BURNER INSTRUCTION MANUAL

FOR GAS AND PRESSURE ATOMIZING OIL FUEL SYSTEMS

P-MODEL

FI 6-FI 81F2OmF22

INTRODUCTION
q

Starting a burner is an event which normally culminates

the effort of severa1 different contractors, manufacturers,
utility and engineering concerns, Sales and factory
representatives, and others.
In order for the burner to operate safely and meet its
design capabilities, the interfacing fuel, air, electrical,
exhaust an.d plant heating contro1 systems must be
properly sized, selected, installed and tested. Additionally,
all conditions must be such that the heat generated by
the burner can be safely used or wasted without
endangering personnel or equipment.
It shall be the policy of CIB UNIGAS BURNERS that no
responsibility is assumed by the Company nor any of its
employees for any liability or damages caused by an
inoperable, inadequate or unsafe burner condition which
is the result, either directly or indirectly, of any of the
improper or inadequate conditions described above.
TO insure that a safe and satisfactory installation has
been made, a pre-start inspection is necessary. This
inspection must be performed by an individua1 who is
thoroughly familiar with all aspects of proper boiler/
burner installation and how it interfaces with overall plant
operation.

n Part I of this bulletin sets forth major inspection items that

must be considered.
1 NOTE 1
This inspection should-be performed before the burner
start-up specialist is called in. An incomplete or inadequate
installation may require additional time and effort by
start-up personnel and cause an untimely and costly
delay.

The result of this inspection will often times identify

corrections that must be made prior to start-up as well as
point out potential or long range problems in plant
operation if corrections are not made.

Burner start-up is serious matter and should not be

viewed as a time for crowd gathering by unconcerned,
uninformed or unauthorized personnel. The number of
persons present should be held to an absolute minimum.

Instruction of operating and other concerned personnel

should be done after the burner has been successfully
fired and adjusted by a qualified service agency or
Commissioning Engineer.

WARNING
Improper servicing of this equipment may create a potential hazard to equipment and operators.
SERVICING MUST BE DONE ONLY BY FULLY TRAINED AND QUALIFIED PERSONNEL.
Before disconnecting or opening up a fuel line and before cleaning or replacing patts of any kind.
W Turn OFF the main manual fuel shutoff valves including pilot gas cock, if applicable. li a multiple fuel burner,
shut OFF all fuels.

n Turn OFF all electrical disconnects to the burner and any other equipment or systems electrically interlocked
with the burner.

SPECIFICATION OF YOUR BURNER:

SERIAL No

BURNER MODEL

FUELS

1)
2)

ELECTRICS

MOTOR

CONTROL

FUEL PRESSURES

1)

2)

IGNITION GAS

NOTES

PARTI
SUGGESTED INSTALLATION INSPECTION CHECKLIST
d CHECK WHEN COMPLETED
0 I S burner installed in accordante with applicable
installation drawings?
0 If a refractory combustion chamber is part of the
installation, is it completely dry, cured, and ready for
firing at full boiler input?

IS all specified auxiliary equipment mounted and wired?

This may include outdoor temperature controls, oil flow
switches, space thermostats, water flow switches,
motorized combustion air louvers, etc.

0 Has the proper electrical voltage been connected to the

burner contro1 cabinetas shown on the burner materia1
list?
0 Has the burner wiring been checked for completeness
and accuracy? Have 3-phase motors been properly
wired and checked for correct rotation?
0 Are the boiler mounted limit controls such as low water
cutoffs, high limit controls, operating controls, modulating
controls, etc., properly installed and wired?

Are the bolier controls the right type and range for the
installation?

c] Are all gas train components installed and have they

been properly selected, sized and assembled?
0 Have properly sized vent lines been installed on all gas
train components which require venting? This inciudes
such items as pressure regulators, normally open vent
valves, diaphragm valves, low and high gas pressure
switches, etc.
0 Have gas train piping and components been tested and
proven gas tight?

0 Is the boiler water supply, including feed pumps, properly

connected and is boiler filled with water?

0 Have the gas lines been purged?

0 IS suff icient load connected to the boiler

fired continuosly at full rating?

0 IS the proper gas pressure available at the inlet to the

controls which meets the requirement shown on the
burner materia1 list?

SO

that it can be

cl If boiler load is not connected, can steam be wasted SO

that boiler can be fired continuosly at full rating without
endangering personnel or equipment?
0 If the installation is a hot water boiler, have the circulating
pumps been comlpletely installed, wired, and tested to
assure proper operation SO that the burner can be fired
continuosly at full rating?

For new boiler installations, has the boiler been boiled

out in accordante with the boiler manufacturers
instructions?

0 Have the boiler breeching connections to the stack been

compteted and are they open and unobstructed?
0 IS draft contro1 equipment required and, if

SO,

installed?

0 Have adequate provisions for combustion air been

installed?

13 IS the oil tank installed and filled with the proper type and
grade of fuel oil as required by the burner materia1 list?
0 IS the proper oil pressure, temperature and viscosity
available at the inlet to the controls which meets the
requirements shown on the burner materia1 list and/or oil
system sheet?
Cl Have oil supply and return lines been properly sized to
meet the maximum pumping capacity of the pump and
has the system been purged and proven leak proof?
1 SIGNATURE OF INSPECTOR(S) 1

0 Have the persons listed below been notified of the burner

start-up date?
Cl Owners Representative
Cl Mechanical Contractors Representative
Cl Electrical Contractors Representative
Cl Service Organizations Representative
CI Boiler Manufacturers Representative

BURNER FAMILARIZATION AND INSPECTION (continuecj)

2. - PRELIMINARY INSPECTION - The burner should be
1. GENERAL - The following data is pertinent to the burner
start-up and should be carefully studied before any attempt visually checked for damage and loose components as
to start the burner is made. This materiai is a part of the . these conditions can occur during shipment, through
improper handling, by tempering, or through improper care
instructions manual which accompanies the burner.
storage at the job site.
0 Burner Wiring Diagram and Operating Sequence.
Check for:
0 Flame Safeguard Leaflet.
0 Gas System Schematic (if applicable).
0 Obvious damage to housing, air inlet, and components
0 Oil System Sheet (if applicable).
mounted thereon.
q Burner Identification and Numbering System.
c] Miscellaneous Manufacturers Data on Controls, Valves,
0 Thightness of fasteners, tube fittings, plugs, etc.
Regulators, etc.
0 Tightness of electrical connections and terminals.
The above cited manual is One of a Kind in that it contains
materia1 covering your specific burner. TO replace it,
considerable time, special handling, and significant costs
are involved. Accordingly, it should be handled with care
and kept in a location free of dust and moisture.

0 Tightness of adjustment mechanism such as ball-joint

swivel connectors and contro1 arms.
0 Accumulations of oil, dust, dirt, water, or other foreign
matter on, in , or near the burner.

PART III

PRELIMINARY ADJUSTMENTS
1. FACTORY ADJUSTMENTS - The burner is adjusted at
the factory to meet norma1 firing conditions. These
adjustments are acceptable for initial start-up but settings
must be verified to insure changes have not occurred from
the time the burner left the factory.
Depending on the mode1 and capacity of the burner, various
adjustment mechanisms contro1 the air and fuel available for
combustion, while others contro1 the safe and reliable function
of the gas-electric ignitor.

2. ADJUSTMENTMECHANISMS - lllustrations which follow

show the items which are subject to adjustment. Determine
the applicability of each illustration to your burner, then
proceed to familarize yourself with the function of the item.
Where a setting is indicated, verify the setting or make
preliminary adjustment as necessary to facilitate initial
start-up.
(1
Adjustable air and fuel contro1 mechanisms which modulate
with the burner firing rate must be adjusted with the 0 to 90
actuator in the Oo position.

BURNER AIR AND FUEL ADJUSTMENTS

ITEMS 1 TNROUGH 10

ITEM

1 ADJUSTMENT OF PRIMARY-SECONDARY AIR CYLINDER

DESCRIPTION

HOW IT WORKS

A separate air adjustment at the firing head provides a

unique air contro1 system enabling quiet, stable combustion
without objectional noise or pulsation. This feature allows
flexibility in adapting to a variety of job conditions and
insures greater combustion eff iciency.

See figure 3-1. Moving the position of the knobs forward

reduces the amount of air available for combustion whije
movement to the rear increases the air supply.
This mechanism automatically proportions the air firing
head as the combustion contro1 programs (modulates) the
burner to meet the boiler load.

ADJUSTMENT PROCEDURE
1. Loosen positioning mechanism.
2. For initial start-up, position air cylinder midway of its stoke.
3. Start the burner and look for optimal cylinder position.
4. Arrange mechanical cam according to positions defined at point 3.
5. Lock mechanism.

If positioned too far forward, the main flame may pulsate. If too far to
the rear, the surplus air may cause noisy operation.

Figure 3 - 1: Adjustment of manual proportioning primary - secondary air control.

ITEM 2

ADJUSTMENT OF AIR INLET LOUVER BOX

DESCRIPTION

HOW IT WORKS

The amount of air available for combustion is controlled by

adjustable louvers located in the air box. The louvers are
interconnected through a series of small linkage arms
secured to a common drive rod.

See figure 3-2. Louver opening and trave1 is controlled by

adjusting the linkage mechanism from the actuator to obtain
the desired opening and stroke. The actuator drives the
louvers open or closed as the combustion contro1 programs
the burner firing rate to meet the boiler load.

AIR LOUVRE BOX

IS
CT
RA
VB
T

- Damper position indicator

- Positioning arm
- Regulating bolt
- Positioning arm clamp bolt
- Operating rod

ADJUSTMENT PROCEDURE
1. Use box end or socked wrench to loosen ball-joint connector.
2. TO adjust low fire (minimum) air setting, loosen ball-joint
connector holding drive rod and manually position louvers to
obtain the desired opening, then retighten connector.
3. TO adjust amount of trave1 (stroke), loosen base of ball-joint
connector located in slotted (louver) actuator arm and reposition
to desired setting, then re-tighten connector.
4. For initial start-up: Position air inlet louvers
approximately 1/4 inch open.

Figure 3 - 2: Adjustment of air inlet louvre box

SO

they are

ITEM 3

ADJUSTMENT OF GAS PILOT IGNITOR ASSEMBLY

DESCRIPTION

HOW IT WORKS

The gas pilot ignitor is basically composed of (1) An

ignitionelectrode insulator which generates an art between
it and the adjacent ground, and (2) A fuel tube through which
the gas is directed to the point of the electrical art.

See Figure 3-3. A charge from a high voltage transformer is

routed to the ignition electrode causing an intense art to
ground. The electrode is then immersed in a concentration
of gas as the pilot solenoid valve opens allowing flow to the
pilot. The art ignites the gas, the electrical discharge from
the transformer terminates and the pilot stands ready to
ignite the main burner flame.

Gas Pilot Ignitor Assembly

1) Using cresent or open end wrench, disconnect air tube

and gas supply line from pilot assembly.
2) Using screw driver, remove screws holding pilot
assembly to burner.
3) Remove pilot and inspect electrode and nozzle for
cleanliness and proper adjustment setting shown in
Figure 3-3.

Ii

ADJUSTMENT PROCEDURE

--.--__-_-_

1 NOTE 1
The gas pilot ignitor assembly is a vital part of the burner and must
be kept clean and properly adjusted at all times.

piiziiq
Turn off all electrical disconnects to the burner and any other
equipment or systems electrically interlocked with the burner. Turn
off the pilot gas cock.

Figure 3 - 3: Adjustment of gas pilot ignitor assembly

!mlllm*s
!
----_---------_-_---.-_-!
!

41

prm

-z+
/l-

4) Tighten nut holding insulator and electrode assembly.

5) Reinstall pilot assembly and flame safeguard.
6) For initial start-up: Verify pposition of electrode.

BURNER AIR AND FUEL ADJUSTMENTS (continued)

/ ITEM 4

1 ADJUSTMENT OF BUTTERFLY GAS VALVE

DESCRIPTION

HOW IT WORKS

The butterfly gas valve is a fuel throttling device which

proportions the gas in proper ratio to the combustion air. The
valve is opened or closed by an actuator as the combustion
contro1 programs the burner firing rate to meet the boiler
load.

See Figure 3-4. A Centrally located disc turns within a

cylindrical body which regulates the gas flow to the main
burner flame. The butterfly valves used are the non-tight
shutoff type.
Through a linkage system, an actuator drives the valve open
orclosed in response to electrical signalsfrom the combustion
control. Since the amount of air available for combustion is
controlled by the same actuator, a proper fuel-air ratio is
maintaned at all times.
ADJUSTMENT PROCEDURE

Butterfly Gas Valve

1) Use box end or socket wrench to loosen or tighten ball joint

connectors.

2) TO adjust low fire (minimum) fuel setting, loosen bali-joint

connector holding drive rod and manually position butterfly
disc to desired opening, then retighten connector.

Slot in end of butterfly shaft indicates position of interna1

disc.
3) For initial start-up: Position actuator arm
approximately 15 open.
Figure 3 - 4: Adjustment of butterfly

ITEM

SO

interna1 disc is

gas valve

5 ADJUSTMENT OF GAS PRESSURE REGULATORS

.

DESCRIPTION

HOW IT WORKS

Gas burners have two gas pressure regulators, one to

regulate the pressure to the main flame and the other to
regulate the gas pilote ignitor. Most mode1 F and FL oil
bumers also use gas pilot Ignition; therefore, the gas pressure
regulator is common to most all F and FL burners.

See Figure 3-5. Simply stated, gas flow is controlled by a

spring of known load range which works against the supply
(from the meter) gas pressure. Accordingly, each regulator
must be fitted with the right spring for it to function properly.
Additionally, the tension on the regulator spring must be
adjusted to obtain the exact pressure required at the inlet to
the controls.

Gas pressure Regulator

ADJUSTMENT PROCEDURE
pEq
See gas pressure regulator manufacturers instructions for
detailed procedures.
1) Remove cap or bonnet from regulator to gain access to

adjustment screw or button.

2) Turn clockwise to increase and counter-clockwise to

decrease outlet pressure.
3) For initial start-up:
Pressure at which gas willed to the burner cannot be
determined without gas flowing thru the regulator. Be prepared
to adjust the regulator as the burner is test fired.
4) Reinstall cap or bonnet after adjustment.

Figure 3 - 5: Adjustment of gas pressure regulators

BURNER AIR AND FUEL ADJUSTMENTS (continued) i

ITEM 6 ADJUSTMENT OF GAS PRESSURE SWlTCHES
DESCRIPTION

HOW IT WORKS

Gas pressure switches are pressure - actuated electrical

switching devices designed for safety shutoff when gas
pressure are either too low or too high.

See figure 3-6. The pressure switch senses any change in

gas pressure and, if properly adjusted, will transmit an
electrical signal to the automatic shutoff valve andlor other
interlocking devices when an unsafe condition exists, The
burner will then re-eyele or completeiy shut down depending
upon the flame safeguard used. Gas pressure switches are
designed to operate over a specified pressure range;
therefore, each switch must be selected to be compatible
with the burner operating gas pressure and also to obtain
the desired electrical features.
.

Gas Pressure Switch

ADJUSTMENT PROCEDURE
pE-]

See gas pressure switch manufactures instructionsfor detailed

procedures.
1) For initial Start-up
a. Low Gas pressure Switch - Adjust to a lower pressure
than that to be experienced for norma1 operation to allow
the burner to be set up.
b. High Gas Pressure Switch - Adjust to a higher pressure
than that to be experienced for norma1 operation to allow
the burner to be set up.
6AS

-5
=40
= 20 cr
=30
0
= 40 7
n
-50

pi--NOTE]
Final adjustment must be done after the burner has been
test fired. See burner start-up procedure%

Figure 3 - 6: Adjustment of gas pressure switches

ITEM 7

ADJUSTMENT OF OlL DRAWER ASSEMBLY

DESCRIPTION

HOW IT WORKS

Oil bumers have an assembly made up of vital oil and air

handling components known as the Oil Drawer Assembly.
Basically, this assemblycontains theoil tube(s), the atomizing
nozzle(s), the air diffuser with mounting bracket and an oil
distnbutor block and backplate which secures the unit to the
burner housing. If the bumer has direct spark oil ignition, the
ignition electrodes are also a part of this assembly.

See Figure 3-7. The oil is forced down the supply tube under
high pressure and is atomized into the combustion chamber
by the oil nozzle. The air diff user distributes the combustion
air through the atomized oil which is then ignited by the gas
pilot ignitor or by an electrical spark if burner has direct spark
ignition. On bypassing oil nozzle systems, the excess oil is
diverted from the nozzle to the bypass return line.

ADJUSTMENT PROCEDURE

1) At back of bumer use Allen key to loosen set screw VI.

This will enable the diff userto be re-positioned in relation
to the burner head.
Generally the diffuser should be positioned as far to the
rear as possible without impinging the oil spray on the
inner surface of the burner firing tube.
2) TO adjust the nozzle in relation to the diffuser loosen set
screw V and position nozzle slightly behind diff user - the
final position cannot be established unti1 the burner is
fired.

Figure 3 - 7: Adjustment of oil drawer assembly

ITEM 8

ADJUSTMENT OF OIL METERING VALVE

DESCRIPTION

HOW IT WORKS

Oil bumers which have low fire start fuel contro1 systems
must deliver oil to the nottle at reduced pressure for low fire.
This is normally accomplished by diverting a portion of the
oil pump delivery thru a bypass return line to the tank.

Most oil metering devices work on the principle of limiting

flow by constrictings the area thru which the oil must Pass.
In order to vary the orifice area, mechanical movement must
take place, thus the oil metering valve requires an actuator
to do its job. By interconnecting a common actuator to the
combustion contro1 and the oil metering valve, this allows
the fuel (oil) to be proportioned in precise ratio to the amount
of air available for combustion. This feature is essential on
modulating type fuel contro1 systems.

The amount of oil delivered to the nozzle versus that

returned to the tank is controlled by a device which limits or
meters flow, thus an oil metering valve is commonly used for
this purpose.

ADJUSTMENT PROCEDURE
The metering valve is adjusted by the position of the ratio
cam - closing the valve increases the return pressure on the
gauge and increases the burner firing rate, opening the
valve lowers the return pressure and reduces the firing rate.
Normally high fire return pressure will be between 18-25 bar
and low fire 5-12 bar.
The return pressure can be adjusted with an Allen key as
shown in the diagram through the full modulating range of
the burner.

Figure 3 - 8: Adjustment of oil metering valve

BURNER AIR AND FUEL ADJUSTMENTS (continued)

IITEM9( ADJUSTMIENT OF OIL SUPPLY PRESSURE REGULATOR VALVE (INTEGRAL TO OIL PUMP)
HOW IT WORKS
Burner oil pumps are generally identify by the rate at which
they can deliver (GPH), the pressure of the delivery (BAB)
and the speed of rotation (RPM). The pump is usually
capable of delivering more fuel than is required to meet firing
requirements; therefore, the amount of oil delivered to the
nozzle must be controlled. This contro1 is accomplished thru
use of an adjustable pressure regulating valve which reduces
flow to the nozzle by causing more oil to be returned to the
tank. Like most regulators, flow is controlled by an adjustable
spring and each regulator has a pressure range over which
it will reliably operate.

11

L
1,

1 - Suction

2 - Return
3 - Pressure (nozzle)
4 - Pressure regulator

5 - Gange port (suction)

6 - Gange port (pressure)

Figure 3 - 9: Adjustment of oil supply pressure regulator valve

ADJUSTMENT OF OIL SUPPLY PRESSURE

The pump is adjusted at the built in pressure regulator as
shown in the diagram.
Remove the cover with a spanner and with a gauge in the
pressure port as shown set the supply pressure between 20
and 25 bar. Replace cover and check supply pressure is
steady through modulating range.

BURNER START UP SEQUENCE

( It wili be assumed that all contro1 links are made and the boiler is calling for heat).
Qn turning on the contro1 switch the damper motor will be driven to fully open and the fan will start. During this pre-purge
time the air pressure switch is automatically checked.
If, eitherfor anelectrical or mechanical failure, the switch does not function correctly, the burner will goto lockout and cannot
be re-startecl unti1 the lockout condition has been reset.
After the pre-purge period and only when the air switch has been proved, the damper motor will drive to the low flame
position. At this position the ignition will occur (a spark is produced) and the pilot valve(s) will open. If, for either an electrical
or mechanical failure, the valves do not open then the burner will go to lockout. When the pilot valve(s) open the fuel will
ignite producing the pilat flame.
A flame signal is electrically produced by the ionitation probe or U. V. Cell, and has to be continually present unti1 a
controlled shut down is required. If the flame signal is lost the burner will go to lockout.
After the pilot flame has been established and electrically sensed the main fuel valve(s) will open. The fuel will be ignited *
by the pilot flame, Should the fuel not be ignited by the pilot flame then the pilot valve(s) will close.
The start-up procedure is completed after the main flame has been achieved and the burner controls have been released
to modulation. The burner will be running under the dictates of the modulation thermostat. Upon reaching a preset
temperature the burner will automatically shut off unti1 more heat is called for.
The landis and Gyr controller is an elettro - mechanical timer unit wich, when the contro1 switch is turned on, will start the
burner on a correct safety sequence. An indication wheel, within the unit, will indicate at what stage the controller is at.
PLEASE CQNSULT THE LANDIS AND GYR LITERATURE FOR THE FULL OPERATING SEQUENCE AND ALARM
CONDITIQNS.

START UP SEQUENCE

- Check the electronic ftame supervision unit is not in the lockout position. In the affirmative, reset it.
- Be certain the temperature and pressure controls are in the closed position.
- When oii has reached the temperature for starting, blower motor starts and pre-purging begins.
Since pre-purgin is to to be carried out with maximum air delivery, the burner contro1 circuit turns the air damper to the
max. position, iva the air servocontrol is fully open position, a signal to the electronic contro1 unit starts the pre-purge cycle,
which lasts 30 seconds.
.

- During that period hot oil is circulated as far as the nozzle to ensure good ignition. After pre-purging, the air servocontrol
returns to the fully closed position, SO that ignition takes place at the minimum firing rate.
Simultaneously the ignition transformer receives voltage and after 3 seconds (pre-ignition) the pilot burner ignites and
is proven following which the 3 port valve is energised. The oil flows to the atomizing nozzle and ignites, being controlled
by the pressure regulator.
- Now the burner is operating at the minimum firing rate (about 30% of the max. firing rate). Afterwards, the air servocontrol
runs to the low flame position and, in case the temperature contro1 should be set for the max. firing rate, to the air damper
fully open position, while the atomizing nozzte is fed at the max. pressure. which is supplied by the regulator being fully
ctosed via the cam: maximum firing rate is thus reached.

- Irrespective of heat required, the contro1 unit continues its programme to the end and retums to its start position for the
next cycle, which will be performed after the burner idle time caused by limit or response switches.

43

eti

i
i
i
i
i

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\

GAS FIRING

1) Isolate the main gas train and operate the burner sequence and ensure that the pilot burner Iights reliably and is capable
of lighting the main flame under all conditions. At the appropriate time the flame safeguard will go to lockout when the
main ftame does not ignite.
2) With the gas butterfly contro1 valve setto approx 15 open the main gas supply, run the burner sequence, and the burner
will ignite on Iow fire.
3) As soon as pratica1 advance the burner to the high fire position and ensure that the gase contro1 valve is fully open - adjust
the main gas governor to give the rated input by observing the gas meter. t
By adjusting the ratio cam for the gas contro1 valve the bumer can now be set throughout its modulating range using
flue gas analysis instruments. Oxygen readings on high fire should be 3-4% and 5-6 % on low fire with zero CO. The
primary air adjustment can also be used for fine regulation of flame shape and excess air.
Adjustment of the main air damper is via the slotted lever.

AIR PRESSURE SWITCH SETTING

Loosen the screw VB. The regulating ring nut is to be setat the bottom of its scale. While the burner is operating, slowly
turn the regulating ring nut clockwise unti1 the burner stops. Then turn the ring back by two tums and re-start the burner.
Should the bumer go to lockout again, turn back by one more full turn.
Tighten the screw VB.

Figure 4.2

OIL DELIVERY ADJUSTMENT

The oil system includes:

A - Fuel oil Pump
B - By-pass Nozrle (Retum Flow Nozzle)

C - Oil Metering Valve

The diagram illustrates the fuel feeding system of these types of burners, which incorpora& a by-pass nozzle with oil flow
regulation in its retum pipe.
The oil supply is varied by acting on the metering valve which determines the oil flow to the nozzle through the pressure
on the return line.
Max oli supply is therefore reached when the pressure in the suction line is about (25 bar Noule Type .W2) and the return
line is fully closed; min. oil supply when the retum line is fully open. Relevant pressure reading in the retum line are as
follows.

NOZZLE TYPE W2

- max. oil supply: 25 bar

- min. oil supply: 9-10 bar
Rate of adjustment: 1 to 4

Figure 4.3

46

THERE ARE TWO POSSIBILITIES:

1 - The burner has already been adjusted for gas firing.

2 - The burner must be oil fired only.

START FLAME SElTlNG

Supposing the.bumer has already been adjusted for gas firing:

- start flame size is to be proportioned to the nozzle size and oil pressure measured at the regulator. Therefore choose
the most suitable nozzle fot the application, SO that during ignition the oil supply should be 113 of the max. one.
- When valves open, the pressure measured by the gauge fitted to the regulator must be of 5-l 2 bar to allow min. oil supply
to the noule. TO obtain that reading, act on the cam coupled with the air servocontrol.
Ouring start flame setting, it is advisable to interrupt the working cycle.
- Air delivery has already been adjusted when burner has been set for gas firing.
Oil and air might not be mixed in the correct proportion, but a futther adjustment of air delivery is negligible as ignition
time is limited by the interval of the servocontrol between ignition sequence and futther steps.
- Before cartying out more operations, trip switch to resume the working cycle.

HIGH FLAME ADJUSTMENT

The servontrol tums the air damper (previously adjusted for gas firing only) to max. delivery. Simultaneously the pressure
regulator controlled by the sector cam is fully closed and casues an increases in the pressure of the nozzle return flow, which
develops max. firing rate.
- As air is delivered at a fixed rate during gas firing, it might be necessary to correct max. oil supply. That can be obtained
by acting on the cam which controls the regulator, resulting in a variation of the oil firing rate, unti1 combustion readings
are found to be satisfactory.

PRE-PURGE

max

IGNITION FlRING

HIGH FLAME FIRING

._;
?.1.

- 2 -

..,. 1.1 ::-ii...

..,,.
.
;-I * -.* '.;
&
.e ' *

i*i

Figure 4.4

MODULATING DRIVE MOTOR:

1) The SQM 10 is always set to 90 operation via Cam A which is preset at the factory.
2) The low fire position of the burner can be set on Cams C or E for gas and oil the small indicator arrow shows the position
of the motor in degrees.
3) Cam l3 is the setting for gas ignition flame.
4) Cam D is the setting for oil ignition flame.

Figure 4.5

I - HIGH FLAME
Il - IGNITION GAS
Ill - LOW FLAME
IV - IGNITION 01L
V - LOW FLAME OIL
VI - NOT USED

BY-PASSING NOZZLES TYPE FLUIDICS W2

Inlet pressure 25 bar
Turn-down ratio 1: 4
Viscosity 5 cSt
500

Supply 25 bar

251
700

90 Spray

angle

supply

357 psi

300 psi

201

Return pressure

R eturn pressure
-

- 200 psi
I

till- 1 0 0

kg/h

over
100 psi

bar

e
20

40

60

80

100 %

Output

Figure 4 - 6

BURNER GAS THROUGPUT VERSUS HEAD PRESSURE

100
90

80

70

60

50
40

30

20

10
9
8

Ill

8 9 1 0 0

Il

8 9 1000

THROUGPUT Nm3/ h

Figure 4 - 7

24

BURNERGASTHROUGPUTVERSUSHEADPRESSURE

MODEL F22

I
I

I
I

I
I

IlIlIII
I111111

THROUGPUT Nm3/ h

Figure 4 - 9

23

HEAVY OIL FIRING ONLY

OlL LINE FILLING
Oil in the pre-heater is to be kept at 50 C approx.
Before starting the burner, set the regulating and oil temperature contro1 thermostats at 130 C and 1 IO C respectively.
These values apply to fuel oil with viscosity ranging from 25 to 50 E at 50C.
TO fill the oil line (pre-heater, oil suction, feed to and return from the nozzle) proceed as follows:
1 - Cut off oil electric heaters via the line switch (off the contro1 panel).
2 - Link oil, interlock thermostat.
3 - Turn on the cock on the vent pipe of the pre-heater.
4 - Turn fuel selector to the position OIL.

At this point the burner performs a complete start-up cycle. As soon as oil flows out of the vent pipe, throw the line switch
to the ON position and turn the cock off. If at the end of the first cycle, when burner goes to lockout and stops, oil has not
filled the line yet, push reset contro1 button to repeat the cycle.
The line is full up when pressure gauge on the pump indicates about 25 bar., which is the pressure required for proper burner
operation.
TO obtain that reading, loosen or tighten the screw 4.
A few minutes time is admitted to fill the oil line, but a longer time might damage the pump seals.
If the line is not full up, it is necessary to check the suction pipe.
Upon completion of filling, disconnect link and connect start-up thermostat there.

24

FUEL OIL THERMOSTATS

(@ {@
140

80

130

140

90

0)

0
CI?

120

0)

Figure 4.11

90

0
Q

120

100

100

110

110

80

130

@@@

Eme

TR

TCN

ADJUSTMENT PROCEDURE

1)

Remove the cover which encloses the thermostat and interlock switch (thermostat).
The pointer (2) controls the thermostat setting while the pointer (1) controls the interlock switch (thermostat).

2)

The thermostat pointer (2) should be set at 190 C and then raised or lowered as required.

3)

The cold oil interlock switch-thermostat is controlled by the pointer (1).

This is setto prevent the burner from starting unti1 a minimum oil temperature is reached and should be set 20 - 25 below
the oil temperature setting on the Heater Contro1 Thermostat.
CAUTION: Do not set the cold oil interlock higher than the oil temperature.

4)

Replace the cover which encloses the thermostat and interlock switch-thermostat.

HEATER CONTROL THERMOSTAT

TO regulate the thermostat use a screwdriver as shown. The temperature to be set can be determined from viscosity
diagram. We suggest the actual oil temperature be set precisely with the burner working using a mercury thermometer in
the pocket.

Figure 4.12

SUNTEC TA

SUCTION HEIGHT

: Max. 0,5 bar Vacum 0,4 bar

advised to prevent air separation from oil.

RATEDSPEED

: Max. 3600 rpm.

OPERATING VISCOSITY RANGE

: 2,8 to 800 cSt.

INLET AND RETURN PRESSURE

: Max 5 bar.

LEGEND:
1 234567-

Figure 4 - 13

Pump Suction
Return
Nozzle
Pressure Regulator
Vacuum Port
Pressure Gauge
Electric Heater

OIL LANCE SCHEMATIC

FLOW
1
v

RETURN
2

NEEDLE OPERATING
3

PORT

AUXILIARY BLOCK HEATER

Figure 4 - 14

OIL LANCE

NOZZL ,E PRE-PURG

Figure 4 - 15

IGNITION FI

Figure 4 - 16

HIGH FLAME FIRING

Figure 4 - 17

LEGEND
1 - Flow
2 - Return
3 - Needle operating pot-t

OIL DELIVERY ADJUSTMENT

The diagram illustrates the fuel feeding system of these types of burners, which incorporates a by-pass with oil flow
regulation on its return pipe.
The oil supply is varied by acting on the regulator which determines the oil flow to the nozzle through the pressure in the
return line.
Max. oil supply is therefore reached when the pressure in the suction line is about 25 bar and the return line is fully closed;
min. oil supply when return line is fully open.
Relevant pressure readings in the return line are as follows:
- max. oil supply

: 25 bar

- min. oil supply

: 9-10 bar

- Rate of adjustment

:1to4

OIL PRESSURE REGULATOR

If gaseous fuel was not available initiaily, the directions given to set the burnerfor gas firing also apply to oil firing, particularly
as far as combustion air adjustment is concerned.

OIL SUPPLY PRESSURE SETTING

It is to be carried out during pre-purge time by tightening or loosening the socket headed screw RP on the oil pump. For
proper burner operation, the pressure reading indicated by the pressure gauge M must be 25 bar appox.

Figure 4

- 18

Figure 4

- 19

OIL PRESSURE REGULATOR SElTING

The shape given to the blade in the oil sector determines the oil supply to the nozzle.
The figure shows two possible shapes:
Ll : blade shape before start flame setting
L2 : final shape after setting

LP

LP

RAB-DISTRIBUTOR BLOCK
AUXILIARY HEATER

Figure 4

- 20

OIL PIPE CONNECTIONS

CARTRIDGE

BELT TYPE HEATER

Figure 4 - 21

LEGEND
1 - Flow
2 - Return
3 - Needle operating port

CARTRIDGE PIPE HEATER

BELT TYPE HEATER

HASBESTOS HOSE

Figure 4 - 22

THERE ARE TWO POSSIBILITIES:

1 - The burner has already been adjusted for gas firing.
2 - The burner must be oil fired only.

START FLAME SETTING

Supposing the burner has already been adjusted for gas firing:
- Start flame size is to be proportioned to the nozzle size and oil pressure measured at the regulator. Therefore choose
the most suitable nozzle for the application, SO that during ignition the oil supply should be one third of the max. one.
- When valve opens, the pressure measured by the gauge fitted to the regulator must be of 5-l 2 bar to allow min. oil supply
to the nozzle.
TO obtain that reading, act on the cam coupled with the air servocontrol.
During start flame setting, it is advisable to interrupt the working cycle.
- Air delivery has already been adjusted when has been set for gas firing.
Oil and air might not be mixed in the correct proportion, but a further adjustment of air delivery is negligible as ignition
time is limited by the intetval of the servocontrol between ignition sequence and further steps.

HIGH FLAME ADJUSTMENT

- The servocontrol turns the air damper (previously adjusted for gas firing only) to max. delivery. Simultaneously the
pressure regulator controlled by the sector is fully closed and causes an increase in the pressure of the nozzle return
flow, which develops max. firing rate.
- As air is delivered at a fixed rate during gas firing, it maight be necessary to correct max. oil supply. That can be obtained
by acting on the cam which controls the regulator resulting in a variation of the oil firing rate, unti1 combustion readings
are found to be satisfactory.

LOW FLAME ADJUSTMENT

- Please, refer to gas firing as well.
- Oil supply regulation is carried out by rotating the cam that controls the oil return pressure regualtor unti1 the pressure
reading corresponds to the correct quantity of oil required to burn the air delivered at low flame rating (already adjusted
during gas firing).

3A

MINIMUM SUPPLY TEMPERATURE TO THE BURNER ACCORDING TO GRADE OF FUEL OIL

100
90
80

I I I I I I I I I I I I

Il

l--t-MT

10
9
8
7

Iiiii i

10

20

30

40

50

60

i0

80

TEMPERATURE C

Figure 4 - 23

The burners must be supplied with oil having a min. temperature at the pump inlet according to the above diagram with
relation to the grade of oil being used.
For example: oil being used 7 E, 15 E, 50 E at 50 C the inlet temperature to the pump must be respectively 35 C,
50 C, and 77 C as indicated by the diagram.

32

GAS TRAINS
The gas train will be supplied in a straight line arrangement and a special DWG and schematic will be provided with each
contract.
There will effectively be a main gas train and a pilot train, the pilot can be either natura1 gas or L.P.G.
All components will comply with loca1 standards.

CONTROL PANEL
This is normally supplied as a remote flor standing unit c/w following
.
1) Flame safeguard
2) Motor starters & fuses
3) Necessary lamps & switches
4) Necessary relays & timers
5) Modulating controller
6) All components wired to a terminal strip
7) Pane1 volator
A specific schematic and wiring diagram will be provided for each contract.
For any further information please contact our engineering department at the following address quoting the full specification
as shown at the front of this manual.

34