILTRO/FILTER /Filtro 2" 2" 2"
DADI ESAGONALI - HEXAGONAL NUTS
Tuercas hexagonales
CARATTERISTICHE TECNICHE
ACCESSORI A CORREDO / STANDARD ACCESSORIES /
Accesorios que se suministranconel quemador
CARACTERISTICAS TECNICAS
GUARNIZIONE ISOLANTE / ISOLATING GASKET
Junta aislante

5
N° 0002370013
n° 3 di 4
1) FOTORESISTENZA
2) TRASFORMATORE D'ACCENSIONE
3) VITE REG. ARIA ALLA TESTA DI COMBUSTIONE
4) TERMOSTATO RITORNO UGELLO
5) VALVOLA REG. DI PRESSIONE 2° FIAMMA
6) VALVOLA REG. DI PRESSIONE 1° FIAMMA
7) PRESSOSTATO ARIA
8) ELETTROVALVOLA 2° FIAMMA (norm. aperta)
9) RESISTENZA RISCALDAMENTO DELLA VALVOLA
REGOLATRICE DI PRESSIONE 1° FIAMMA
10) MOTORE POMPA
11) PRERISCALDATORE
12) FLANGE ATTACCO BRUCIATORE
13) GUARNIZIONE ISOLANTE
14) TESTA DI COMBUSTIONE
15) MOTORE VENTOLA
16) ELETTROMAGNETE
17) QUADRO ELETTRICO
18) SERVOMOTORE REGOLAZIONE ARIA
19) POMPA
20) FILTRO AUTOPULENTE SUL SERBATOIO PRERISCALDATORE
1) PHOTORESISTANCE
2) IGNITION TRANSFORMER
3) COMBUSTION HEAD CONTROL KNOB
4) BACKNOZZLE THERMOSTAT
5) 2nd FLAME PRESSURE REGULATOR VALVE
6) 1st FLAME PRESSURE REGULATOR VALVE
7) AIR PRESSURE SWITCH
8) 2nd FLAME ELECTROVALVE (usually open)
9) 1st FLAME PRESSURE REGULATOR VALVE
HEATING RESISTANCES
10) PUMP MOTOR
11) PRE-HEATER
12) BURNER FIXING FLANGES
13) INSULATING GASKET
14) COMBUSTION HEAD
15) FAN MOTOR
16) ELECTROMAGNET
17) ELECTRIC BOARD
18) AIR REGULATION SERVOMOTOR
19) PUMP
20) SELF-CLEANING FILTER MOUNTED
ON THE PRE-HEATER TANK
1) FOTORESISTENCIA
2) TRANSFORMADOR DE ENCENDIDO
3) TORNILLO DE REGULACION DE AIRE EN LA
CABEZA DE COMBUSTION
4) TERMOSTATO RETORNO BOQUILLA
5) VALVULA REGULADORA DE PRESION 2aLLAMA
6) VALVULA REGULADORA DE PRESION 1a LLAMA
7) PRESOSTATO AIRE
8) ELECTROVALVULA 2aLLAMA (norm. abierta)
9) RESISTENCIA CALENTAMIENTO DE LA VALVULA
REGULADORA DE PRESION 1aLLAMA
10) MOTOR BOMBA
11) PRECALENTADOR
12) BRIDA UNION AL QUEMADOR
13) JUNTA AISLANTE
14) CABEZA DE COMBUSTION
15) MOTOR IMPULSOR
16) ELECTROIMANES
17) CUADRO ELECTRICO
18) SERVOMOTOR REGULACION AIRE
19) BOMBA
20) FILTRO AUTOLIMPIANTE EN EL DEPOSITO PRECALENTADOR
CARATTERISTICHETECNICHE/
TECHNICALDATA/
CARACTERISTICASTECNICAS

6
N° 0002370013
n° 4 di 4
CARATTERISTICHETECNICHE/
TECHNICALDATA/
CARACTERISTICASTECNICAS
MOD. OVERAL DIMENSIONS
A A1 A2 B B1 B2 C D D E F L M N
MIN MAX Ø Ø
BT 75 DSNM-D 860 410 450 550 400 150 1385 170 430 205 160 235 M12 165
BT 100 DSNM-D 910 460 450 550 400 150 1445 210 400 230 195 275 M16 240
BT 120 DSNM-D 910 460 450 640 480 160 1385 185 450 230 195 275 M16 240
BT 180 DSNM-D 1035 545 490 800 600 200 1635 200 535 260 220 340 M16 280
BT 250 DSNM-D 1035 545 490 800 600 200 1635 235 590 260 220 340 M16 280
BT 300 DSNM-D 1120 630 490 860 600 260 1940 245 605 356 273 480 M20 380
BT 350 DSNM-D 1200 675 525 920 660 260 1900 350 560 356 273 490 M20 380

7
WORKING FIELD
N° 0002921710
N°0002921701
WORKING FIELD

8
FUEL FEED PLANT
The burner pump must receive fuel from a suitable feed circuit including an auxiliary pump with pressure adjustable
from 0,5 to 2 bar, pre-heated at 50 - 60 °C.
Fuel feed pressure value to the burner pump (0,5 ÷ 2 bar) must not vary both when the burner is not operating and
when the burner is in operation at the maximum fuel output level requested by the boiler.
The feed circuit must be built according to our drawings n° BT 8511/6 or n° BT 8513/7 also when using low viscosity-
fuel.
Pipe dimensions must be in relation to their length and to the delivery of the pump used.
Our instructions only concern everything necessary to ensure good operation.
Viscosity - Temperature Diagram

9
BASIC HYDRAULIC DIAGRAM FOR MULTIPLE
TWO-FLAME OR MODULATING BURNERS USING
FUEL OIL (MAX 15 °E AT 50 °C) N° BT 8511/6
rev.: 2/10/2002
BASIC HYDRAULIC DIAGRAM FOR MULTIPLE TWO-FLAME OR
MODULATING BURNERS FUNCTIONING WITH DENSE FUEL OIL
(MAX 50 °E AT 50 °C) AND AUXILIARY HEATER
N° BT 8513/7
rev.: 3/10/2002
1 - MAIN TANK
2 - FILTER
3 - CIRCULATION PUMP
4 - WATER AND SYSTEM DISCHARGE
5 - NORMALLY CLOSED AIR-GAS DISCHARGE
6 - FUEL RECOVERY TANK AND DEGASSING UNIT
7 - NON-RETURN VALVE
6 - BY PASS (NORMALLY CLOSED)
9 - ADJUSTABLE PRESSURE REGULATOR, 0.5 - 2 BAR
10 - PRESSURE GAUGE (0-4 BAR)
11 - THERMOMETER
12 - ELEMENT
13 - AUXILIARY HEATER
14 - STEAM COIL OR HOT WATER TO HEAT THE OIL
15 - HEAVY OIL HEATING COIL, STEAM OR HOT
WATER
16 - HUB DIAMETER 100MM, HEIGHT 300MM
HEATING ELECTRICAL LEAD (IF NECESSARY)
N.B. The thank for recovery of hot oil (diameter 150 mm, height
400 mm) should be installed as near as possible to the
burner and about 0.5 m, above the pump.
1 - MAIN TANK
2 - FILTER
3 - CIRCULATION PUMP
4 - WATER AND SYSTEM DISCHARGE
5 - NORMALLY CLOSED AIR-GAS DISCHARGE
6 - FUEL RECOVERY TANK AND DEGASSING UNIT
7 - NON-RETURN VALVE
6 - BY PASS (NORMALLY CLOSED)
9 -ADJUSTABLE PRESSURE REGULATOR, 0.5 - 2 BAR
10 - PRESSURE GAUGE (0-4 BAR)
11 - HEAVY OILHEATING COIL, STEAM OR HOT WATER
HEATING ELECTRICAL LEAD (IF NECESSARY)
N.B. The thank for recovery of hot oil
(diameter 150 mm, height 400 mm) should
be installed as near as possible to the
burner and about 0.5 m, above the pump.

10
APPLICATION OF THE BURNER TO BOILER
for model BT 75 - 100 - 120 - 180 - 250 DSNM-D (steel fixing flange)
1 - Boiler plate
2 - Insulating gasket
3 - Burner fixing flange
4 - Elastic collar
for model BT 300 - 350 DSNM-D
5 - Stud bolt
6 - Locking nut with washer
7 - Nut and washer for fastening the first flange
0002933330
0002933340
1 - Boiler plate
2 - Insulating gasket
3 - Burner fixing flange
4 - Stud bolt
5 - Locking nut with washer
Remarks
When tightening the flange, it is important to do it evenly so that the inner faces are parallel between them.
Since the locking system is highly efficient, do not tighten the nuts too much.
During this operation (tightening of the flange locking nuts) keep the body of the burner lifted so that the
combustion head is kept in a horizontal position.
Remarks
The burner is correctly installed when the pre-heating tank is slightly inclined (higher on the side where fuel exits
to go to the nozzle).
This inclination serves to prevent gas from building up inside the tank.
Presence of gas in the pre-heating tank will greatly increase the time required to pressurise the fuel, and it is quite
likely that the burner will go into “block”.
Be careful when installing the burner on the boiler that the burner is not positioned where it cancels this inclination
or, even worse, where the pre-heating tank is sloping in the opposite direction to the direction desired.

11
ELECTRIC CONNECTIONS
The burner electrical connections have been kept to a minimum. We recommend that all connections are made of
flexible electric wire. Electric lines must be installed at a suitable distance from hot parts.
Make sure that the electric line you wish to connect to the apparatus is fed with voltage and frequency values suitable
for the burner. Make sure that the main line, the relative fuse switch (fuses are essential) and the limiting device, if any,
are suitable for bearing the maximum current absorbed by the burner.
DESCRIPTION OF OPERATION (see BT 8713/1)
Duringthefuel oil pre-heating stage, voltagepassesthrough the pre-heater regulation thermostatandreaches the coil
oftheresistancesremote switch. This remote switchshutsandtakes current to the pre-heater resistances,whichheat
the fuel contained in the pre-heater. The resistances heating the pump, the unit for atomizing fuel and regulating first-
flame return pressure are also cut-in, through the panel ( I ) switch.
The pre-heater minimum level thermostat shuts off when the temperature reaches the value at which the pre-heater is
set. The equipment is only cut-in when the temperature at which resistances are cut-out (opening of the regulation
thermostatcontact)isreached inthepre-heater.This isthereforeachieved whenfueloil inthepre-heater isatmaximum
temperature. The burner control box (a cyclic relay) is then cut-in by the heating tank regulation thermostat when the
latter cuts-out the resistances by switching off the relative remote switch.
Control box specifications
The control box cyclic relay carries out the ignition programme, by putting into operation the fan motor for executing
the preventilation stage. If the pressure of the air supplied by the fan is sufficient to put the relative pressure switch
into action, cutting in also occurs of the motor of the pump that carries out hot oil pre-circulation in the burner pipes.
Oil from the pump reaches the pre-heater, passes through it, reaching the temperature envisaged, exits through a
filter and then reaches the atomizing unit. The oil circulates in the atomizing unit without flowing out of the nozzle
becausethechannelsleadingtowards the nozzle (outward flow) and from thenozzle(returnflow)are closed. Closure
is carried out by “closing cones” fixed to the rod ends. These “cones” are pressed against their seats by strong
springs located at the opposite end of the rods. Oil circulates and flows out of the return end of the atomizing unit,
passes through the trap where the TRU thermostat is and reaches the 1st flame return pressure regulator, passes
through it, goes through the 2nd flame solenoid valve (usually open), reaches the pump return pipe and from this it
discharges into the feed system return pipe. Hot oil circulation as described above is carried out at slightly higher
pressure (a few bar) compered to the minimum pressure at which the 1st flame return pressure regulator is set (10 ÷
12 bar). This oil precirculation and preventilation phase lasts 22,5 seconds. This time can be prolonged (infinitely, in
theory)becausetheelectriccircuit is built in such a way that it does notenablethecontrolbox to continue carrying out
the ignition programme, until the fuel temperature, in the nozzle return piping, has reached the level at which the TRU
thermostat is set. This particular design does not allow fuel to pass through the nozzle until the fuel itself reaches at
least the temperature at which the TRU thermostat is set. Usually, the TRU thermostat operates within normal
preventilation time (22,5 seconds), otherwise the fuel oil preventilation and pre-circulation stages are prolonged until
theTRUgoesinto action.TRU operation (oilcirculatingis sufficientlyhot) enables thecontrolbox to continueexecuting
the ignition programme, by cutting-in the ignition transformer which feeds high voltage to the electrodes.
High tension between the electrodes triggers the electric charge (spark) to ignite the air-fuel mixture.
2,5 seconds after the ignition spark begins, the control box takes voltage to the magnet which, through suitable
levers, moves back the two rods that intercept the flow of fuel (outgoing and return) to the nozzle. The moving back of
therodsalsoclosestheby-passinsidethe atomizing unit, and consequently pump pressure reaches the normal level
of about 20 ÷ 22 bar. Withdrawal of the two rods from the closure seats now enables fuel to enter the nozzle at a
pressure of 20 ÷ 22 bar set at the pump and to exit the nozzle, sufficiently atomized.
Return pressure, which determines oil flow to the combustion chamber, is now regulated by the 1st flame return
pressure regulator.
Control box
& relative
Programmer
LAL 1.25
Cyclicrelay
Safety Time
in seconds
5
Pre-Ventilation & Oil
Pre-circulation Time
in seconds
22,5
Pre-ignition Time
in seconds
2,5
Post-ignition
Time
in seconds
5
Time between
1st and 2nd
flames
in seconds
20

12
This value is about 10 ÷ 12 bar for the 1st flame (minimum output).
Atomizedfuel exiting fromthenozzle, mixes withtheair suppliedbythe fan andisignited bythespark at theelectrodes.
Flame presence is detected by the photoresistance.
Theprogrammercontinues and after5 seconds,overcomesthe locking position,turnsoffignitionand then, commands
2nd flame cut-in.
This operation takes place by feeding current, through the relative thermostat or pressure switch, to the motor that
controls the air inlet in the position corresponding to the 2nd flame.
Rotation of the air motor shaft allied to a suitable cam closes a contact which feeds voltage to the coil of the 2nd flame
solenoid valve. This valve closes and thus intercepts fuel flow through the 1st flame return pressure regulator.
Return fuel is now compelled to flow through the 2nd flame pressure regulator and return pressure rises up to the set
level of the regulator.
As a result, nozzle output increases and the burner now operates at maximum capacity.
Nozzle return pressure is about 18 ÷ 20 bar if pump pressure is 20 ÷ 22 bar.
Fuel and comburent air output stay at maximum level until the boiler temperature (pressure if it is a steam boiler)
reachesthe level setat the 2ndflamethermostat (pressureswitchin caseofsteam boilers)andoperates thethermostat
by bringing the 1st flame back into operation. The return movement to the 1st flame position causes a reduction of
fuel output and relative combustion air.
The 1st flame on its own is not usually enough to keep pressure or temperature at the desired value and therefore,
pressure diminishes until it reaches the level at which the 2nd flame control device (pressure switch or thermostat),
again cuts in air and fuel flow totally.
Theburnerstopsoperatingcompletelywhen, even with just the 1st flame cut-in, pressure or temperature reaches the
interventionlevelof the relevantcontroldevice (pressure switchorthermostat). The apparatus re-ignites automatically
when pressure or temperature drops below the level at which the pressure switch or thermostat has been set.
Please note that the output variation range with good combustion is roughly from 1 to 1/3 compared to the maximum
specified output.
Note: The burner is equipped with an air pressure switch that does not permit the pump motor to operate if the
combustion air pressure supplied by the fan does not reach the level at which the pressure switch has
been set. The air pressure switch must be set during burner ignition according to the pressure level noted
for 1st flame operation.

13
GENERAL DIAGRAM FOR TWO FLAME FUEL OIL
BURNERS (MAGNET - NOZZLE WITHOUT PIN) N° BT 8713/1
Access to setting screws
Pressure regulator 0,5 ÷ 2 bar
Bleed and by-pass
Gas and air bleeder
Bleed valve
Pumps
Filter and optional resistance and thermostat
Pump pressure regulator (20 ÷ 22 bar)
Heating coil
Pump inlet pressure gauge (0,5 ÷ 2 bar)
Pump
Degasifier and hot oil recovery
Air regulation gates
Air gate control motor
Opening magnet
2nd flame solenoid valve usually open
Access to setting screws
1st flame return pressure regulator (10 ÷ 12 bar)
Closing springs
Pump outlet pressure gauge (20 ÷ 22 bar)
Pre-heater
By-pass holes
2nd flame pressure regolator (18 ÷ 20 bar)
TRU thermostat for ...D version
Return nozzle without needle
Shaft with closing cones
Atomizer unit
Pre-heater filter
1 = Gauge to detect 1st to 2nd flame return pressure
Min.H = 0,5 m.

14
DIAGRAM OF A DISMANTLED (CB)
CHARLES BERGONZO NOZZLE
(WITHOUT PIN)
N° BT 9353/1
BALTUR PUMP MODEL BT..... N° 0002900580
Suction 1/4” Vacuum-meter connection
Return
Pump plate
Delivery (nozzle)
1/4” Pressure gauge connection
Heating element seal
Pump pressure
regulation (20 ÷ 22 bar)
Suction
Return
Delivery (nozzle)
Pump plate
1/4” Vacuum-meter connection
Heating element seal
1/4” Pressure gauge connection
Pump pressure
regulation (20 ÷ 22 bar)

15
REGULATION DEVICE HEAVY OIL BT...DSNM-D
IDENTIFICATION DIAGRAM N° BT 8716
Backnozzle thermostat (TRU) Enter plugs to the regulation screw
10 ÷ 12 bar
1st flame pressure regulator
2nd flame udually opened
electrovalve =
Opened = 1st flame switched
on regolator
Closed = 1st flame switched
off regulator
Tie-down point pressure
gauge to get the backpressure
which cause the output
variation for the 1st and 2nd
flame
Pump heating resistance
Enter plug to the 20 ÷ 22 bar
regulation pressure pump
screw
1st flame pressure regulator
heating resistance
18 ÷ 20 bar
Flame backpressure regulator
(almost less 2 bar than the
pump pressure)

16
1) Check that the nozzle characteristics (output and spray angle) are suitable for the combustion chamber
(see BT 9351/1). Otherwise, replace the nozzle, fitting one of the right type.
2) Check that there is fuel in the main tank and that fuel is suitable for the burner, to judge by its appearance at least.
3) Check there is water in the boiler and that the plant gates are open.
4) Make absolutely sure that discharge of combustion waste cannot occur without hindrance
(boiler gates and chimney open).
5) Check that the operating voltage of the electric line corresponds to what the burner requires and that electrical
connections of the motors and resistances are correct for the available voltage level. Also check that all electrical
connections carried out locally have been done properly according to our electrical diagram.
6) Make sure that the combustion head penetrates into the combustion chamber to the extent specified by the boiler
manufacturer. Check that the combustion head is in the position considered suitable for supplying the desired
quantityoffuel (for relativelylowfuel supply theairpassage between disk andheadmust be considerablyreduced;
for fairly high nozzle output the passage between disk and head must be relatively open) - see the chapter
“Combustion head regulation”.
7) Remove the cover of the air damper motor. Following the specific instructions (see BT 8655/1), put the 1st flame
air regulation cam in the position considered suitable for supplying sufficient air to the 1st flame. In the same way,
set the position of the second flame air regulation cam. You then set the solenoid valve cutting-in cam (to cut-in
the 2nd flame) in an intermediate position between the cam positions mentioned above.
8) Disconnect,ifalreadyconnected, thesecondflamethermostator pressureswitchtoavoidcutting-inthesecondflame.
9) Check that the setting of the two thermostats (minimum level and regulation thermostats) is suitable for the type
of fuel intended to be used. If the nominal value of fuel viscosity is known, the exact value of fuel oil pre-heating
temperature can be verified on the viscosity-temperature graph. Bear in mind that fuel must reach the nozzle at a
viscosity not exceeding 2° E. To avoid snags which would lead to burner stoppage, the regulation thermostat
should be set at a temperature 15 ÷ 20° C higher than the minimum level thermostat.
After you have ignited the burner, check that the thermostats are operating correctly, by reading the appropriate
pre-heater thermometer. Set the resistance control thermostat mounted on the line filter to about 50 °C.
10) Run the auxiliary fuel feed circuit, checking for efficiency and setting pressure to about 1 bar.
11) Remove the plug on the vacuum gauge connection point of the pump and then slightly open the gate on the fuel
supply pipe. Wait until fuel out of the hole without any air bubbles and then close the gate.
12) Fit a pressure gauge (about 3 bar at the bottom of the scale) at the connection point of the vacuum gauge on the
pumpin ordertocheck thepressurelevel ofthefuel asitenters theburnerpump. Fitapressure gauge(about 30 bar
atthebottom of thescale)to the pressuregaugeconnection point on thepumpto check theworkingpressure of the
pump. Fit a pressure gauge (about 30 bar at the bottom of the scale) to the appropriate connection point of the first
flame return pressure regulator (see BT 8713/1) in order to check the first and second flame return pressure.
13) Now open all gates and any other flow stopping valves on the fuel pipe-line.
14) Turn the switch on the control panel into the “O” (OFF) position to avoid cutting-in resistances when the tank is
empty, and cut-in current to the electric line to which the burner is connected. Press the relative remote switches
manuallytocheckwhetherthetwomotors (fan and pump) turn in the right direction and if necessary, change over
the two main line wires to reverse the turning direction.
15) Run the burner pump, manually pressing the relative remote switch till the pressure gauge, which shows the pump
workingpressure,indicatesslightpressure.Lowpressureinthecircuitconfirmsthatthepre-heatingtankhasbeenfilled.
16) Cut-in the control panel switch to feed current to the control box. This way, the resistances heating the fuel in the
tank and the resistance line filter are cut-in by commend of the relevant thermostat. The heating resistances for
theatomizerunitand the pump are cut-in atthesame time. An appropriate pilot-light onthecontrolpanel indicates
cutting-in of the resistances.
17) The minimum level thermostat closes when fuel contained in the pre-heater reaches the temperature at which
the thermostat is set. Closure of the minimum level thermostat does not cause immediate cut-in of the burner
controlbox.Thiscontrolboxcut-inby the regulation thermostat (contact by commutation) when the latter cuts-out
the resistances because fuel temperature has reached the level at which the regulation thermostat has been set.
Burnerstart-upthereforeonlybegins, provided the boiler and safety thermostats or pressure switches areclosed,
when the resistances have been cut-out and maximum pre-heater temperature has been reached. As the burner
operates,an appropriateauxiliaryrelay (partof theminimumlevel thermostat)avoidsit stoppingwhen theregulation
thermostat commutates the contact to cut-in the resistances once again (see electric diagram). When the control
box is cut-in the burner ignition stages begin.
IGNITION AND REGULATION

17
The programme involves simultaneous pre-ventilation and pre-circulation (with hot oil at low pressure) in the
entire fuel circuit of the burner. Burner ignition occurs as described in the previous chapter (see “Description of
operation”), and the burner ignites at minimum level.
18) When the burner is operating on the first flame, the air should be set (keeping to the specific instructions) for the
quantity needed to ensure good combustion (see BT 8655/1). It is preferable that air quantity for the first flame be
rather low, so that perfect ignition is guaranteed even under the most difficult conditions.
19) After air for the first flame has been set, the burner has to be stopped by cutting-out current by the main switch,
andtheterminals of the secondflamethermostatterminal boardmustbe connected to each other.Thisconnection
makes it possible to cut-in the second flame.
20) The main switch must now be cut-in once again causing ignition, thus automatically proceeding to the second
flame, according to the programme set by the cyclic relay.
21) As the burner operates on the second flame, the quantity of air should now be set (by following the specific
instructions)toensuregoodcombustion.Combustionshouldbe controlled by use of the appropriate instruments.
Theairregulator must be set to permitapercentageof carbon dioxide (CO2) in the fumes, varyingfromaminimum
of 10% to a maximum of 13%. Please remember that in order to regulate correctly, water temperature in the plant
must be at normal operating level and the burner must have been operating for at least 15 minutes.
Ifappropriate instrumentsare notavailable, youcanjudgebythecolouroftheflame. Airadjustmentisrecommended
to achieve a light orange flame colour, avoiding a red smoky flame, or a white flame due to excessive air. Check
that setting of the pre-heater thermostats do not cause any inconvenience (poor ignition, smoke, gas formation in
the pre-heater, etc.). If necessary, you may vary these values upward or downward, but bear in mind that the
regulation thermostat must anyway be set at a temperature about 15 ÷ 20 °C higher than the minimum level
thermostat setting. The minimum level thermostat must close at the lowest possible temperature to give a good
atomization (viscosity at the nozzle about 2° E). See the viscosity-temperature graph relating to the type of oil
used, as a rough guide.
COMBUSTION HEAD SETTING
The burner is equipped with an adjustable (forwards and backwards) combustion head to ensure an opening and
closure of the air passage between head and disk. This way, high pressure at the pre-disk position can be obtained
even at low flow. Consequently, high pressure and air turbulence enable better air penetration into the fuel giving an
optimum mixture and flame stability.
High air pressure in the pre-disk position might be indispensable to avoid flame pulsation. This state is essential when
the burner is operating with a pressurized furnace and/or at high thermal output. From what has been said above, it is
clear that the combustion head must be brought into a position giving decidedly high air pressure behind the disk.
We recommend you to set enough air throttling between disk and head, in order to open up well the air gate that
regulates air flow to the burner fan aspiration. These conditions must obviously exist when the burner is operating at
maximum output required. In practice, setting should begin with the combustion head in an intermediate position.
The burner is ignited and pre-setting should be carried out, as already explained.
When maximum desired pressure has been achieved, the combustion head position should be corrected, by shifting it
either backwards or forwards in order to get sufficient air flow in relation to the fuel supplied, with the air aspiration
regulation gate fairly wide open. If the combustion head is pushed forward (reduction of the passage between head
and disk) full closure must be avoided. When setting the combustion head make sure you centre it perfectly in relation
to the disk. If the combustion head is not perfectly centred in relation to the disk, poor combustion and excessive
heating of the head could occur and the latter would, as a result, deteriorate quickly.
You check as follows: with the flame lit, look through the window on the rear of the burner.
You then fully tighten the two screws that lock the combustion head into position.
SETTING THE DISTANCE BETWEEN DISK AND NOZZLE
Burners are equipped with a device that allows the distance between disk and nozzle to be varied. To change this
distance, turn the three disk fixing screws. By screwing (turning clock-wise) you reduce the distance between disk and
nozzle,byunscrewing (turning anti-clockwise) youincreasethedistance between disk andnozzle.Checkthat the disk
isina perpendicularpositionin relation toairflow, by measuringthe distancebetween the outeredgeof thecombustion
head and the disk. This position is achieved when this distance is identical at each of the three disk fixing-regulating
screw positions. The distance between disk and nozzle, set in the factory, should be reduced only if it is found that the
atomized fuel come exiting from the nozzle wets and dirties the disk.

18
DRAWING (AS REFERENCE POINT) SHOWING THE
PLACING OF NOZZLE, ELECTRODES, FLAME DISK
AND REGULATION OF HEAD/DISK “D” DISTANCE
HOW TO USE THE BURNER
The burner have fully automatic operation; if the main and control panel switches are turned on the burner is cut-in.
The burner operation is carried out by means control box and devices as described in the chapter “Description of
operation”.Theburnerautomaticallygoes into the safety“locked”position when partof theburnerorplant is inefficient;
it is therefore a good idea to make sure that there are no abnormal conditions in the heating system, before cutting-in
the burner again by “unlocking” it. The burner can remain in the locked position for any length of time.
To unlockit,you mustpressthe appropriate push-button(“sblocco” = unlock).Lockingcan alsobecaused bytemporary
inconveniences (water in the fuel, air in the pipe lines, etc.); if you unlock the burner in these cases, the burner starts
up without any snags. If instead, locking occurs several times after ( 3 or 4 times) do not go on unlocking, but ask for
a call by the Assistance Service in your area, which will put the fault right.
MAINTENANCE
Theburnersdonot call for any special maintenance; itisaswell however, to carry out thefollowingoperations,atleast
at the end of the heating season:
1) Remove and wash carefully with solvents (petrol, trichloroethylene, oil) filters, nozzle, turbulence disk and ignition
electrodes. When cleaning the nozzle, avoid using metal objects (use wood or plastic objects).
2) Cleaning the photoresistance.
3) Arrange for cleaning of the boiler and, if necessary, the chimney, by qualified personnel (stove fitters); clean
burners have better output, longer life and are quieter.
N° 0002931451
rev.: 20/09/2002

19
TWO - FLAME BURNER OPERATION
The two-flame burner always ignites at reduced fuel and air flow (1st flame) and a few seconds later change to full fuel
and air (2nd flame) flow operation.
Cutting-in of the second flame depends on control box and control device (pressure switch or thermostat) consent.
When the burner is working at full flow, it stays in this position until the pressure or temperature level at which the
control device (pressure switch or thermostat) has been set, is reached. The control device is triggered off cutting-off
the second flame (fuel and air) when the value at which the device has been set, is reached.
The burner therefore stays in operation on the first flame only.
Thefirst flameon itsownis notusually enoughto maintainpressureortemperatureatthedesiredlevelandconsequently,
pressure or temperature drops until it reaches the level at which the second flame control device (pressure switch or
thermostat) again cuts-in total air and fuel flow (second flame).
Theburnerstops operating completely when,withonly the first-flame cut-in,pressureor temperature reaches thelevel
at which the device being used (pressure switch or thermostat) open contact.
The burner automatically re-ignites when pressure or temperature drops below the level at which the pressure switch
or thermostat has been set.
WHEN SHOULD TWO-FLAME BURNERS BE USED
Atwo-flameburner is usually foundnecessaryif it has tobecoupled to boilers producingsteam;however there may be
other reasons why two-flame burners are necessary.
Forsteamboilers,two-flame operation enables, to a certainextent only, the vapour quantity produced tobeinlinewith
the actual needs of the plant, reducing ignition frequency and thus also boiler thermal stress.
This is why steam boiler manufacturers specify two-flame burners for their boilers.
It is also important to note that low pressure steam boilers (max. 0,5 bar) strictly call for two-flame burners in order to
keep working pressure sufficiently constant.
Two-flame burnersare requiredforpressurizedboilers(where combustionchamber pressureis higherthanatmospheric
pressure) in order to give sufficiently gradual ignition (two-flame burners always ignite on the first flame only, which
means at reduced flow; they only change to full flow operation later on).
In these kinds of boilers, full flow ignition would cause considerable damage over a short time due to the excessive
pressure the combustion chamber would have to bear.
From what has been said above, it is quite clear that with regard to pressurized boilers, it is necessary to use burners
that can ignite automatically at reduced flow and only change to full flow operation later on (after a few seconds).
N.B. It is not advisable that a burner operating with a boiler for the production of water for heating purposes be
connected up for two flame operation.
In this case, when the burner is operating on one flame only (this can be over long periods, too) the boiler is
insufficiently fed; consequently, the products of combustion exit at an excessively low temperature (less than
180 °C) creating soot at the chimney outlet. When the boiler is not sufficiently fed, acid condensate and soot
formation is very likely in the boiler with the result that the boiler quickly gets clogged and corroded.
When a two-flame burner is installed in a boiler producing water for heating purposes, it must be connected to enable
two flame full-flow operation and must stop operation completely, without change-over to the first flame, when the pre-
set temperature is reached.
To achieve this type of operation, the second flame thermometer must note installed and a direct (bridge) connection
as to be effected between the relevant terminals.
In this way, only the reduced flow ignition capacity of the burner is used in order to have gradual ignition, which is
essential for boilers with combustion chamber under pressure (pressurized) but it is also very useful for boilers (nega-
tive pressure combustion chamber).
The burner control device (cutting-in and stop) depends on the usual operation and safety thermostats.

20
VARIANTS FOR BURNERS PROVIDED WITH STEAM PRE-HEATER TO HEAT THE FUEL OIL
Theburnercan be providedwitha pre-heater of thefueloil which operateswithsteam; thefuel will beheatedby steam
and there will be a consequent saving in electricity.
This device consists of a small tank in which steam circulates and inside the tank is a coil in which the fuel oil to be
heated circulates.
This particular device permits a notable reduction in the dimension of the pre-heater.
When the burner starts up, cold fuel oil would be forced to pass through the coil of the steam pre-heater still cold
becauseitwould notyethave been heatedbythe steam. The highviscosityof the fuel(cold),the notable development
(length)ofthe coil itsrelativelysmall diameter (necessaryinorder to obtain ahighthermal exchange), woulddetermine
a strong pressure loss and consequently the fuel would reach the nozzle at insufficient pressure.
To avoid this situation, the steam pre-heater has been provided with a manual-controlled by-pass which prevents,
when open, the fuel passing through the coil (see BT 8576).
Installation
The user should provide and install on the pipeline that takes the steam to the fuel heater the following: a gate valve,
a suitable pressure reducer (adjustable from 1 to 8 bar) and a control manometer (end of the scale 10 bar).
Do not recuperate the condensate which is discharged from the heater to avoid, in case there is a leak in the coil, fuel
oil going into the steam system.
Regulation
Whentheboiler has reachedsufficient pressure, openthegate valve which allowsthesteam inflow toreachthe oil pre-
heater, and open slightly the “air discharge” gate valve fitted on the condensate outlet pipeline.
While the steam is discharging from the gate valve slightly opened, regulate the pressure reducer at a sufficient value
in order to heat the fuel oil to a temperature a little above (about 10 ÷ 15 °C) that at which the regulation thermostat of
the electric heater has been set. An orientative regulation can be carried out by operating the pressure reducer in
function with the value indicated by the manometer; if necessary, correct the regulation after having controlled the
temperature of the fuel coming out of the steam heater.
Steam Pressure
at manometer bar 1 1,5 2 2,5 3 3,5 4 4,5 5 6 7 8
Approximate
Corresponding
Temperature °C 120 127 133 138 143 147 151 155 158 164 169 174
When regulation has been carried out, close the air discharge gate valve.
The thermostats (minimum and regulation) of the electric pre-heater should be regulate normally as described in
Chapter “Start up and Regulation”.