baltur GI MIST 1000 DSPNM-D User manual

EN
GIMIST1000DSPNM-D
Manuale
istruzioniperl'uso.
Instructions
for use
ISTRUZIONI ORIGINALI (IT)
0006080766
- TWO STAGES PROGRESSIVE / MODULATING NATURAL GAS / HEAVY
OILMIXED BURNERS
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0006080766
- Before using the burner for the rst time please carefully read the chapter “WARNINGS NOTES FOR THE USER : HOW TO USE
THE BURNER SAFELY” in this instruction manual, which is an integral and essential part of the product. The works on the burner
and on the esystem have to be carried out only by competent people.
- Read carefully the instructions before starting the burner and service it.
- The system electric feeding must be disconnected before starting working on it.
- If the works are not carried out correctly it is possible to cause dangerous accidents.
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0006080766
IWARNING NOTES FOR THE USER HOW TO
USE THE BURNER SAFELY
FOREWORD
These warning notes are aimed at ensuring the safe use of the compo-
nents of heating systems for civil use and the production of hot water.
They indicate how to act to avoid the essential safety of the components
being compromised by incorrect or erroneous installation and by improper
or unreasonable use. The warning notes provided in this guide also seek
to make the consumer more aware of safety problems in general, using
necessarily technical but easily understood language. The manufacturer
is not liable contractually or extra contractually for any damage caused
by errors in installation and in use, or where there has been any failure to
follow the manufacturer’s instructions.
GENERAL WARNING NOTES
• Theinstructionbookletisanintegralandessentialpartoftheproduct
and must be given to the user. Carefully read the warnings in the bo-
oklet as they contain important information regarding safe installation,
use and maintenance. Keep the booklet to hand for consultation when
needed.
• Equipmentmustbeinstalledinaccordancewithcurrentregulations,
withthemanufacturer’s instructions and by qualiedtechnicians.By
theterm‘qualiedtechnicians’ismeantpersonsthatarecompetentin
theeldofheatingcomponentsforciviluseandfortheproductionof
hotwaterand,in particular, assistancecentres authorisedby themanu-
facturer. Incorrect installation may cause damage or injury to persons,
animals or things. The manufacturer will not in such cases be liable.
• Afterremovingallthepackagingmakesurethecontentsarecomplete
andintact.If indoubtdonotusetheequipment andreturnit tothe
supplier.Thepackagingmaterials(woodencrates,nails,staples, plastic
bags, expanded polystyrene, etc.) must not be left within reach of chil-
dren as they may be dangerous to them. They should also be collected
and disposed on in suitably prepared places so that they do no pollute
the environment.
• Beforecarryingoutanycleaningormaintenance,switchofftheequipment
atthemainssupply,usingthesystem’sswitch orshut-offsystems.
• Ifthereisanyfaultoriftheequipmentisnotworkingproperly,de-ac-
tivatetheequipmentanddonotattempttorepairitortamperwithit
directly.Insuchcasegetintouchwithonlyqualiedtechnicians.Any
product repairs must only be carried out by BALTUR authorised assi-
stance centres using only original spare parts. Failure to act as above
mayjeopardisethesafetyoftheequipment.Toensuretheefciency
andcorrectworkingoftheequipment,itisessentialtohaveperiodic
maintenancecarriedoutbyqualiedtechniciansfollowingthemanufac-
turer’s instructions.
• Iftheequipmentissoldortransferredtoanotherowneroriftheowner
movesandleavestheequipment,makesurethatthebookletalways
goeswiththeequipmentsoitcanbeconsultedbythenewownerand/
or installer.
• Forallequipmentwithoptionalsorkits(includingelectrical),onlyorigi-
nal accessories must be used.
BURNERS
• Thisequipmentmustbeusedonlyforitsexpresslystateduse:applied
to boilers, hot air boilers, ovens or other similar equipment and not
exposed to atmospheric agents. Any other use must be regarded as
improper use and hence dangerous.
• Theburnermustbeinstalledinasuitableroomthathasventilationin
accordancewithcurrentregulationsandinanycasesufcienttoensure
correct combustion
• Donotobstructorreducethesizeoftheburner’airintakegrillsorthe
ventilation openings for the room where a burner or a boiler is installed
or dangerous mixtures of toxic and explosive gases may form.
• Beforeconnectingtheburnercheckthatthedetailsontheplatecorrespond
tothoseoftheutilitysupplies(electricity,gas,lightoilorotherfuel).
• Donottouchhotpartsoftheburner.These,normallyintheareasnear
totheameandanyfuelpre-heatingsystem,becomehotwhenthe
equipmentisworkingandstayhotforsometimeaftertheburnerhas
stopped.
• Ifitisdecidednottousetheburneranymore,thefollowingactionsmust
beperformedbyqualiedtechnicians:
a)Switchofftheelectricalsupplybydisconnectingthepowercablefrom
the master switch.
b)Cutoffthefuel supplyusingtheshut-offvalveand removethecontrol
wheels from their position.
c) Render harmless any potentially dangerous parts.
Special warning notes
• Checkthatthepersonwhocarriedouttheinstallationoftheburnerxed
itsecurelytotheheatgeneratorsothattheameisgeneratedinside
the combustion chamber of the generator itself.
• Beforestartinguptheburner,andatleastonceayear,havequalied
techniciansperformthefollowingoperations:
a) Settheburnerfuelcapacitytothepowerrequiredbytheheatge-
nerator.
b)Adjustthecombustionairowtoobtaincombustionyieldofatleast
the minimum set by current regulations.
c) Carry out a check on combustion to ensure the production of no-
xious or polluting unburnt gases does not exceed limits permitted
by current regulations.
d) Check the adjustment and safety devices are working properly.
e) Checktheefciencyofthecombustionproductsexhaustduct.
f) Check at the end of the adjustments that all the adjustment devices
mechanical securing systems are properly tightened.
g) Make sure that the use and maintenance manual for the burner is
in the boiler room.
• Iftheburnerrepeatedlystopsinlock-out,donotkeeptryingtomanually
resetbutcallaqualiedtechnicianstosortouttheproblem.
• Therunningandmaintenanceoftheequipmentmustonlybecarriedout
byqualiedtechnicians,incompliancewithcurrentregulations.

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IWARNING NOTES FOR THE USER HOW TO
USE THE BURNER SAFELY
ELECTRICAL SUPPLY
• Theequipmentiselectricallysafeonlywhenitiscorrectlyconnectedtoan
efcientgroundconnectioncarriedoutinaccordancewithcurrentsafety
regulations.Itisnecessarytocheckthisessentialsafetyrequirement.
Ifindoubt,callforacarefulelectricalcheckbyaqualiedtechnicians,
since the manufacturer will not be liable for any damage caused by a
poor ground connection.
• Havequaliedtechnicianscheckthatthewiringissuitable forthe
maximumpowerabsorptionoftheequipment,asindicatedinthetechnical
plate,makingsureinparticularthatthediameterofcablesissufcient
fortheequipment’spowerabsorption.
• Adapters,multipleplugsandextensioncablesmaynotbeusedforthe
equipment’spowersupply.
• Anominpolarswitchinaccordancewithcurrentsafetyregulationsis
requiredforthemainssupplyconnection.
• Theelectricalsupplytotheburnermusthaveneutraltoground
connection.Iftheionisationcurrenthascontrolwithneutralnottoground
itisessentialto make aconnectionbetweenterminal 2(neutral)andthe
ground for the RC circuit.
• Theuseofanycomponentsthatuseelectricitymeansthatcertain
fundamentalruleshavetofollowed,includingthefollowing:
-donottouchtheequipmentwithpartsofthebodythatarewetordamp
or with damp feet
- do not pull on electrical cables
-donotleavetheequipmentexposedtoatmosphericagents(suchas
rain or sun etc.) unless there is express provision for this.
-donotallowtheequipmenttobeusedbychildrenorinexpertpersons.
• Thepowersupplycablefortheequipmentnotmustbereplacedbythe
user.Ifthecablegetsdamaged,switchofftheequipment,andcallonly
onqualiedtechniciansforitsreplacement.
• Ifyoudecidenottousetheequipmentforawhileitisadvisabletoswitch
off the electrical power supply to all components in the system that use
electricity (pumps, burner, etc.).
GAS, LIGHT OIL, OR OTHER FUEL SUPPLIES
General warning notes
• Installationoftheburnermustbecarriedoutbyqualiedtechnicians
and in compliance with current law and regulations, since incorrect
installation may cause damage to person, animals or things, for which
damage the manufacturer shall not can be held responsible.
• Beforeinstallationitisadvisabletocarryoutcarefulinternalcleaning
of all tubing for the fuel feed system to remove any residues that could
jeopardise the proper working of the burner.
• Forrststartupoftheequipmenthavequaliedtechnicianscarryout
thefollowingchecks:
• Ifyoudecidenottousetheburnerforawhile,closethetaportapsthat
supply the fuel.
Special warning notes when using gas
• Havequaliedtechnicianscheckthefollowing:
a)thatthefeedlineandthetraincomplywithcurrentlawandregulations.
b) that all the gas connections are properly sealed.
• Donotusethegaspipestogroundelectricalequipment.
• Donotleavetheequipmentonwhenitisnotinuseandalwaysclose
the gas tap.
• Iftheuserofisawayforsometime,closethemaingasfeedtaptothe
burner.
• Ifyousmellgas:
a)do not useany electrical switches,the telephoneor any otherobject
that could produce a spark;
b) immediately open doors and windows to create a current of air that
will purify the room;
c) close the gas taps;
d) askforthehelpofqualiedtechnicians.
• Donotblockventilationopeningsinthe roomwherethereisgas
equipmentordangeroussituationsmayarisewiththebuildupoftoxic
and explosive mixtures.
FLUES FOR HIGH EFFICIENCY BOILERS AND SIMILAR
Itshouldbepointedoutthathighefciencyboilersandsimilardischarge
combustionproducts(fumes)atrelativelylowtemperaturesintotheue.
Intheabovesituation,traditionalues(intermsoftheirdiameterandheat
insulation)maybesuitablebecausethesignicantcoolingofthecombustion
productsinthesepermitstemperaturestofallevenbelowthecondensation
point.Inauethatworkswithcondensationthereissootatthepointthe
exhaust reaches the atmosphere when burning light oil or heavy oil or the
presenceofcondensatewateralongtheueitselfwhengasisbeingburnt
(methane,LPG,etc.).Fluesconnectedtohighefciencyboilersandsimilar
mustthereforebeofasize(sectionandheatinsulation)forthespecicuse
to avoid such problems as those described above.

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0006080766
TECHNICAL SPECIFICATIONS
*) The electrical preheaters are not mounted on the burner
MOD. GI mist 1000 DSPNM
GI mist 1000 DSPNM-D
THERMIC CAPACITY
MAX kW 10 500
MIN kW 2 500
FLOW RATE
MAX kW 1 056
MIN kW 251
MIN. PRESSURE
(Inordertoobtainthemaximumowrate)
MAX mbar 500
NATURAL GAS TRANSFORMER
8kV - 20mA
THERMIC CAPACITY
MAX kW 10 500
MIN kW 2 500
FLOW RATE MAX kg/h 940
MIN kg/h 224
MAXIMUM FUEL VISCOSITY
50° E - 50° C
HEAVY OIL TRANSFORMER
8kV - 30mA
VOLTAGE
Volt 3N~400V-50Hz
FAN MOTOR
kW 22 x 2800 r.p.m
PUMP MOTOR
kW 4 x 1400 r.p.m.
ABSORBED ELECTRICAL POWER kW 26,6
STANDARD ACCESSORIES
BURNER FIXING FLANGE
n° 1
INSULATING GASKET
n° 2
FILTER
n° 1 - Rp 2”
FLEXIBLE PIPE
n°2-1”1/2X1500
STUD BOLTS
n° 8 M16 x 72
EXAGONAL NUTS
n° 8 M16
FLAT WASHERS
n° 8 M16
NATURAL GASHEAVY OIL
TECHNICAL AND FUNCTIONAL CHARACTERIS-
TICS
• Alternatemethanegas/fueloilburner.
• Two-stageprogressiveoutputoperation.
• Abilitytooperatewithoutputmodulationbymeansofautomatic
RWF40 regulator mounted on the control panel (to be ordered
separately with the modulation kit).
• Abilitytooperatewithanytypeofcombustionchamber.
• Air-gasmixingatcombustionheadandhighpressuremechani-
calatomisationoffuelusingnozzle.
• Abilitytoobtainoptimalcombustionvaluesbyregulatingcom-
bustion air and combustion head.
• Maintenancefacilitatedbythefactthatthemixingunitandthe
atomisation unit can be removed without having to remove the
burner from the boiler.
• Minimumandmaximumairowregulationforrstandsecond
Methanegas: Hi=35.80MJ/m3=8550kcal/h,atthereferenceconditions0°C,1013mbar
Fueloil: Hi=40.19MJ/kg=9600kcal/kg
stage by means of electric servomotor with pause closure of
shuttertopreventanyheatdispersiontoue.
• Ondemanditispossibletointegratetheburnerwithasupple-
mentary fuel oil preheater operating by vapour which allows, at
arateofow,toheatthefuelwithvapourfromtheboiler,hence
obtaining electrical energy savings.
• ValvestightnesscontroldevicecompliantwithEuropeanstand-
ard EN676.
• Preparedforautomaticfuelswitching.
• Equippedwith1insulatinggaskettobexedtotheboiler,2ex-
iblepipes,1self-cleaninglterwithresistor;nozzlenotincluded
andtobeorderedseperatelyaccordingtocapabilityrequired.
• Optional:vapourpreheater

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Mod. A A1 A2 B B1 B2 B3 B4 B5 B6 C D E Ø
GI mist 1000 DSPNM-D 1465 800 665 1257 855 402 450 575 175 163 2350 440 480
Mod. F Ø G G1 L Ø M N Ø P Q R S
GI mist 1000 DSPNM-D 685 DN80 Rp1/2 630 M16 495 740 1910 1575 795
N°0002670552
OVERALL DIMENSIONS

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Pressure in the combustion chamber
Burner output
OPERATING RANGE
heavy oil
DESCRIPTION OF SERIES GI 1000 INDUSTRIAL
BURNERS
The GI 1000 burner is a packaged version made up of separately
supplied units; these components must be connected at the bur-
ner installation site in full observance of the instructions given by
BALTUR.
A - Combustion head with fan
B - Power board
C- Pumping unitfor liquid fuels. If heavy oil is to be used
this unit also includes an electric heavy oil preheater
and,onrequest,anauxiliarysteampreheater.
D - Gas valve unit for burners employing gaseous fuels (usually
methane).
These burners are available in a range of versions to suit the em-
ployedfueltype.Morespecically,theseare:
- GAS (Methane) version DSPGN
- LIGHT OIL version DSPG
-HEAVYOIL(ratedviscositymax.50°Eat50°C)version DSPN-D
-GAS(Methane)/HEAVYOIL(ratedviscositymax.5°Eat50°C)
version GI Mist ... DSPNM
-GAS(Methane)/LIGHTOILversionGI-Mist...DSPGM
Note that the GI-Mist 1000 DSPGM and GI-Mist 1000 DSPNM
burners have been designed for operation with methane gas or
withliquidfuel.
- The“GI1000”burnerisamodulatingburnerwithamodulation
rangeof1-4.Adjustmenttocurrentheatrequirementsispro-
vided by means of a servomotor that regulates the combined
quantityofcombustionairandfuelaccordingtothesignals
from the in-boiler probe.
- The burneristtedwithadevicethat automatically varies
the cross-section of the air passage in the combustion head,
doingsoproportionatelytovariationsinload.Thisdevicegives
optimum combustion under all load conditions as a result of
optimisationoftheair/fuelmix;therethusresults reduced
excessofairwithbetterqualitycombustion.

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ELECTRICAL CONNECTIONS
Itisadvisabletoeffectallelectricalconnectionswithexibleelec-
trical wire. Electrical lines must be kept away from hot parts.
Make sure that the power line to which you intend to connect
theunitisofvoltageandfrequencysuitablefortheburner.Make
surethatthemainpowerline,therelativefuse-equippedswitch
(indispensable)and any limiter are able to withstand the maximum
currentabsorbedbytheburner.Fordetailsseethespecicwiring
diagrams for each individual burner.
FIXING THE BURNER TO THE BOILER
-Makeaholeintheironplateoftheboilerinrespecttothedrillplate,
- Fix the stud bolts supplied with the accessories. It is advisable to
electricallysoldertheboltstotheinternalpartoftheplatetoavoid
losingthem,suchasintheeventofthedisassemblyoftheburner.
- If the iron plate doesn’t have insulation protection, it is necessary
totinsulationprotectionbetweentheironplateandtheheater
that is at least 10 mm thick. Check that combustion head pene-
tratesthecombustionchamberbythemeasurerequestedbythe
manufacturer of the boiler.
CONNECTING THE BURNER TO THE GAS SUP-
PLY PIPE
After youhavesecured the burner to theboiler, remember thatthe
burner headmust penetratethe combustion chamber tothe extent
prescribed by the boiler manufacturer. Connect the burner to the
gaspipe.Weadviseyoutoinstallatwin-angeuniononthepipeas
closeaspossibletotheburner,tofacilitateopeningtheboilerhatch
and/ortodismantletheburner.Beforeyouclosethisunion-with
due precautions and with doors and windows open - vent the air
inthegaspipe.Thetightnessofthepipettingshouldbechecked
before switching on the burner.
VISCOSITY - TEMPERATURE DIAGRAM
VISCOSITY
TEMPERATURE
Viscosityeldforatomisation
Pumping limits
Curve 1 Diesel oil
" 2 Extrauid
" 3 Fluid3/5
" 4 Fluid5/7
" 5 Dense 8
" 6 Dense 15 - 20
" 7 Viscosity density 24 at 50° C
" 8 Viscosity density 35 at 50° C
" 9 Viscosity density 50 at 50° C
" 10 Viscosity density 85 at 50° C

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0006080766
FUEL FEED UNIT
The burner pump mustreceive the fuel from asuitable feed circuit
withanauxiliarypumphavingapressurethatisadjustablebetween
0.5 and2 bar; iffuel ofa ratedviscosity greaterthan 5° Eat50° C
is to be used, it must be preheated to 50 - 60° C.
Fuelfeedpressure at theburner pump(0.5-2bar)mustbepracti-
cally constant bothwith theburner atstandstill andwith the burner
working atthemaximumfuelfeedraterequestedbytheboiler.
Thefeedcircuitmustbeasillustratedinourdrawings(shownbelow)
even where low viscosity fuels are used.
Pipingmustbesizedasafunctionofbothitslengthandtheow-
rateoftheemployedpump.Ourinstructionsregardonlythatwhich
is necessary for proper operation.
HYDRAULIC DIAGRAM OPERATING FOR ONE OR MORE BURNERS WITH MAX NOMINAL VISCOSITY
5° E AT 50° C
N° 0002901180
1 - Main tank
2 - Filter
3 - Circulation pumps
4 - By pass (normally closed)
5 - Pressure regulator adjustable from 0,5 to 2 bar
6 - Pressure gauge (0 ÷ 4 bar)
The tank for recovery of hot oil (diameter 150 mm
height 400 mm) schould be installed as near as
possible to the burner and about 0.5 m above
the pump.
With regarding the fuel feed system, comply to local anti-pollution
laws where the burner is installed
TO THE DEGASSING
BARREL
SEE 0002901140
TO THE DEGASSING
BARREL
SEE 0002901140
TO THE DEGASSING
BARREL
SEE 0002901140

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HYDRAULIC DIAGRAM FOR ONE OR MORE MODULATING BURNERS OPERATING WITH HEAVY OIL
(15° E AT 50° C)
N° 0002901190
1 Main tank
2 Steamorhotwaterheatingoiltokeepasufcienttemperaturefortheslideinthepipe-linealsoduringthe
pause
3 Filter
4 Circulation pumps
5 By pass (normally closed)
6 Pressure regulator adjustable from 0,5 to 2 bar
7 Pressure gauge (0 ÷ 4 bar)
Electric heating wires
The tankfor recovery ofhot oil(diameter150
mm height 400 mm) schould be installed as
near as possible to the burner and about 0.5
m above the pump.
HYDRAULIC DIAGRAM FOR ONE OR MORE MODULATING BURNERS OPERATING WITH HEAVY OIL
(50°E AT 50°C) WITH AUXILIARY HEATER
N° 0002901200
1 Main tank
2 Steamorhotwaterheatingoiltokeepasufcienttemperaturefortheslideinthepipe-linealsoduringthepause
3 Filter
4 Circulation pumps
5 Steam or hot water coil to heat oil
6 Auxiliary heater
7 resistance
8 Thermometer
9 Degasier(Ø=100mm-H=300mm)
10 By pass (normally closed)
11 Pressure regulator adjustable from 0,5 to 2 bar
12 Pressure gauge (0 ÷ 4 bar)
Electric heating wires
The tank for recovery of hot oil (diameter 150
mm height 400 mm) schould be installed as
near as possible to the burner and about 0.5
m above the pump.
TO THE DEGASSING
BARREL
SEE 0002901140
TO THE DEGASSING
BARREL
SEE 0002901140
TO THE DEGASSING
BARREL
SEE 0002901140

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0006080766
N° 0002901140
HYDRAULIC DIAGRAM BURNERS
NOSHUTOFFDEVICEMAYBEINTERPOSED
CONNECTION TO SUPPLY CIR-
CUITS0002901180,0002901190,
0002901200
1 - Filter
2 - Flexible pipe
3 - Burner pump
4 - Pressure gauge (0 ÷ 40 bar)
5 - Modulation servomotor
6 -DISKWITHSCREWSFORAIR/FUELSUPPLYREGULATION
7 - DISK WITHADJUSTMENTSCREWS FORTHEOPENING AND
CLOSING OF AIR TO THE COMBUSTION HEAD
8 - Air pressure
9 - NOZZLE RETURN THERMOSTAT
10 - Return pressure regulator MIN 10-12 bar MAX 18-20 bar
11 - Pressure gauge (0 ÷ 40 bar)
12 - Electrics pre-heaters
13 - MINIMUM PRE-HEAT THERMOSTAT
14 - PRE-HEAT MAXIMUM THERMOSTAT
15 -AIR/GASVENTVALVE,NORMALLYCLOSED,OPENSLIGHTLY
ONLY IN CASE OF GAS DISCHARGE
16 -Selfcleaniglter0.3mm
17 - Pressure gauge (0 ÷ 40 bar)
18 - THERMOSTAT (PT100) AND THERMOMETER
19 - PRE-HEATER SAFETY VALVE (SET AT 32 BAR)
20 - REDUCTION UNIT OR (PILOT) PRESSURE STABILISER
21 - GAS MINIMUM AND MAXIMUM PRESSURE SWITCH WITH
(PILOT) PRESSURE INTAKES
22 - PILOT LIGHT IGNITION SAFETY VALVE
23 - MAIN GAS VALVE FOR IGNITION FLAME
24 - NONRETURN VALVE
25 - AIR-GAS DISCHARGE NORMALLY CLOSED
26 - FUEL RECYCLING TANK AND DEGASSER WITH RESISTOR
- - - PIPINGTOBECARRIEDOUTBYTHEINSTALLINGTECHNICIAN
BALTUR SUPPLY
BALTUR SUPPLY

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DESCRIPTION OF OPERATION WITH HEAVY OIL
(SEE 0002900311)
Turnthemainisolatingswitch“Q1”toon:thepowerindicatorlightwill
comeon,aswilltheauxiliaryelementsofthepump,lter,atomising
unit and regulating valve (.....N-D version only).
Turnthestart/stopswitch“S1”toon:powerreachesthe“LFL...”
controlboxatterminal“1”andthepreheaterregulationthermostats.
Thevoltagecrossesthethermostatcontactsandreachesthe“KR1”
and“KR2”elementcontactorcoilswhichcomeonandheatthefuel
contained in the preheaters.
Thepreheaterminimumthermostatscomeonwhenthetemperature
reaches the value towhich they areset, thusturning onthe control
box via the pressure switch line.
The cyclic relay control box carries out the ignition programme by
running the fan motor to effect pre-ventilation.
Iftheairpressuresuppliedbythefanissufcienttotriptherelative
pressure switch then the motor of the pump which pre-circulates
the hot air in the burner conduits starts immediately.
Theoilowsfrompumptopreheater,passesthroughthelatter,
heatsuptothesettemperatureandexitsviaalterwhereitthen
reaches the atomising unit. The hot oil circulates in the atomising
unitwithoutexitingthenozzlebecausethepassagewaystowards
thenozzle(delivery)andfromthenozzle(return)areclosed.Clo-
sure is effected by means of the “closing cones” applied to the rod
extremities.
These“cones”arepressedagainsttheseatsbystrongspringstted
at the opposite end of the rods. The oil circulates and exits from
the atomising unit return via the sump where the TRU thermostat
is inserted. It then arrives at the return pressure regulator, passes
through it and reaches the pump return. From this, it is discharged
into the return. The above-described hot oil circuit is effected at
a pressure slightly higher (a few atmospheres higher) than the
minimum to which thereturnpressureregulator isset(10- 12bar).
This oil pre-ventilation stage lasts 22.5 seconds. This time can be
extended(intheory,indenitely)becausethedesignoftheelectrical
circuit does not allow the ignition programme to proceed until the
fuelinthenozzlereturnpipinghasreachedthetemperaturetowhich
theTRU(ThermostatonNozzleReturn)isset.
Thisspecialdesignfeaturestopsthefuelpassingthroughthenozzle
until the fuel itself reaches at least the temperature to which the
TRU thermostat isset.The TRUthermostat usuallytrips within the
standard pre-ventilation time (37.5 seconds); if it does not, heavy
oil pre-ventilation and pre-circulation are extended until the TRU
trips. When the TRU trips (circulating oil hot enough) it allows the
controlboxtoproceedwiththeignition programmebyswitchingon
theignitiontransformerandthenthegaspilotamevalves.
The high voltage between the burner electrode and its ground
causesthesparkwhichignitesthegas/airmix.Flowisregulated
bytheow-rateregulatorincorporatedinoneofthetwopilotame
valves.TheameisdetectedbytheUVphotocell.
!
IftheUVphotocelldoesnotdetecttheamethentheburner
locks out. When more than one burner is operating in the
combustionchamber, youmustmakesurethattheUVpho-
tocellofoneburnerdoesnotdetecttheameoftheother.
This is prevented by installing the photocell on a rotatable
support so that it can be positioned to avoid the above-
described interference.
Just2.5secondsaftertheignitionofthepilotame,thecontrolbox
powersthemagnetwhich,viaaseriesoflevermechanisms,moves
thetwonozzlefuelow(deliveryandreturn)interceptionrods.
The movingof theserods causes closure ofthe by-pass insidethe
atomisingunit;consequently,thein-pumppressureisbroughtto
thestandard valueofabout 20-22bar.Theshifting ofthetwo rods
fromtheclosureseatsnowletsthefuelowintothenozzleata
pump-regulatedpressureof20-22barandexitthenozzleproperly
atomised.Thereturnpressure,whichdeterminestheowinthe
chamber, is adjusted by the return pressure regulator.
Forignitionowrate(minimumdelivery)thisvalueisabout10-12
bar.Theatomisedfuelwhichexitsthenozzlemixeswiththefan-fed
airandisignitedbythealready-litgaspilotame.
Afterthemagnetisswitchedonthepilotameisswitchedoffand
the burner is run at the modulation minimum.
Flow increase occurs automatically and continuously according to
thesignalsfromthemodulationprobe:increaseiseffectedbymeans
of a servomotor. The modulation motor controls a simultaneous
increaseintheowofbothfuelandcombustionair.
Theincreaseintheowoffuelisdeterminedbythevariable-prole
disk which, by rotating, causes greater compression of the return
pressure regulator spring and thus an increase in return pressure
correspondstoanincreaseinfuelow.
Anincreaseinfuelowmustcorrespondtoanincrease(ofadequate
quantity)ofcombustionair.Thisconditionisbroughtaboutduring
therstadjustmentbyactingonthescrewsthatvarythecombustion
airadjustercontroldiskprole.
Fuelowand,atthesametime,combustionairow,increaseup
tomaximum pressure(fuelpressure atreturnpressure regulatorof
about 18 - 20 bar) if pressure at the pump is 20 - 22 bar.
Fuelandcombustionairowratesremainatmaximumuntilboiler
temperature (pressure in the case of a steam boiler) nears the set
value and causes the modulation control motor to invert rotation.
The return movement of the modulation motor causes a reduction
intheowoffuelandrelativecombustionair.
Themodulationsystemreaches apositionofequilibriumwhich
correspondstoaowoffuelandrelativecombustionairequalto
thequantityofheatrequestedbytheboiler.
With the burner working the in-boiler probe detects variations in
boilerloadandautomaticallysendsasignaltothemodulationmotor
toadjusttheowoffuelandrelativecombustionairaccordingly.
If,evenwithjusttheminimumowoffuelandcombustionair,the
maximum temperature (or pressure in the case of a steam boiler)
is reached, the thermostat (pressure switch in the case of a steam
boiler) will shut down the burner completely.
Subsequently,thetemperature(orpressureinthecaseofasteam
boiler)willdropbackbelowtheshutdownsettingandtheburnerwill
re-igniteasdescribedabove.Bearinmindthatthepossibleow
range, with good combustion, is approximatelyfrom1to1/3ofthe
maxowrateindicatedontheIDplate.
Shouldtheamefailtoappearwithintwosecondsofthepilota-
me igniting, the control box places the unit in “lock-out” (complete
shutdown of burner with relative warning light).
To “reset” the control box press the appropriate reset button.
!The air pressure switch must be adjusted on igniting the
burner as a function of the pressure value observed for
operationwiththepilotame.

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0006080766
Safety time
in seconds
2.5
Pre-ventilation and
pre-circulation time
in seconds
37.5
Pre-ignition
in seconds
5
Post-ignition
in seconds
2.5
Time between 1st
(pilot) ame and start
of modulation
in seconds
12.5
Control box
and
programmer
LFL 1.335
Cyclic relay
CONTROL BOX CHARACTERISTICS
No. 0002900312
DETAIL OF BURNER WITH ATOMIZER UNIT, MODULATION SERVOMOTOR, RETURN PRESSURE CON-
TROL, AIR WITH LPG OR NATURAL GAS PILOT BURNER
RETURN PRESSURE CONTROL
MIN=10+12bur
MAX=18+20bur
1 FILTER
2 BURNER PUMP (20-22 BAR)
3 PRESSURE GAUGE O-40 BAR
4 ATOMIZER BODY
5 RETURN NOZZLE WITHOUT PIN
6 RODS WITH CLOSING PINS
7 BY PASS HOLES
8 CLOSING SPRINGS
9 OPENING ELECTROMAGNETS
10 RETURNPRESSURECONTROL MIN=10-12BAR
MAX=18-20BAR
11 MODULATION SERVOMOTOR
12 AIR/FUELREGULATIONCONTROLDISK
13 AIR LOCKS
14 FLEXIBLE TUBE
15 IGNITION PILOT
16 MAIN GAS VALVE FOR IGNITION FLAME WITH FLOW CON-
TROL (PILOT FLAME)
CONNECTION TO
POWER SUPPLY CIRCUIT
SEE 0002901120 FOR
ONE OR MORE BUR-
NERS
100 mbar PILOT GAS RAMP INLET
FOR VERSION ...D
THERMOSTAT T R U
17 SAFETY GAS VALVE FOR IGNITION (PILOT) FLAME
18 MINIMUMANDMAXIMUMGASPRESSURESWITCHPILOTRAMP
19 PRESSURE CONTROLWITH BUILT-IN FILTER
20 NOZZLERETURNTHERMOSTATFORFUELOILVERSIONONLY

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N° 0002933990
DETAIL OF FUEL PRESSURE ADJUSTING VALVE
DETAIL OF FUEL PRESSURE ADJUSTING VALVE FOR AUXILIARY CIRCUIT
1 - Valve body
2 - Adjusting screw support plug
3 - Adjusting screw stop nut
4 - Adjusting screw
5 - Spring centering bush
N° 0002932080
6 - Spring
7 - Shutter
8 - Pressure gauge connection
9 - Fuel inlet
10- Fuel outlet
1
2
5
4
3
1 - Valve body
2 - Adjusting screw tap
3 - Pressure gauge (0 ÷ 40 bar)
4 - To the pump return
5-Fromtheatomizinggroupreturn

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0006080766
WIRING DIAGRAM FOR DANDOSS PUMP MODEL KSVB 1000 ÷ 6000 R
N° 0002900430
Return Delivery
CockCock
Pressure gauge
Intake
Pressure regulator screw
DIAGRAM OF A DISMANTLED (CB) CHARLES BERGONZO NOZZLE (WITHOUT PIN)
N°BT9353/1
NozzleID:
Flowrateinkg/h
Spray angle (30° - 45° - 60° - 80°)
Flowratio(1/3=B3-1/5=B5)
Viton O-ring
(oil and temperature reristant)
Air turbulence chamber
Fuel outlet
Fuel return holes
Fuel inlet Fuel return
N.B.Forthenozzletooperateproperly,its“return”sectionmustneverbecompletelyclosed.
Thisisachievedbyregulatingwhentheburnerisstartedupforthersttime.Inpractice,whenthenozzleisoperatingatthemaximumow
rate, the difference in pressure between the “delivery” (pump pressure) and “return” (pressure at hte returnpressure regulator) pressures
(runningtoandfromthenozzle)mustbeatleast2÷3bar.
Example: Pumppressure 20bar Pumppressure 22bar
Returnpressure 20-2=18 Returnpressure 22-3=19bar
20-3=17 22-2=20bar

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IGNITION AND ADJUSTMENT WITH HEAVY OIL
1) Checkthatnozzlecharacteristics(owandsprayangle)are
suitableforthecombustionchamber(seeBT9353);iftheyare
notreplacethenozzlewithonethatissuitable.
2) Check that there is fuel in the tank and that it is, at least on a
visual check, suitable for the burner.
3) Check that there is water in the boiler and that system gate
valves are open.
4) Check with absolute certainty, that combustion products are
abletoescapefreely(boilerdamperandueopen).
5) Check that the voltage on the power line to which you intend
toconnectcorrespondswiththatrequiredbytheburnerand
that all motor and heating element connections are properly
arranged for the available voltage. Check that all electrical
connectionsmadeattheinstallationsitearecarriedoutproperly
as per our wiring diagram.
6) Makesurethatthecombustionheadpenetratesintothecombustion
chambertotheextentrequestedbytheboilermakers.
Checkthattheairadjusterdeviceonthecombustionheadisin
apositionassumedtobesuitableforsupplyoftherelevantfuel
(theairpassagebetweendiskandheadmustbesignicantly
closedwherefuelowisrelativelyreduced;ontheotherhand,
wherenozzleowisratherhigh,theairpassagebetweendisk
andhead mustbe relativelyopen). See the chapter“Adjusting
the combustion head”.
7) Remove the cover from the rotating disk (on the modulation
motor)wherethe adjuster screwsthatcontrol fuelandrelative
combustion air are housed.
8) Turn the two modulation switches in the “MIN” (minimum)
position to “MAN” (manual).
9) Adjust the element control thermostat incorporated in the line
ltertoaround50°C.Adjusttheminimumthermostat“Tmin”in
the preheater thermostats unit to a temperature thought to be
adequate. The temperature to which the minimum ther-
mostat must be adjusted depends on the type of fuel
used. Consult the viscosity-temperature chart, bea-
ring in mind that the fuel must reach the nozzle with
viscosity no greater than 2° E. Heavy oil heating tem-
perature can be modified via the adjuster thermostat
or(whereinstalled) viathe“MS 30” electronicregulator;such
temperature must be around 20° C higher than the setting on
the minimum thermostat.
!
Thespecicinstructionsfortheelectronicregulatoraregiven
on the following pages.
10) Start up the auxiliary fuel feed circuit, check that it is working
efcientlyandadjustpressuretoapproximately1bar.
11) Remove the plug (on the vacuum meter coupling seat) from
the burner pump and then slightly open the gate valve on the
fuel infeed pipe. Wait for the fuel to exit the hole (there should
be no air bubbles) and then re-close the gate valve.
12) Fitapressuregauge(endofscaleapprox.3bar)totheon-pump
vacuum meter coupling seat in order to check the pressure
at which fuel arrives at the burner pump. Apply a pressure
gauge (end of scale approx. 30 bar) to the on-pump pressure
gauge coupling seatin order tocheck the working pressure of
the pump itself. Apply a pressure gauge (end of scale approx.
30 bar) to the return pressure regulator coupling to check the
valuethatdeterminesow(seedrawing.n°0002900311).
13) Turnthemainswitch“Q1”toonandthestart/stopswitch“S1”
to “0” (off) to prevent the elements being switched on with the
tankempty.Makesurethatthefanmotorandpumpmotorturn
the right way. For the pump motor turn the switch “S1” to on
and press the tank loading switch; for the fan motor manually
close contactors “KL” (line) and “KY” (star) simultaneously by
pushing the mobile part of the contactor; do not close “KD”
(triangle).Toinvertthedirectionofrotationexchangetwopower
line wires relative to the motor which turns the wrong way.
IWARNING. Pressing the tank loading button cuts power to
the control boxand the heatingelements on thepreheaters
arethereforeoff.Nevertheless,donot turnonthepreheater
elements with the preheater tank empty.
14) Runtheburnerpumpbypressingthetankllingbuttonuntilthe
gaugethatreadstheworkingpressureofthepumpshowsslight
pressure.Slightpressureinthecircuitconrmsthatpreheater
tankllinghasbeencompleted.
15) Close burner switch “S1” and the main switch. The elements
containedin thefuel preheaters are thusturnedon. Switching
on of the elements is signalled by the relative control panel
indicator lights. The contactor coils on elements “KR1” and
“KR2” are powered via contacts “Y1” and “Y2” of the “MS 30”
electronic temperature regulator (where applicable) or the
regulator thermostat. The burner still does not start because
minimum thermostat consensus is absent (i.e. the fuel in the
preheater is not hot enough).
!
Do not turnon theelements with thetank empty asdoing so
could damage them.
16) The minimum thermostat closes its contact (i.e. comes on)
when the temperature in the preheater reaches its setting
value. Tripping of the minimum thermostat immediately cau-
ses switching on of the burner control box (as long as boiler
safety thermostats/pressure switches are closed).
Withtheburnercontrolboxnowontheburnerignitionsequence
begins.The programmeincludes simultaneous pre-ventilation
and pre-circulation, with low pressure hot oil, throughout the
burnerfuelcircuit.Burnerignitionisasdescribedintheprevious
chapter, “Description of Operation”; the burner is ignited at its
minimum.
!Toadjustthegaspilotameproceedasfollows:
- disconnect the wire from terminal n° 18 of the LFL...
control box to prevent the electromagnet being
switched on.
- disconnect the wire from terminal n° 17 of the LFL...
control box (intermittent pilot) and connect it to
terminal n° 18 (pilot always on).

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0006080766
- ignite the burner, adjust the quantity of gas and air
for the pilot flame and check for proper ignition
several times.
- when adjustment is over restore the original connections.
UV CELL
Detectionof the pilotame is effected by a UVcell: the
following information should be born in mind. Even slight
greasiness will compromise passage of the UV rays through
the UV photocell bulb, thus preventing the sensitive device
insideitreceivingthequantityofradiationneededforcorrect
operation. If the bulb is smeared with light oil, heavy oil,
etc. it must be cleaned thoroughly. Note that even gentle
contactwithngerscanleaveaslightlmofgreasewhich
issufcienttocompromiseproperUVphotocelloperation.
The UV cell does not “see” daylight or the light emitted by a
common bulb. A sensitivity check can be carried out using
aame(lighter,candle)orthesparkgeneratedbetweenthe
electrodesofacommonignitiontransformer.Toensureproper
operationtheUVcellcurrentmustbesufcientlystableand
mustnotdropbelowtheminimumrequiredbythespeciccon-
trol box. It may be necessary to try different positions in order
tondthebestone:dothisbyshifting(axialorrotaryshift)the
bodythatcontainsthephotocellwithrespecttotheattachment
strap. The check is effected by connecting a micro-ammeter
(with suitable scale), in series, to one of the two UV photocell
connectionwires;itis,ofcourse,necessarytoobservepolarity
(+and-).Thecellcurrentneededtoensurepropercontrol
box operation is given on the wiring diagram.
17) When the burner is working at “minimum” adjust the air to
thequantityneeded toensuregoodcombustion.Turnthe
adjuster screws in or out at the point of contact with the lever
that transmits combustion air regulation damper movement.
Thequantityofairat“minimum”shouldbealittlescarceso
as to ensure perfect ignition even under the most demanding
circumstances.
18) After adjusting the air for the “minimum” turn the modulation
switches to position “MAN” and to position “MAX”.
19) Themodulation motorstarts moving: wait forthedisk (on
whichtheadjusterscrewsare tted)to sweepthroughan
angle of about12°(thiscorresponds tothe space takenup by
three screws) and then stop modulation by turning the switch
backtoposition“0”.Runavisualcheckontheameand,if
necessary, regulate combustion air as described in point 17.
Then check combustion using the appropriate instruments
and, if necessary, correct the adjustment previously made
by way of visual check. The above-described operation must
be repeated by proceeding progressively (by advancing the
disk about 12° at a time) and, each time, modifying, where
necessary, the fuel-air ratio throughout the entire modulation
range. It is necessary to make sure that fuel feed progression
occursgraduallyandthatmaximumfuelowoccursatthe
end of the modulation range. This condition is necessary for
attainmentofsmooth,gradualmodulation.Ifnecessarymodify
thepositionofthefuelcontrolscrewstoobtainthatspecied
above. Note that maximum flow is attained when return
pressure is about 2 - 3 bar less than delivery pressure (gene-
rally 20 - 22 bar). A correct air-fuel ratio should give a carbon
dioxide (CO2)valuethatincreasesasfuelowincreases:as
aroughguide,itshouldbeatleast10%atminimumowand
reachanoptimumofabout13%atmaximumow.
ItisinadvisabletoexceedaCO2gureof13%soastoprevent
operationwitharatherlimitedexcessofair,possiblyleadingto
asignicantincreaseinsmokenumberowingtounavoidable
causes (changes in atmospheric pressure, small dust depo-
sits in the fan air ducts etc.). The resulting smoke (i.e. fume)
number is closely linked to the type of fuel used (latest regu-
lations indicate n° 6 on the Bacharach scale as a maximum).
it is advisable, if possible, to keep the smoke number below
n° 6 on the Bacharach scale evenif the CO2value could, asa
consequence,beslightlylower.Reducedopacity(i.e.alower
smokenumber)soilstheboilerlessandtheaverageefciency
of the latter is normally higher even if CO2levels are slightly
lower. Remember that to achieve proper adjustment system
water must be up to normal working temperature and that the
burnermusthavebeenworkingforatleastfteenminutes.In
the absence of proper instrumentation use fume colour as a
guide. We recommend that adjustment be effected so as to
obtainalightorangeame;avoidredameswithsmokeand
whiteameswithanexaggeratedexcessofair.
20) The purpose of the air pressure switch is to place the control
box in lock-out (safety mode) if air pressure is incorrect. The
pressure switchmustbeadjustedsothatittripsbyclosingthe
N.O.(Normally Open)contact when air pressure in the burner
reachesasufcientvalue.Thepressureswitchconnection
circuit features self-control so it is necessary that the N.C.
(Normally Closed) contact (with fan at standstill and therefore
noairpressureinburner)actuallybringsaboutthiscondition.If
itdoes not thecontrolboxisnotswitchedon(theburner stays
off).Moreprecisely,notethatifthecontactdesignedtobeclo-
sed whenworking fails toclose(airpressure toolow)then the
control box goes through its cycle but the ignition transformer
doesnotcomeon,thepilotamegasvalvesstayclosedand
the burner thus shuts down in “lock-out”. To check that the air
pressure switch is working properly it is necessary, with the
burneratminimumowrate to increase the adjustment value
untilittrips:immediateburner“lock-out”mustfollow.Reset
the burner by pressing the appropriate button and adjust the
pressureswitchtoavaluesufcienttodetecttheairpressure
during pre-ventilation.
21) Thegaspressureswitches(minimumandmaximum)aredesig-
nedtostoptheburnerworkingwhengaspressureisoutsidethe
setrange.Giventhespecicfunctionofthepressureswitchesit
isevidentthattheminimumpressurecontrolswitchmustutilise
theclosedcontactwhenthepressureswitchdetectsapressure
higherthanthattowhich it is set. It isalso evidentthatthema-
ximum pressure switchmust utilisethe closed contactwhen it
detectsapressurelowerthanthattowhichitisset.Adjustment
ofminimumand maximum gaspressure switches must there-
fore be effected during burner testing as a function of actual
pressureateachindividualinstallation.Thepressureswitches
areelectricallyconnectedinseries;consequently,ifanyoneof
thepressureswitchestrips(i.e.openingofthecircuit)whenthe
burnerisworking(amelit)theburnershutsdownimmediately.
When testing the burner it is extremely important to check
that pressure switches are working properly. Proper pressure

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switch operation (opening of the circuit) must cause burner
shutdown:thiscanbecheckedforbyactingontherelevant
adjustment devices.
22) Nowcheckthatmodulationworksproperlyinautomaticmode.
Turn the AUT - O - MAN switch to “AUT” and the MIN - O -
MAX switch to “O”. The modulation system is now on and
under the exclusive automatic control of the boiler probe. It is
not normally necessary to act on the internal adjusters of the
“RWF 40” power regulator; however, the relevant instructions
are contained in the pamphlet.
23) Checkthatpreheaterthermostatsarenotadjustedinsuchaway
asto cause anomalies (poor ignition, smoke,formation of gas
in the preheater etc.). Note that good atomisation can only be
obtainedwhentheheavyoilarrivesatthenozzlewithviscosity
no greater than 2° E. Therefore adjust the “MS 30” electronic
regulatororregulationthermostataccordingly.Fortheminimum
thermostatweadviseatemperaturesettingapproximately20°
C lower than the “MS 30” electronic regulator setting.
As a guideline consult the viscosity-temperature chart for the
type of oil used.
N° 0002933930
BURNER GI 1000 DSPN-D GAS PILOT
ADJUSTMENT PRINCIPLE DIAGRAM
During the pre-purge stage the air and gas supply regulating ser-
vomotor provides the maximum aperture, so that pre-purge, takes
place with the maximum aperture for air intake.
Fromthe above, thetotalpre-ventilation time is provided by:
airshutteropeningtime+pre-purgetime+timeforreturnofair
shutter to minimum position .
Ifsufcientpressureisdetectedbytheventilationairpressurestat,
theignitiontransformerwillcutinattheendoftheventilationphase
andlaterthepilotamevalveswillopen.Thegaswillnowreachthe
combustion head, mix with the air delivered by the fan, and ignite.
Gasthroughputisregulatedbytheowregulatorincorporatedinone
ofthetwopilotamevalves.Theignitiontransformerdisconnects
afterthepilotamevalvesopen.Attheendofthissequenceof
events the burner will be running on pilot only.
PilotamepresenceismonitoredbytheUVphotocell.
At this point the programmer relay resets lockout position and
supplies power to the main valves causing them to open. The gas
passestroughthemainvalvesandowsoutofthecombustion
headinthequantitypermittedbythe“minimum”settingoftheow
regulatorvalve.Themainameoftheburnerisnowignitedatthemi-
nimumsetting.Thepilotcircuitcutsout afterthemainvalvesopen.
Themodulatorservo-motorcutsin afterthemainvalvesopen,and
onaconsentsignalfromthemodulatingthermostatorpressurestat
(assuming they are set a temperature or pressure value in excess
of the temperature or pressure in the boiler), the servo-motor will
start turning to provide agradual increase in thesupply ofgas and
combustionairuntilthemaximumratedowatwhichtheburner
has been set is obtained.
!Gas distribution is not determined by the main valve but by
the position of the gas distribution adjustment valve (see
drawing 0002933530).
Theburnercontinuestooperateundermaximumowconditions
untiltemperatureorpressurereachalevelthatissufcienttocause
oneofthemodulationdetectorstocutin; atthispointthemodulator
servo-motor will turn ina reverse direction. Reverse rotation of the
servo-motor,andconsequentlyreductioninthroughputofgasand
combustion air, is effected in a series of short steps.
By this method, the modulation system operates towards bringing
into line the amount of heat supplied to the boiler and the heat that
the boiler puts out to the service.
Duringoperationoftheburner,themodulatingdetectormountedon
theboilerdetectsvariationsinthedemandandautomaticallyadjusts
the supply of fuel and combustion air by causing the modulating
servo-motor to turn in increase or decrease direction. If even at
minimumthroughput thethresholdvalue(temperatureorpressure)
setting of the shut down device is reached, the shut down device
will operate and the burner will turn off.
When the temperature or pressure drops below the shut down
device intervention threshold, the burner will cut in once again,
followingthesequenceofeventsdescribedabove.Ifaameis
notdetectedwithinthesafetitime,thecontrolequipmentgoesinto
“lockout” mode(complete shutdown ofthe burner andillumination
ofthelockoutindicatorlight).Toreleasethelockoutcondition,press
the reset button.
DESCRIPTION OF OPERATIONS WITH METHANE
GAS (SEE N° 0002910771)
Thethroughputratevariationrangeavailableisapproximatelyfrom
1to1/5inrespecttothemaximumthroughputrateoftheappliance.
Theburnerisequippedwithalimitmicroswitchwhichinhibitsstart-
upiftheowregulatorisnotsettominimum.
Inaccordancewithsafetystandards,burnerignitionisprecededby
a pre-purge stage of the combustion chamber.

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0006080766
N°0002933530
BASIC DIAGRAM OF GAS TRAIN
DETAIL OF BUTTERFLY VALVE DAMPER REGULATING GAS FLOW FOR GI 1000
SERIES BURNERS
1- Indicatorpositionofthegasbutteryvalve
2- Gasbutteryvalve
3 - The slot on the end of the shaft indicates the position of the
butteryvalve(damper)
4 - Gas valve minimum position micro-switch control cam
5 - Micro-switch
No. 0002910771
1 MODULATION SERVOMOTOR
2 DISCWITHSCREWSFORCONTROLLINGAIR/GASSUPPLY
3 VALVE SEAL CONTROLDEVICEAND PRESSURE SWITCH
(LDU)
4 MAIN GAS FLAME VALVE
5 MINIMUM GAS PRESSURE SWITCHAND MAXIMUM PILOT
RAMP
6 GAS SUPPLY MODULATING CONTROL BUTTERFLY VALVE
7 GAS PRESSURE CONTROLWITH BUILT-IN FILTER
8 VIBRATION-PROOF JOINT
9 BALLCOCK
10 GAS FILTER
11 DISC WITHADJUSTMENT SCREWS FOR OPENINGAND
CLOSINGAIR SUPPLY TO HEAD
12 FLAME SAFETY GAS IGNITION (PILOT) VALVE
13 OPERATING GAS VALVE WITH PRESSURE CONTROL
14 SAFETY GAS VALVE
15 MAIN GAS VALVE FOR IGNITION FLAME (PILOT FLAME)
WITH FLOW CONTROL
16 AIR PRESSURE SWITCH
17 MAXIMUM MAIN RAMP GAS PRESSURE SWITCH
LIMITS ON BALTUR
SUPPLY
LIMITS ON BALTUR
SUPPLY

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STARTING UP AND REGULATION WITH METHA-
NE GAS
1) If not already done at the moment of connecting the burner to
thegaspipeline,itisindispensabletocarryoutapurgeoftheair
containedinthepipeline.Asaprecaution,specialcareshouldbe
takenanddoorsandwindowsshouldbeopened.Openthepipe
union on the pipeline situated near the burner and then open
a little the gas cut-off cock (or cocks). When the characteristic
odour of gas can be smelled, close the cut-off cock. Wait until
thegaspresentintheroomhasdispersed,andthenreconnect
theburnertothegaspipeline.Subsequently,re-openthegas
cut-off cock.
2) Check that there is water in the boiler and that the system’s
gate valves are open.
3) Check,withabsolutecertaintythatthedischargeofcombustion
products can take place freely (boiler and chimney lock-gates
should be open).
4) Makesurethatthevoltageoftheelectriclinetowhichtheburner
istobeconnected,correspondstothatrequiredbytheburner
andthattheelectricalconnections(motororprincipleline)have
beenpreparedtomatchthevoltageratingavailable.Alsocheck
thatall the electrical connections carriedout on thespot arein
accordance with our electric wiring diagram.
5) Make sure that the combustion head is long enough to enter
thefurnacetotheextentspeciedbytheboilermanufacturer.
6) Removetheprotectioncover from the disk carrying theairand
gasowregulatorscrewsandslackenthescrewsthatblock
the regulator screws.
7) Checkthattheairregulatordeviceonthecombustionheadisin
correctpositionforthefuelthroughputrequired(theairpassage
between the diffusor disk and the head must be small for low
throughputandrelativelywidewhenthroughputishigher).See
“Combustionheadairowregulation”heading.
8) Fitapressuregaugewithsuitablefullscale(wherethepressure
levelenvisagedallows,aliquidmanometerispreferable;donot
use pointer gauges for low pressures) to the pressure outlet
port on the gas pressurestat.
9) Open,asfarasconsiderednecessary,theowregulator
incorporatedinthepilotamevalve(s).Alsocheckthatthe
combustionairowcontrolshutterissufcientlyopen;ifneces-
sary,alterthe positionbyactingonthe regulatorscrewsonthe
regulator disk.
10) With the burner panel switch on “O” and the master switch in
‘make’, that the fan motor rotates in the correct direction. If
necessary, reverse two phases of the motor power supply line
to change the direction.
11) Now switch the panel switch to “I” and turn the modulation
switches to MIN (minimum) and MAN (manual). With the
control system receiving electrical power, the programmer
will cause the burner to start up as described under the
foregoing heading “Description of natural gas operation”.
During pre-purge time, check for operation of the air pressu-
restat, the contacts of which should change from a pressure-
zero‘make’toapressure-positive‘make’.Intheeventthatthe
pressureissufcientandthepressurestatfailstorespond,
neithertheignitiontransformernorthepilotamegasvalves
will operate so the burner will shut down in lockout.
Notethatlockoutsduringthisrstignitionsequenceshouldbe
considerednormal sincethefuelsupplylinewillstill containair
whichmustbepurgedbeforeastableamecanbeobtained.
Press the “reset” button to re-start.
UV Cell
If flame detection is carried out with the UV cell,
the following should be taken into consideration.
Even the slightest greasiness will compromise the passage
of the ultraviolet rays through the UV photoelectric cell bulb,
thus preventing the sensitive internal element from receiving
thequantityofradiationnecessaryforittofunctionproperly.
Should the bulb be fouled by light oil, fuel oil, etc., it is in-
dispensable to clean it thoroughly. It should be pointed out
thatevenbysimplytouchingthebulbwiththengers, itis
possible to leave a slight greasiness which could compromise
the working of the UV photoelectric cell. The UV cell does
not “see” daylight or light from an ordinary lamp. It is pos-
sibletoverifyitssensibilitywithaame(orcigarettelighter
or a candle) or with the electric spark that occurs between
electrodes in an ordinary ignition transformer.
To ensure that the UV cell works properly, its current value
shouldbesufcientlystablesoasnottofallbelowtheminimum
valuerequiredforthespeciccontrolbox.Itmaybenecessary
tosearchexperimentallyforthebestpositionbysliding (axialor
rotationmovement)thebodythatcontainsthephotoelectriccell
inrespecttothefasteningclamp.Aninspectioncanbecarried
outbyinsertingamicroammeter,withanadequatescale,in
seriestooneofthetwoUVphotoelectriccellconnectionwires.
Itisobviouslynecessarytorespectthepolarity(+e-).The
minimum cell current value,to ensure the correct operation of
the control box, is shiwn on the wirung diagram.
12) Assoonastheburnerisignitedatlowame(mainamevalve
open and modulator on minimum) make a visual inspection
of thestrengthand appearanceofthe ame, making any
correctionsrequired(adjustthegasorairregulatorscrewson
the modulating disk). The next step is to take a meter reading
of the volume of gas put through the burner (see the “Meter
Reading” section). If necessary, a further correction in the
gasowmaybemadeasdescribedabove.Oncefueland
airowaresatisfactorilyregulated,acheckmustbemadeon
combustioncharacteristics,usingtheappropriateinstruments.
Iftheair/gasratioiscorrectthelevelofcarbondioxide(CO2)
per unit of fuel put through should be approximately - in the
case of natural gas - 8% at minimum burner output, rising to
an optimum 10% at maximum output. We recommend that
the value of 10% should not be exceeded, as operation in too
limited an excess of air can give rise to unacceptable carbon
monoxide (CO) levels (due to variations in atmospheric pres-
sure, or dust deposits in the air lines). It is essential to verify,
using the appropriate instrument, that the percentage of CO
inuegasesdoesnotexceedthemaximumpermissiblelevel
of 0,1%.