Unigas IDEA Series User manual

IDEA RANGE
LIGHT OIL BURNERS
LO280
LO400
®
Documentazione Tecnica CIB UNIGAS spa - Campodarsego (Padova - Italy)
M039134CB Rev. 1 12-06
Compying with
EMC 79/336/CEE
LV 73/23/CEE

2
TABLE OF CONTENTS
WARNINGS ...................................................................................................................................................... 3
PART I: INSTALLATION................................................................................................................................. 5
BURNERS CHARACTERISTICS .........................................................................................................................................5
Burner model identification................................................................................................................................................... 5
Technical Specifications .......................................................................................................................................................5
Overall dimensions (mm) .....................................................................................................................................................6
Performance curves ............................................................................................................................................................7
How to modify blast tube length (mod. LO400) ....................................................................................................................8
MOUNTING AND CONNECTIONS ....................................................................................................................................10
Fitting the burner to the boiler ............................................................................................................................................10
LIGHT OIL PIPING INSTALLATION DIAGRAM ................................................................................................................ 12
Pump operating principle ....................................................................................................................................................13
about the use of fuel pumps ...............................................................................................................................................14
Mounting of flexible light oil hoses...................................................................................................................................... 14
SETTING LO280 ................................................................................................................................................................15
Oil rate adjustment - Single stage burners .........................................................................................................................15
Priming the pump ...............................................................................................................................................................15
Choosing oil nozzles ..........................................................................................................................................................15
Oil rate adjustment - High-low flame burners .....................................................................................................................16
Priming the pump ...............................................................................................................................................................16
mod. LO280 Air rate setting ...............................................................................................................................................17
MOD. LO400 SETTINGS ...................................................................................................................................................18
Priming the pump ...............................................................................................................................................................18
Fuel rate adjustment ...........................................................................................................................................................18
Choosing the light oil nozzles .............................................................................................................................................18
First start and air rate setting (MOD. LO400) ..................................................................................................................... 20
SERVOCONTROL CAMS SETTING - Adjustment of cams microswitches .......................................................................21
LIGHT OIL PUMPS ............................................................................................................................................................ 22
mod. LO280 Pumps ...........................................................................................................................................................22
Pumps for mod. LO400 ......................................................................................................................................................23
ADJUSTING THE COMBUSTION HEAD .......................................................................................................................... 23
PART II: OPERATION................................................................................................................................... 24
OPERATION ...................................................................................................................................................................... 25
Single-stage burners ..........................................................................................................................................................25
Double-stage burners......................................................................................................................................................... 25
Burner’s control panel .......................................................................................................................................................25
PART III: MAINTENANCE............................................................................................................................. 26
ROUTINE OPERATIONS................................................................................................................................................... 26
Removing the combustion head .........................................................................................................................................26
Removing burner components plate .................................................................................................................................. 28
Assembling burner components plate ................................................................................................................................28
Removing the electrodes ....................................................................................................................................................29
DISASSEMBLY OF THE NOZZLE mod. LO280 ............................................................................................................... 29
Removing the nozzles LO400 ............................................................................................................................................30
Correct position of electrodes and combustion head .........................................................................................................31
Check the detection current ...............................................................................................................................................31
TROUBLESHOOTING ....................................................................................................................................................... 32
WIRING DIAGRAMS.......................................................................................................................................................... 33
SPARE PARTS ..................................................................................................................................................................41
APPENDIX..................................................................................................................................................... 43

WARNINGS3
WARNINGS
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED
TO THE USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING
PRODUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SEC-
TION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.
1) GENERAL INTRODUCTION
zThe equipment must be installed in compliance with the
regulations in force, following the manufacturer’s instruc-
tions, by qualified personnel.
zQualified personnel means those having technical knowle-
dge in the field of components for civil or industrial heating
systems, sanitary hot water generation and particularly ser-
vice centres authorised by the manufacturer.
zImproper installation may cause injury to people and ani-
mals, or damage to property, for which the manufacturer
cannot be held liable.
zRemove all packaging material and inspect the equipment
for integrity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devi-
ces, plastic bags, foamed polystyrene, etc), should not be left
within the reach of children, as they may prove harmful.
zBefore any cleaning or servicing operation, disconnect the
unit from the mains by turning the master switch OFF, and/
or through the cut-out devices that are provided.
zMake sure that inlet or exhaust grilles are unobstructed.
zIn case of breakdown and/or defective unit operation,
disconnect the unit. Make no attempt to repair the unit or
take any direct action.
Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly
authorised by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair
the unit’s safety.
To ensure equipment efficiency and proper operation, it is
essential that maintenance operations are performed by quali-
fied personnel at regular intervals, following the manufactu-
rer’s instructions.
zWhen a decision is made to discontinue the use of the
equipment, those parts likely to constitute sources of dan-
ger shall be made harmless.
zIn case the equipment is to be sold or transferred to
another user, or in case the original user should move and
leave the unit behind, make sure that these instructions
accompany the equipment at all times so that they can be
consulted by the new owner and/or the installer.
zFor all the units that have been modified or have options fit-
ted then original accessory equipment only shall be used.
zThis unit shall be employed exclusively for the use for
which it is meant. Any other use shall be considered as
improper and, therefore, dangerous.
The manufacturer shall not be held liable, by agreement or
otherwise, for damages resulting from improper installation,
use and failure to comply with the instructions supplied by the
manufacturer.
2) SPECIAL INSTRUCTIONS FOR BURNERS
zThe burner should be installed in a suitable room, with ven-
tilation openings complying with the requirements of the
regulations in force, and sufficient for good combustion.
zOnly burners designed according to the regulations in force
should be used.
zThis burner should be employed exclusively for the use for
which it was designed.
zBefore connecting the burner, make sure that the unit
rating is the same as delivery mains (electricity, gas oil, or
other fuel).
zObserve caution with hot burner components. These are,
usually, near to the flame and the fuel pre-heating system,
they become hot during the unit operation and will remain
hot for some time after the burner has stopped.
When the decision is made to discontinue the use of the bur-
ner, the user shall have qualified personnel carry out the fol-
lowing operations:
a) Remove the power supply by disconnecting the power cord
from the mains.
b) Disconnect the fuel supply by means of the hand-operated
shut-off valve and remove the control handwheels from
their spindles.
Special warnings
zMake sure that the burner has, on installation, been firmly
secured to the appliance, so that the flame is generated
inside the appliance firebox.
zBefore the burner is started and, thereafter, at least once a
year, have qualified personnel perform the following opera-
tions:
a) set the burner fuel flow rate depending on the heat input of
the appliance;
b) set the flow rate of the combustion-supporting air to obtain
a combustion efficiency level at least equal to the lower
level required by the regulations in force;
c) check the unit operation for proper combustion, to avoid
any harmful or polluting unburnt gases in excess of the
limits permitted by the regulations in force;
d) make sure that control and safety devices are operating
properly;
e) make sure that exhaust ducts intended to discharge the
products of combustion are operating properly;
f) on completion of setting and adjustment operations, make
sure that all mechanical locking devices of controls have
been duly tightened;
g) make sure that a copy of the burner use and maintenance
instructions is available in the boiler room.
zIn case of repeated burner shut-downs, do not continue re-
setting the unit manually. Contact qualified personnel to
take care of such defects.
zThe unit shall be operated and serviced by qualified per-
sonnel only, in compliance with the regulations in force.

WARNINGS 4
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL
USED
3a) ELECTRICAL CONNECTION
zFor safety reasons the unit must be efficiently earthed and
installed as required by current safety regulations.
zIt is vital that all saftey requirements are met. In case of any
doubt, ask for an accurate inspection of electrics by quali-
fied personnel, since the manufacturer cannot be held lia-
ble for damages that may be caused by failure to correctly
earth the equipment.
zQualified personnel must inspect the system to make sure
that it is adequate to take the maximum power used by the
equipment shown on the equipment rating plate. In particu-
lar, make sure that the system cable cross section is ade-
quate for the power absorbed by the unit.
zNo adaptors, multiple outlet sockets and/or extension
cables are permitted to connect the unit to the electric
mains.
zAn omnipolar switch shall be provided for connection to
mains, as required by the current safety regulations.
zThe use of any power-operated component implies obser-
vance of a few basic rules, for example:
◆do not touch the unit with wet or damp parts of the body
and/or with bare feet;
◆do not pull electric cables;
◆do not leave the equipment exposed to weather (rain,
sun, etc.) unless expressly required to do so;
◆do not allow children or inexperienced persons to use
equipment;
zThe unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact
qualified personnel to replace.
When the unit is out of use for some time the electric switch
supplying all the power-driven components in the system (i.e.
pumps, burner, etc.) should be switched off.
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
zThe burner shall be installed by qualified personnel and in
compliance with regulations and provisions in force; wrong
installation can cause injuries to people and animals, or
damage to property, for which the manufacturer cannot be
held liable.
zBefore installation, it is recommended that all the fuel sup-
ply system pipes be carefully cleaned inside, to remove
foreign matter that might impair the burner operation.
zBefore the burner is commissioned, qualified personnel
should inspect the following:
a) the fuel supply system, for proper sealing;
b) the fuel flow rate, to make sure that it has been set based
on the firing rate required of the burner;
c) the burner firing system, to make sure that it is supplied for
the designed fuel type;
d) the fuel supply pressure, to make sure that it is included in
the range shown on the rating plate;
e) the fuel supply system, to make sure that the system
dimensions are adequate to the burner firing rate, and that
the system is equipped with all the safety and control devi-
ces required by the regulations in force.
zWhen the burner is to remain idle for some time, the fuel
supply tap or taps should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
Have qualified personnel inspect the installation to ensure
that:
a) the gas delivery line and train are in compliance with the
regulations and provisions in force;
b) all gas connections are tight;
c) the boiler room ventilation openings are such that they
ensure the air supply flow required by the current regula-
tions, and in any case are sufficient for proper combustion.
zDo not use gas pipes to earth electrical equipment.
zNever leave the burner connected when not in use. Always
shut the gas valve off.
zIn case of prolonged absence of the user, the main gas
delivery valve to the burner should be shut off.
Precautions if you can smell gas
a) do not operate electric switches, the telephone, or any
other item likely to generate sparks;
b) immediately open doors and windows to create an air flow
to purge the room;
c) close the gas valves;
d) contact qualified personnel.
zDo not obstruct the ventilation openings of the room where
gas appliances are installed, to avoid dangerous conditions
such as the development of toxic or explosive mixtures.

PART I: INSTALLATION 5
BURNERS CHARACTERISTICS
Technical Specifications
WARNING: if fuel used is BIODIESEL, some components must be replaced. Please contact our Technical Depart-
ment for further details.
BURNERS LO280
G-.TN.x.xx.A
LO280
G-.AB.x.xx.A
Output min. - max. kW 115 - 310 70 - 310
Light oil rate min.- max. kg/h - 9.6 - 26 5.8 - 26
Fuel Light oil Light oil
Power supply 230V 50Hz
Electric motor kW 0.25 0.25
Total power consumption W 0.55 0.55
Weight kg 42 42
Operation Single stage éDouble stage
Operating temperature °C -10 ÷ +50
Storage Temperature °C -20 ÷ +60
Working service* Intermittent
BURNERS LO400
G-.TN.x.xx.A
LO400
G-.AB.x.xx.A
Output min.-max.kW 195 - 420 115 - 420
Light oil rate min. - max. kg/h 16 - 35 10 - 35
Fuel Light oil Light oil
Power supply 230V 50Hz
Electric motor kW 0.37 0.37
Total power consumption W 0.67 0.67
Weight Kg 42 42
Operation Single stage éDouble stage
Operating temperature °C -10 ÷ +50
Storage Temperature °C -20 ÷ +60
Working service* Intermittent
*NOTE ON THE BURNER WORKING SERVICE: for safety reasons, one controlled shutdown must take place every 24
hours.
PART I: INSTALLATION
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follow.
Type LO400 Model G-. TN. S. *. A.
(1) (2) (3) (4) (5) (6)
(1) BURNER TYPE LO280- LO400
(2) FUEL G - Light oil
A - Biodiesell
(3) OPERATION Available versions TN - Single stage
AB - Double stage
(4) BLAST TUBE M - Modular
S - Standard
L - Long
(5) DESTINATION COUNTRY * - destination country (see data plate)
(6) BURNER VERSION A - Standard
Y - Special
M -Hydraulic jack

PART I: INSTALLATION6
OVERALL DIMENSIONS (mm) *S = standard blast tube *L = long blast tube .As far as modifying the blast tube for mod. LO400, see page 8.
Fig. 4 Fig. 5: Boiler’s drilling plate and burner’s flange
AS* AL* BS* BL* C F G H K1 K2 L M N Omin Omax P X Y
LO280 732.5 877.5 162.5 307.5 570 396 108 128 215 223 348 M10 219 131 179 155 492 108 LO400 748 877.5 178 307.5 570 396 125 164 215 223 348 M10 219 131 179 155 491 144
X
F
C
T
B
A
L
G
O
Y
P
H
P
N
O max.
O min.
Omin.
Omax.
K2
K1
M

PART I: INSTALLATION 7
Performance curves
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar
LO280 Single stage
kW
LO280 High-Low flame
kW
Fig. 6 Fig. 7
BACK PRESSURE IN
CCOMBUSTION CHAMBER mbar
LO400 Single stage
kW
LO400 High-Low flame
kW
Fig. 8 Fig. 9
0
1
2
3
4
5
6
100 150 200 250 300 350 0
1
2
3
4
5
6
50 100 150 200 250 300 350
-1
0
1
2
3
4
5
6
7
8
150 200 250 300 350 400 450
-1
0
1
2
3
4
5
6
7
8
9
100 150 200 250 300 350 400 450

PART I: INSTALLATION8
How to modify blast tube length (mod. LO400)
To modify blast tube length please read the following instructions.
1 Remove combustion head (See “Removing the combustion head” - Part III of this user’s manual).
2 Remove the flanged piece T by removing the 4 socket head screws VTF (Fig. 10).
3 Remove the 4 screws which hold the blast tube to the flanged piece (Fig. 2).
4 Extract the blast tube from the flanged piece and assemble it in the other way round as shown in pictures Fig. 12 and Fig.
13. Now fasten the two pieces using the same screws (Fig. 14).
5 Assemble the whole piece to the burner by caring attention to the indication in picture Fig. 15.
Fig. 10 Fig. 11
Fig. 12 - Short blast tube Fig. 13 - Long blast tube
Fig. 14 Fig. 15
T
VTF

PART I: INSTALLATION 9
If you modify the blast tube length you have to modify also the combustion head length by reading the following instructions:
1 Loosen the light oil feeding pipes connected to the nozzle-holder by using two spanners size 22 and 10 (Fig. 16).
2 Adjust cables length by pulling them very slightly as shown in Fig. 17.
3 Loosen the screw VA which tights the rod A (Fig. 18) and shift backward the flange as shown.
4 Tight the screw in the backward hole on the rod, see picture Fig. 19.
5 Fix the two extensions (supplied along with the burner inside the accessories carton box) on the light oil feeding pipes (Fig.
20) and tight them by using two spanners size 13 and 10 (Fig. 21). Fix the extensions to the nozzle holder by using two
spanners size 22 and 10 (Fig. 16).
6 Assemble again the combustion head (See “Removing the combustion head” - Part III of this user’s manual).
Fig. 16 Fig. 17
Fig. 18 Fig. 19 Fig. 20
Fig. 21
10
22
VA
A
10
13

PART I: INSTALLATION10
MOUNTING AND CONNECTIONS
Packing
The burners are despatched in packages of dimensions 795 x 550 x 490 mm (W x H x D).
Packing cases of this kind are affected by humidity; the maximum number of cases to be stacked is indicated outside the
packing .
The following are placed in each packing case:
1 burner;
2 light oil flexible hoses;
1 light oil filter;
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual.
To get rid of the burner’s packing and in the event of scrapping of the latter, follow the procedures laid down by current laws on
disposal of materials.
ATTENZIONE: LEGGERE SCRUPOLOSAMENTE LE AVVERTENZE RIPORTATE ALL’INIZIO DEL MANUALE.
Fitting the burner to the boiler
To perform the installation, proceed as follows:
1 fix 4 holes on the boiler’s door, according to the burner’s drilling plate described on
paragraph “Overall dimensions”;
2 place the gasket on the burner’s flange;
3 install the burner into the boiler;
4 fix the burner to the stud bolt, by means of the fixing nuts, according to Fig. 22.
5 After fitting the burner to the boiler, ensure that the gap between the blast tube and
the refractory lining is sealed with appropriate insulating material (ceramic fibre
cord or refractory cement).
Key
1Burner
2 Fixing nut
3 Washer
4 Sealing gasket
5 Stud bolt
7Blasttube
Fig. 22

PART I: INSTALLATION 11
ELECTRICAL WIRING
ATTENTION: PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER, AT THE BEGINNIG OF THIS MANUAL.
Identification of linking connectors
Make the electric connections following the diagrams below.
HIGH/LOW flame connector
(CONN-TAB, ) - mod. LO400
Fig. 23
Burner power supply connector
(CONN-LINEA, Fig. 24, )
Fig. 24
IMPORTANT: before operating the burner, be sure all connectors are linked as indicated in the diagrams.
WARNING: the burner is fitted with a bridge between terminals T6 and T8 on CN2-TAB connector
(external side link, male connector); remove this bridge before thermostat connection.
Fig. 25: Single stage burners Fig. 26: High - Low flame burners
Key
C1-C2 Time counter
CONN-LINEAConnectors on electrical board
CONN-TABConnectors on electrical board
F1-F3 Fuses
IL Line switch for burner’s auxiliaries
IM Fan motor line switch
L Phase
LAF Burner in high flame signalling lamp (high-low flame and progressive versions only)
LB Burner lockout signalling lamp
LBF Burner in low flame signalling lamp (high-low flame and progressive versions only)
N Neutral
ST Thermostats or pressure switches group
TAB High-Low flame thermostat
TS Boiler safety thermostat

PART I: INSTALLATION12
LIGHT OIL PIPING INSTALLATION DIAGRAM
PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIGN OF THIS MANUAL
Fig. 27
Key
1Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
6 Gate valve
7 Quick-closing gate-valve (not in vicinity of tank or boiler)
(*) Only for installations with gravity, siphon or for-
ced circulation feed systems. If the device installed
is a solenoid valve, a timer must be installed to
delay the valve closing.
The direct connection of the device without a timer
may cause pump breaks.
From tank
To tank

PART I: INSTALLATION 13
Pump operating principle
In the burners, the mixture bertween oil and air, to perform a clean and efficient combustion, is activated by atomization of oil
into very small particles. This process is achieved making oil passing through the nozzle at a determined pressure
The pump’s main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure. To adjust this pres-
sure, pumps are provided with a pressure regulator (except for some models for which a separate regulating valve si provided).
Other pumps are provided with two pressure regulators: one for the high and one for low pressure (in tow-stage systems with
one nozzle).
These pumps can be installed both into single-pipe and double-pipe systems.
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is
driven to the nozzle: a part comes out from the nozzle while the othe part goes back to the pump. In this system, the by-pass
pulg, if provided, must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another
pipe that connects the pum’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be con-
sidered self-bleeding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners come out from the factory provided for double-stage systems. They can be suited for single-pipe system (recommen-
ded in the case of gravity feed) as decribed before.
Bleed
Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the plug of a pres-
sure gauge port must be loosened until the air is evacuated from the system.
As far as the pipes installation, refer to the following values, considering as well, the plant’s needs.
Syphon twin pipe feed Twin pipe suction feed
Fig. 28 Fig. 29
SUNTEC AL65 - AS47 - AT2 45 SUNTEC AL65 - AS47 - AT2 45
H (m) L (m) H (m) L (m)
ø6 ø8 ø10 ø12 ø6 ø8 ø10 ø12
0 14 49 123 150 0 14 49 123 150
0,5 16 55 136 150 0,5 12 44 110 150
1 18 61 150 150 1 10 38 96 150
2 22 73 150 150 2 7 26 66 140
3 2585150150 3 3 131375
4 29 96 150 150 4 0 1 1 15

PART I: INSTALLATION14
about the use of fuel pumps
zMake sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and
damage to the pump and burner motor could result.
zDo not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear
teeth, thus obstructing them.
zAfter filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of
the tank, thus avoiding the possibility that they might be sucked into the pump.
zOn initial commissioning a "dry" operation is foreseen for a considerable length of time (for example, when there is a long
suction line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet.
zCare must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear
on the joint, noise and overloading the gears.
zPipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal
junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The num-
ber of junctions should be kept to a minimum as they are a possible source of leakage.
zDo not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These
could deposit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or alumi-
nium gaskets) junctions if possible.
zFilter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit. To remove the filter,
unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted with the feet toward the pump
body. If the gasket between cover and pump housing should be damaged, it must be replaced. An external filter should
always be installed in the suction line upstream of the fuel unit.
Mounting of flexible light oil hoses
To connect the flexible hoses to the pump, proceed as follows.
1 Remove burner’s cover.
2 Remove the light oil pump delivery and return line plugs.
3 Screw the rotating nut D of the two flexible hoses F on the pump being careful to avoid inverting the delivery and return lines.
4 Fix the flexible hoses as shoewed on Fig. 33
Fig. 33
5 Replace burner’s cover.
WARNING: if fuel used is BIODIESEL, some components must be replaced. Please contact our Technical Depart-
ment for further details.
Fig. 30
mod. LO280
Fig. 31
mod. LO400
Fig. 32
ABDD
F
F

PART I: INSTALLATION 15
SETTINGS LO280
Oil rate adjustment - Single stage burners
Priming the pump
Before carrying out the adjustment it is necessary to start up the fuel pump, proceeding as follows:
Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
Start the burner, light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port.
The fuel flow rate is set choosing a properly dimensioned nozzle and setting the inlet pressure on the pump (see the hydraulic
diagram in Fig. 34
To choose the correct nozzle refer to table Tab. 1; for setting of the pump pressure, see pag. 23.
Choosing oil nozzles
Tab. 1 - Choice of the oil nozzle - Single stage burners
Note: all pumps are set to 12 bar. The nozzle rate must be higher than the rate referred to the minimum burner
output.
Key
EVG Light oil solenoid valve
M Manometer
P Pump (see chapter “LIGHT OIL PUMPS”)
Fig. 34
NOZZLE PUMP PRESSURE (bar)
67891011121314
G.P.H. kg/h
1,35 3,97 4,29 4,59 4,86 5,13 5,38 5,62 5,85 6,07
1,50 4,41 4,77 5,10 5,41 5,70 5,98 6,24 6,50 6,74
1,65 4,85 5,24 5,61 5,95 6,27 6,57 6,87 7,15 7,42
1,75 5,15 5,56 5,95 6,31 6,65 6,97 7,28 7,58 7,87
2,00 5,88 6,36 6,80 7,21 7,60 7,97 8,32 8,66 8,99
2,25 6,62 7,15 7,64 8,11 8,55 8,96 9,36 9,74 10,11
2,50 7,36 7,95 8,49 9,01 9,50 9,96 10,40 10,83 11,24
3,00 8,83 9,53 10,19 10,81 11,40 11,95 12,48 12,99 13,48
3,50 10,30 11,12 11,89 12,61 13,29 13,94 14,56 15,16 15,73
4,00 11,77 12,71 13,59 14,41 15,19 15,94 16,64 17,32 17,98
4,50 13,24 14,30 15,29 16,22 17,09 17,93 18,72 19,49 20,23
5,00 14,71 15,89 16,99 18,02 18,99 19,92 20,81 21,65 22,47
5,50 16,18 17,48 18,69 19,82 20,89 21,91 22,89 23,82 24,72
6,00 17,65 19,07 20,39 21,62 22,79 23,90 24,97 25,99 26,97
6,50 19,13 20,66 22,08 23,42 24,69 25,90 27,05 28,15 29,21
EVG
MP

PART I: INSTALLATION16
Oil rate adjustment - High-low flame burners
Priming the pump
Before carrying out the adjustment it is necessary to start up the fuel pump, proceeding as follows:
Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
Start the burner, light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port.
The light oil flow rate is adjusted choosing a nozzle of proper dimensions and setting the inlet pump pressure.
To choose the nozzle refer to the table below.
Setting the light oil pump
Adjust the ignition stage of the pump, to a pressure value of 8 - 10 bar. After 10”, the safety device switch to the second stage.
The pump setting must be fixed to 24 bar, by means of the adjusting screw (see chapter “LIGHT OIL PUMPS”).
NOTE: The nozzle oil rate at a pressure of 8 bar, must be greather than the oil rate at the minimum output.
Tab. 2 - Choice of the oil nozzle - High-low flame burners
NOZZLE PUMP PRESSURE (bar)
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
G.P.H. kg/h
0,40 1,36 1,44 1,52 1,59 1,66 1,73 1,80 1,86 1,92 1,98 2,04 2,09 2,15 2,20 2,25 2,30 2,35 2,40
0,50 1,70 1,80 1,90 1,99 2,08 2,17 2,25 2,33 2,40 2,48 2,55 2,62 2,69 2,75 2,82 2,88 2,94 3,00
0,60 2,04 2,16 2,28 2,39 2,50 2,60 2,70 2,79 2,88 2,97 3,06 3,14 3,22 3,30 3,38 3,46 3,53 3,60
0,65 2,21 2,34 2,47 2,59 2,70 2,82 2,92 3,02 3,12 3,22 3,31 3,40 3,49 3,58 3,66 3,74 3,83 3,90
0,75 2,55 2,70 2,85 2,99 3,12 3,25 3,37 3,49 3,60 3,71 3,82 3,93 4,03 4,13 4,23 4,32 4,41 4,50
0,85 2,89 3,06 3,23 3,39 3,54 3,68 3,82 3,95 4,08 4,21 4,33 4,45 4,57 4,68 4,79 4,90 5,00 5,11
1,00 3,40 3,60 3,80 3,98 4,16 4,33 4,49 4,65 4,80 4,95 5,10 5,24 5,37 5,50 5,63 5,76 5,88 6,01
1,10 3,74 3,96 4,18 4,38 4,58 4,76 4,94 5,12 5,29 5,45 5,61 5,76 5,91 6,06 6,20 6,34 6,47 6,61
1,20 4,08 4,32 4,56 4,78 4,99 5,20 5,39 5,58 5,77 5,94 6,12 6,28 6,45 6,61 6,76 6,91 7,06 7,21
1,25 4,25 4,50 4,75 4,98 5,20 5,41 5,62 5,82 6,01 6,19 6,37 6,54 6,71 6,88 7,04 7,20 7,36 7,51
1,35 4,59 4,86 5,13 5,38 5,62 5,85 6,07 6,28 6,49 6,69 6,88 7,07 7,25 7,43 7,61 7,78 7,94 8,11
1,50 5,10 5,41 5,70 5,98 6,24 6,50 6,74 6,98 7,21 7,43 7,64 7,85 8,06 8,26 8,45 8,64 8,83 9,01
1,65 5,61 5,95 6,27 6,57 6,87 7,15 7,42 7,68 7,93 8,17 8,41 8,64 8,86 9,08 9,30 9,51 9,71 9,91
1,75 5,95 6,31 6,65 6,97 7,28 7,58 7,87 8,14 8,41 8,67 8,92 9,16 9,40 9,63 9,86 10,08 10,30 10,51
2,00 6,80 7,21 7,60 7,97 8,32 8,66 8,99 9,30 9,61 9,91 10,19 10,47 10,74 11,01 11,27 11,52 11,77 12,01
2,25 7,64 8,11 8,55 8,96 9,36 9,74 10,11 10,47 10,81 11,14 11,47 11,78 12,09 12,39 12,68 12,96 13,24 13,51
2,50 8,49 9,01 9,50 9,96 10,40 10,83 11,24 11,63 12,01 12,38 12,74 13,09 13,43 13,76 14,09 14,40 14,71 15,02
3,00 10,19 10,81 11,40 11,95 12,48 12,99 13,48 13,96 14,41 14,86 15,29 15,71 16,12 16,51 16,90 17,28 17,65 18,02
3,50 11,89 12,61 13,29 13,94 14,56 15,16 15,73 16,28 16,82 17,33 17,84 18,33 18,80 19,27 19,72 20,16 20,60 21,02
4,00 13,59 14,41 15,19 15,94 16,64 17,32 17,98 18,61 19,22 19,81 20,39 20,94 21,49 22,02 22,54 23,04 23,54 24,02
4,50 15,29 16,22 17,09 17,93 18,72 19,49 20,23 20,94 21,62 22,29 22,93 23,56 24,17 24,77 25,35 25,92 26,48 27,03
Regulator
low flame
Regulator
high flame
low flame: 8÷10 bar
high flame: 24 bar

PART I: INSTALLATION 17
mod. LO280 Air rate setting
zSingle stage burners
zDouble stage burners
Servocontrol cams adjustement
.
.Air damper position is set by means of the servocontrol cams. As for the setting, refer to the next table
The STA4.5B0.37 is not provided with the manual contrl for the air damper. The cams adjustement must be performed by
means of a screwdriver acting on the VS screw placed inside the cam. During the first setting, set the cam III betweenthe
camsI and II. Then, passing from the low to high flame stage, or viceversa, change the setting according to the flame composi-
tion: if cam III is too near to the low flame position (cam II), flue gas can take place, because there is more fuel than air; if cam III
is too near to high flame (cam I), the flame could fade because of too much air.
zloosen VR screw.
zmove the ID index along the graduated
slot towards + or -, in order to increase
or decrease the air flow-rate, according
to the required combustion values.
zasten the VR screw again.
Fig. 35
Fig. 36 - Berger STA4.5B0.37/63N30L
BERGER
STA4.5B0.37/6..
I High flame
II Low flame - stand by - ignition
III EVG2 opening (2nd nozzle)
VR
ID
I
II
III
VS

PART I: INSTALLATION18
MOD. LO400 SETTINGS
Priming the pump
Before carrying out the adjustment it is necessary to start up the fuel pump, proceeding as follows:
Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
Start the burner, light up the photoresistor after the opening of the solenoid valve and escape the air from the pressure port.
Fuel rate adjustment
The fuel rate is setting choosing properly sized nozzles and adjusting the fuel pressure at the pump inlet (see the diagram Fig.
37 and Fig. 38). To choose the nozzles refer to Tab. 3b and Tab. 1b; for pump pressure regulation see on pag. 23. For further
information on fuel pump see also the appendix.
Choosing the light oil nozzles
Tab. 3a - Single-stage LO400
Note: all pumps are set to 12 bar. The nozzle rate must be higher than the rate referred to the minimum burner
output.
Key
EV Fuel solenoid valve
EVG1 Fuel solenoid valve - low flame
EVG2 Fuel solenoid valve - high flame (only hi-lo
flame burners)
M Manometer
PPump
Fig. 37 - Single stage burners
Fig. 38 - Double stage burners
PUMP PRESSURE (bar)
10 12 14
NOZZLE (G.P.H.) FUEL RATE kg/h
4,00 15,19 16,64 17,98
4,50 17,09 18,72 20,23
5,00 18,99 20,81 22,47
5,50 20,89 22,89 24,72
6,00 22,79 24,97 26,97
6,50 24,69 27,05 29,21
7,00 26,59 29,13 31,46
7,50 28,49 31,21 33,71
8,30 31,53 34,54 37,30
9,50 36,09 39,53 42,70
EVG
EVG1
P
M
EVG2

PART I: INSTALLATION 19
Tab. 3b - Double-stage LO400
RATE OUTPUT PUMP PRESSURE
kg kcal/h kW 10bar 12bar 14bar
30 306.300 356 3.50+4.50 3.00+4.00 3.00+3.50
35 357.350 416 4.00+5.00 3.50+5.00 3.50+4.00
40 408.400 475 4.50+6.00 4.00+5.50 4.00+5.00
45 459.450 534 5.00+6.50 4.50+6.00 4.00+6.00
50 510.500 594 5.50+7.50 5.00+7.00 4.50+6.50

PART I: INSTALLATION20
First start and air rate setting (MOD. LO400)
Connections for pressure measurement
Single stage burners
Set the air rate working on the screw VBS (Fig. 39); screw to
decrease the air rate or unscrew to increase it.
Two-stage burners
zThe air flow can be adjusted using the air damper servo-con-
trol cams as follows.
zRemove the burner's cover cover.
zRemove the servo-control's cover.
zStart the burner and let it burn at low flame (remove the bri-
dge between Terminals T6 and T8).
zAdjust the air flow in low flame by working on the appropriate
cam (Fig. 42).
zPrime the second nozzle using the following procedure:
♦Start the burner
♦When the flame appears press the P1 button (Fig. 40) for a
few seconds to fill the second nozzle pipe;
zThe cycle continues, and if the TAB thermostat is con-
nected, the flame control apparatus brings the burner to high
flame. If the TAB thermostat is not connected, bridge Termi-
nals T6 and T8 on the connector (see “Identification of linking
connectors” on page 11 and “Connectors layout on printed
board” on page 41). Adjust the air flow at high flame by
working on the appropriate cam.
zThe cam that triggers the opening of the 2nd stage fuel valve
(valve EVG2) must be set in an intermediate position
between the other two cams.
zReplace the cover on the servo-control.
zReplace the burner's cover.
Fig. 39
Fig. 40 - Second nozzle’s ignition pushbutton on double stage
burners
Fig. 41
VBS
P1
Fan air pressure port
Combustion chamber pressure port