BRUCIATORI DI GASOLIO BISTADIO

DOUBLE-STAGE DIESEL BURNERS

ITALIANO

Manuale istruzioni per l'installazione, l'uso e la

manutenzione
IT TBL 85P / P DACA
Installation, use and maintenance instruction
manual EN TBL 105P / P DACA
TBL 130P / P DACA
TBL 160P / P DACA
TBL 210P / P DACA
TBL 260P / P DACA

ISTRUZIONI ORIGINALI (IT)

ORIGINAL INSTRUCTIONS (IT)
0006081053_201805
 ENGLISH

ENGLISH

SUMMARY

Warnings for use in safety conditions.......................................................................................................................................................7

Technical specifications..........................................................................................................................................................................10
Standard accessories....................................................................................................................................................................... 11
Burner identification plate................................................................................................................................................................. 11
Technical functional characteristics..................................................................................................................................................12
Design characteristics......................................................................................................................................................................12
Operating range...............................................................................................................................................................................13
Component description....................................................................................................................................................................14
Electrical panel.................................................................................................................................................................................14
Overall dimensions...........................................................................................................................................................................15

Burner connection to the boiler...............................................................................................................................................................16

connecting the burner to the liquid fuel supply line.................................................................................................................................17

Supply line........................................................................................................................................................................................17
Auxiliary pump..................................................................................................................................................................................21

Electrical connections.............................................................................................................................................................................22

Operating description.............................................................................................................................................................................24

First hydraulic circuit filling......................................................................................................................................................................25

Fuel pipes.........................................................................................................................................................................................25

Starting up and regulation......................................................................................................................................................................26

Controls............................................................................................................................................................................................27
Diagram for regulating the electrode disk distance..........................................................................................................................27
Air regulation on the combustion head.............................................................................................................................................28
Details of pumps..............................................................................................................................................................................29

Oscillating jack........................................................................................................................................................................................30

Servomotor cams adjustment SQN72.2B4A20......................................................................................................................................31

Control and command equipment LMO..................................................................................................................................................32

Maintenance...........................................................................................................................................................................................34
maintenance time.............................................................................................................................................................................35
Expected lifespan.............................................................................................................................................................................36

Instructions for determining the cause leading to irregularities in the operation and their elimination...................................................37

nozzle flow rate table..............................................................................................................................................................................39

Wiring diagrams......................................................................................................................................................................................40

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DECLARATION OF CONFORMITY

We hereby declare that our Diesel oil-fuelled blown air burners, series:
BTL…; TBL...; GI…; RiNOx; IB...L; BT...

comply with the essential requirements of the following European Directives and Regulations:
• 2014/30/EC (CEM)
• 2014/35/EC (DBT)
• 2006/42/EC (DM)
• 2014/68/EU(*) (PED)
(EU) 811/2013(**) (ErP)
(EU) 813/2013(***) (ErP)

(*) with appropriate choice of components

(**) (P ≤ 70 kW)
(***) (P ≤ 400 kW)

and have been designed and tested in accordance with the European Standards:
• EN 267

Cento, November 14th 2018

Managing Director Director of Research & Development

Dr. Riccardo Fava Ing. Paolo Bolognin

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WARNINGS FOR USE IN SAFETY have access to, through a responsible person, the information
concerning their safety, surveillance and instructions concerning
CONDITIONS equipment use.
• Children must be watched over to prevent them from playing
PURPOSE OF THIS MANUAL with the equipment.
This manual is aimed at ensuring the safe use of the product • This appliance should only be used for the purpose it has been
to which it refers, through the indication of the necessary designed for. Any other use is to be considered improper and
components in order to prevent the original safety features from therefore dangerous.
being jeopardized by improper or erroneous installation and by • The equipment must be installed in accordance with current
improper, erroneous or unreasonable use. regulations, with the manufacturer’s instructions and by
The manufacturer accepts no liability for any damage caused by qualified technicians.
improper installation and use or in case of non-compliance with • The term ‘qualified personnel’ refers to those specifically trained
the manufacturer's instructions. in the field and with proven skills, in accordance with the local
• The manufactured machines have a minimum life of 10 years, law in force.
if normal working conditions are met and periodic maintenance • An incorrect installation can cause injury or damage to persons,
specified by the manufacturer is done. animals and objects, for which the manufacturer cannot be held
• The instruction booklet is an integral and essential part of the responsible.
product and must be given to the user. • After removing all the packaging make sure the contents are
• The user must keep the booklet to hand for consultation when complete and intact. If in doubt, do not use the equipment
needed. and contact your supplier. The packing pieces are potentially
• Before starting to use the equipment, carefully read the dangerous and must be kept away from children.
"Instructions for use" in this manual and those directly • The majority of the equipment components and its package is
applied to the product in order to minimize risks and made with reusable materials. The package, the equipment and
accidents. its components cannot be disposed of with the standard waste
• Observe the SAFETY WARNINGS, avoid IMPROPER USES. but according to the regulations in force.
• Installer must evaluate any RESIDUAL RISK that might arise. • Before carrying out any cleaning or maintenance, disconnect
• This manual contains symbols to highlight some parts of the the equipment at the mains supply, using the system’s switch
text or to indicate some important specifications. You find their and/or shut-off systems.
description below. • If the equipment is sold or transferred to another owner or if the
DANGER / ATTENTION owner moves and leaves the equipment, make sure that the
This symbol indicates a very dangerous situation that, if booklet always goes with the equipment so it can be consulted
ignored, can seriously endanger people health and safety. by the new owner and/or installer.
• When the equipment is working, do not touch hot parts that
CAUTION / WARNINGS are usually positioned near the flame and the fuel pre-heating
This symbol indicates that it is necessary to behave properly system, if any. They could still be hot after the equipment is
to void endangering people's health and safety and causing turned off for a short period of time.
economical damages.
IMPORTANT
This symbol indicates particularly important technical and
operative information that must not be neglected.
CONDITIONS AND DURATION OF STORAGE
The equipment is shipped with the manufacturer package and
transported on road, by boat or by train in compliance with the
standards on goods transport in force for the actual mean of
transport used.
The unused equipment must be placed in closed rooms with
enough air circulation in standard conditions with temperature
between -25° C and + 55° C.
The storage time is 3 years.

GENERAL WARNINGS
• The equipment production date (month, year) is written on the
burner identification plate located on the equipment.
• The equipment cannot be used by people (including children)
with reduced physical, sensory or mental capacities or lacking
experience or know-how.
• The equipment use is allowed to such people only if they can

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• If there is any fault or if the equipment is not working properly, -- Check combustion and adjust combustion and/or fuel
de-activate the equipment and do not attempt to repair it or air flow to optimize combustion and reduce emissions in
tamper with it directly. Contact only qualified personnel. accordance with the law in force.
• Any product repairs must only be carried out by BALTUR -- Check the adjustment and safety devices are working
authorised assistance centres or by its local distributor using properly.
only original spare parts. -- Check the efficiency of the combustion products exhaust
• The manufacturer and/or its local distributor are not liable for duct.
any accident or damage caused by unauthorised changes of -- Check seal in the fuel supply pipe internal and external
the product and by failure to follow the rules described in the section.
manual. -- At the end of the adjustment procedures, check that all
the locking devices of mechanical securing systems are
SAFETY WARNINGS FOR INSTALLATION
properly tightened.
• The equipment must be installed in a well-ventilated suitable
-- Make sure that the use and maintenance manual of the
room in compliance with the laws and regulations in force.
burner is available.
• Ventilation grille section and installation room aeration openings
• If the burner repeatedly stops in lock-out, do not keep trying to
must not be obstructed or reduced.
manually reset it but call a qualified technician.
• The installation room must NOT have the risk of explosion and/
• If you decide not to use the burner for a while, close the valve or
or fire.
valves that supply the fuel.
• Before installing the equipment we recommend to carefully
clean the interior area of all fuel supply system pipes.
• Before connecting the equipment check that the details on the
plate correspond to those of the utility supplies (electricity, gas,
light oil or other fuel).
• Make sure the burner is firmly fixed to heat generator according
to manufacturer instructions.
• Connect to the source of energy according to state-of-the-art
standards as described in the explanatory diagrams and in
compliance with the regulatory and law requirements in force at
the moment of installation.
• Check that the fume disposal system is NOT obstructed.
• If it is decided not to use the burner any more, the following
procedures must be performed by qualified technicians:
-- Switch off the electrical supply by disconnecting the power
cable from the main switch.
-- Cut off the fuel supply using the shut-off valve and remove
the control wheels from their position.
-- Render harmless any potentially dangerous parts.
WARNINGS FOR START UP, TEST, USE AND
MAINTENANCE
• Start up, test and maintenance of the equipment must only be
carried out by qualified technicians, in compliance with current
regulations.
• Once the burner is fixed to the heat generator, make sure
that the generated flame does not come out of any slot during
testing.
• Check equipment fuel supply pipe seal.
• Check that fuel flow rate equals the power required to the
burner.
• Set the burner fuel capacity to the power required by the heat
generator.
• Fuel supply pressure must be within the values indicated on the
plate on the burner and/or manual
• The fuel supply system is suitably sized for the flow required
by the burner and that it has all the safety and control devices
required by current standards.
• Before starting up the burner, and at least once a year, have
qualified technicians perform the following operations:
-- Set the burner fuel capacity to the power required by the
heat generator.
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RESIDUAL RISKS -- in case of PVC sheath, at least type H05VV-F;

• Even though the product was designed in compliance with the -- in case of rubber sheath, at least type H05RR-F;
obligatory standards, residual risks may still be present during -- without any sheath at least type FG7 or FROR.
correct operation. They are signalled on the burner through • The electric equipment works correctly when the relative
special Pictograms. humidity does not exceed the 50% at a maximum temperature
of +40° C. Higher relative humidity are allowed at lower
CAUTION
temperatures(e.g. 90 % at 20° C)
Moving mechanical organs.
• The electric equipment works correctly at altitudes of up to 1000
CAUTION m above the see level.
Materials at high temperature.
CAUTION
Powered electric panel.
ELECTRIC SAFETY WARNINGS
• Check that the equipment has a suitable ground system, carried
out following safety standards in force.
• Do not use the gas pipes to ground electrical equipment.
• If in doubt, call for a careful electrical check by a qualified
technician, since the manufacturer will not be liable for any
damage caused by a poor ground connection.
• Have qualified personnel check that the electric system is
adequate to equipment maximum power consumption indicated
on the plate.
• Make sure that system cable section is suitable to equipment
power consumption.
• Adapters, multiple plugs and/or extension cables may not be
used for the equipment’s power supply.
• For the mains supply connection is required an omnipolar switch
with a contact opening gap equal or above 3 mm in accordance
with current safety regulations (condition of overvoltage
category III).
• For burner electricity supply use double insulation cables only,
with external isolation at least 1 mm thick.
• Remove the external insulating seal of the supply pipe necessary
for the connection, preventing the cable to touch metal parts.
• The electrical supply to the burner must have neutral to ground
connection. If the ionisation current has control with neutral not
to ground, it is essential to make a connection between terminal
2 (neutral) and the ground for the RC circuit.
• If the user is absent for a prolonged period of time, close the
main gas feed tap to the burner.
• The use of any electrically fed components entails complying
with certain fundamental rules, 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 explicit provision
for this;
-- do not allow the equipment to be used by children or
inexpert persons;
-- The power supply cable for the equipment must not be
replaced by the user. In case of cable damage, turn the
equipment off. To replace it contact qualified personnel only;
-- If you decide not to use the equipment for a certain period of
time it is advisable to switch off the electrical power supply
to all components in the system that use electricity (pumps,
burner, etc.).
• Use regulation-compliant flexible cables EN60335-1:
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TECHNICAL SPECIFICATIONS
TBL 85P / P TBL 105P / P TBL 130P / P TBL 160P / P TBL 210P/P TBL 260P/P
MODEL
DACA DACA DACA DACA DACA DACA
Minimum thermal flow Kg/h 16.9 27 33.7 42.1 67.4 80.1
Maximum thermal flow Kg/h 71.7 88.5 109.6 134.9 177.1 219.1
Minimum thermal power kW 200 320 400 500 800 950
Maximum thermal power kW 850 1050 1300 1600 2100 2600
mg/
³) emissions Class 1 Class 1 Class 1 Class 1 Class 1 Class 1
kWh
Viscosity 1.5° E - 20° C 1.5° E - 20° C 1.5° E - 20° C 1.5° E - 20° C 1.5° E - 20° C 1.5° E - 20° C
Operation Two-stage Two-stage Two-stage Two-stage Two-stage Two-stage
50hz transformer 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 12kV - 35 mA
60hz transformer 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 10 kV - 30 mA 12kV - 35 mA
50hz fan motor kW 1.1 1.5 2.2 2.2 3 5.5
60hz fan motor kW 1.1 1.5 2.6 2.6 2.6 7.5
Absorbed electrical power* 50hz kW 1.6 2 2.8 2.8 3.7 6.5
Absorbed electrical power* 60hz kW 1.6 2 3.3 3.3 3.3 8.5
3N~ 400V ± 3N~ 400V ± 3N~ 400V ± 3N~ 400V ± 3N~ 400V ±
50 Hz power supply voltage 3N~400V±10%
10% 10% 10% 10% 10%
3N~ 380V ± 3N~ 380V ± 3N~ 380V ± 3N~ 380V ± 3N~ 380V ±
60 Hz power supply voltage 3N~380V±10%
10% 10% 10% 10% 10%
Protection rating IP40 / IP44 IP40 / IP44 IP40 / IP44 IP40 / IP44 IP44 IP44
Control box LMO 44 LMO 44 LMO 44 LMO 44 LMO 44 LMO 44
Flame detection Photoresistor Photoresistor Photoresistor Photoresistor Photoresistor Photoresistor
hydraulic jack / hydraulic jack / hydraulic jack / hydraulic jack / hydraulic jack / hydraulic jack /
Air flow rate regulation
servomotor servomotor servomotor servomotor servomotor servomotor
Operating ambient air temperature °C -15 ÷ +40 -15 ÷ +40 -15 ÷ +40 -15 ÷ +40 -15 ÷ +40 -15 ÷ +40
Sound pressure** dBA 75.1 78.2 80.5 82.6 86.6 87
Weight with packaging kg 79 80 85 90 94 105
Weight without packaging kg 75 76 80 84 89 94

Lower calorific power:

Diesel fuel: Hi = 11.86 kWh/kg = 42.70 Mj/kg
* Total absorption at start-up with ignition transformer on.
** The acoustic pressure measured with burner operating at maximum rated thermal output refers to the manufacturer's laboratory
environment conditions and cannot be compared to measurements carried out in different locations.
³) DIESEL EMISSIONS
Classes defined according to EN 267 standards.
NOx emissions in CO emissions in mg/
Class
mg/kWh diesel fuel kWh diesel fuel
1 ≤ 250 ≤ 110
2 ≤ 185 ≤ 110
3 ≤ 120 ≤ 60

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STANDARD ACCESSORIES
TBL 85P / P TBL 105P / P TBL 130P / P TBL 160P / P TBL 210P/P TBL 260P/P
MODEL
DACA DACA DACA DACA DACA DACA
Burner connection flange - - - - -
Insulating gasket 1 1 1 1 1 1
Stud bolts N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12
Hexagon nuts N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12 N°4 - M12
Flat washers No.4 Ø 12 No.4 Ø 12 No.4 Ø 12 No.4 Ø 12 No.4 Ø 12 No.4 Ø 12
Insulating cord 1 1 1 1 1 1
Hoses N°2 - 1/2" N°2 - 1/2" N°2 - 1/2" N°2 - 1/2" N°2 - 1/2" N°2 - 3/4"
Filter 3/8" 3/8" 3/8" 3/8" 1" 1
No.2 - 1/2" x No.2 - 1/2" x No.2 - 1/2" x No.2 - 1" x 1/2"
No.2 - 1/2" x No.2
Nipple 3/8" / No.2 - 1/2" 3/8" / No.2 - 1/2" 3/8" / No.2 - 1/2" / No.2 - 1/2" x
3/8" 1"x3/4"x3/4"
x 1/4" x 1/4" x 1/4" 1/4"
Nozzle n°2 n°2 n°2 n°2 n°2 n°2

BURNER IDENTIFICATION PLATE

1 Company logo
2 Company name
1 2 Targa_descr_bru 3 Product code
4 Burner model
3 4 5 5 Serial number
6 Liquid fuel power
6 7 7 Gaseous fuel power
8 Gaseous fuel pressure
8 9 Liquid fuel viscosity
10 Fan motor power
9 14 11 Power supply voltage
12 Protection rating
10 11 12 13
13 Country of origin and numbers of certificate of approval
14 Manufacturing date - month / year
15 16 15 -
16 Bar code serial number of burner

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TECHNICAL FUNCTIONAL CHARACTERISTICS DESIGN CHARACTERISTICS

• Gas burner with low NOx and CO emissions in accordance with • Combustion head complete with stainless steel nozzle.
European standard EN267. • Ventilating part in light aluminium alloy.
• Combustion air and combustion head regulation. • Conveyor with combustion air flow regulation dampers
• Easy maintenance as the mixing unit can be removed without • Flame inspection glass.
having to disassemble the burner from the boiler. • Fuel supply circuit comprising gear pump with pressure
• Mounting flange to the sliding generator, to adapt the regulation and shut-off valve/s.
protuberance of the head to various types of heating generators. • 7-pole socket for burner power and thermostatic supply.
• Combustion air intake with throttle gate for the regulation of the • 4-pole plug for second operation stage control.
air flow rate. • Electric panel in light die-cast aluminium with protection rating
• Air damper closing in pause to prevent any heat dispersion to IP55.
the flue through air regulation servomotor. • Automatic command equipment and burner control according to
• Flame presence control with photoresistor. European regulation EN298.
• Display showing the operating sequence and error code in the
event of a lockout.
• Combustion air intake with throttle damper. Air flow adjustment
using hydraulic jack.
• Combustion air intake with throttle damper. Air flow adjustment
using electric servomotor.

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OPERATING RANGE

TBL 85P TBL 105P TBL 130P TBL 160P TBL 210P
mbar
15

0002922543
14
12
10
8
6
4
2
0 kW
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
kg/h
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

0002929520

IMPORTANT
The operating ranges are obtained from test boilers corresponding to Standard EN267 and are indicative of the burner-boiler
combination. For correct working of the burner, the size of the combustion chamber must correspond to current regulations; if not
the manufacturers must be consulted.
The burner shall not operate outside its specific operating range.

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COMPONENT DESCRIPTION
1 Combustion head
1 2 3 4 5 6

0002471141N1
2 Seal
3 Burner connection flange
4 Combustion head adjustment device
5 2nd stage solenoid valve
6 Safety solenoid valve
7 1st stage solenoid valve
8 Hinge
9 Hydraulic air control jack
9a Air regulation servomotor (DACA version)
10 12-bar pump
11 Electrical panel 8 7
12 Motor
13 Burner identification plate 13

9 11

10

9a 12

ELECTRICAL PANEL
1 Control box 7
2 Ignition transformer
3 Motor contactor
4 Thermal relay
4
5 7-pole connector
6 4-pole connector 3
0002935090

7 Synoptic panel

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OVERALL DIMENSIONS

ØF

B2
ØE

B
B1
D
A1 A2

0002471141N2
C
A

45 45
M
I

N
I
L

Model A A1 A2 B B1 B2 C
TBL 85P / P DACA 670 300 370 510 380 130 1250
TBL 105P / P DACA 680 310 370 520 380 140 1250
TBL 130P / P DACA 680 310 370 520 380 140 1250
TBL 160P / P DACA 680 310 370 540 380 160 1300
TBL 210P/P DACA 680 310 370 540 380 160 1300
TBL 260P/P DACA 760 340 420 560 400 160 1300
Model D min D max EØ FØ I I1 L min L max
TBL 85P / P DACA 175 400 161 159 260 260 225 300
TBL 105P / P DACA 175 400 180 178 280 280 250 325
TBL 130P / P DACA 175 400 180 178 280 280 250 325
TBL 160P / P DACA 200 450 224 219 320 320 280 370
TBL 210P/P DACA 210 450 250 219 320 320 280 370
TBL 260P/P DACA 210 450 250 219 320 280 370
Model M NØ
TBL 85P / P DACA M12 170
TBL 105P / P DACA M12 190
TBL 130P / P DACA M12 190
TBL 160P / P DACA M12 235
TBL 210P/P DACA M12 255
TBL 260P/P DACA M12 255

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BURNER CONNECTION TO THE BOILER

• Adjust the position of the coupling flange (19) by loosening the 1

0002935100
screws (6) so that the burner head enters the furnace to the 13
extent recommended by the generator manufacturer.
• Position the insulating gasket (13) on the sleeve, by inserting
2
the cord (2) between the flange and the gasket. 7
• Fasten the head unit to the boiler(1) by means of the stud bolts,
washers and the nuts provided (7).
DANGER / ATTENTION
Seal the space between the burner sleeve and the hold on
the refractory material inside the boiler door completely with
suitable material.
ASSEMBLY OF VENTILATION SYSTEM
For a correct installation of the ventilating body, follow the
procedure described below:
Position the half-hinge on the burner scroll in line with those on the
combustion head assembly. 25
• Insert the hinge pin (10) in the position considered most suitable 6
• Connect the ignition cable to the relevant electrode, close the
hinge by fastening the burner with the screws (11).
COMPLETING BURNER SETUP
• Remove the protective (black) caps from the fittings placed

0002935110
beneath the head unit and near the solenoid valves.
• Connect the light oil pipes (24) provided with the burner to 10
their corresponding connectors, making sure they are properly 11
sealed.
DANGER / ATTENTION
Do not change the tie rod factory positions.

24

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CONNECTING THE BURNER TO THE

LIQUID FUEL SUPPLY LINE
SUPPLY LINE
The fuel supply pressure to the burner pump must not change
both with burner off and with working burner at the maximum fuel
output required by the boiler.
The supply circuit can be realized without pressure regulator,
using the dedicated hydraulic diagram.
The burner tank connection pipes must be perfectly airtight. It is
recommended to use copper or steel pipes of a suitable diameter.
The pipe dimensioning must be carried out according to the pipe
length and the flow rate of the installed pump.
These instructions ensure a good operation of the product.
At the end of the rigid pipes, fuel shut-off gate valves must be
installed.
Install the filter on the suction piping after the gate, then connect
the hose to the burner pump's suction coupling nipple; all parts are
supplied with the burner.
The pump is provided with specific connections to fit control
instruments (pressure gauge and vacuum gauge).
For a safe and silent operation, the suction vacuum cannot exceed
35 cm/Hg corresponding to 0.46 bar.
The anti-pollution prescriptions, as well as the provisions set forth
by the local authorities, refer to the specific publications in force in
the country where the product will be installed.
Maximum suction and return pressure = 1 bar.

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TBL 85 - 105 ..
GRAVITY SUPPLY SYSTEM
1 Serbatoio 6 Suction pipe
2 Feeding pipe 7 Burner return pipe
3 Mesh filter 8 Automatic shut-off device with
4 Pompa burner off

0002900740N1
1
5 Degasificatore 9 Unidirectional valve

H Total L.
H

2 Meters
4
9 7 Meters Øi 14 mm
1 30
6 1,5 35
5 2 35
8 3 2,5 40
3 40

SIPHON FEED SYSTEM WITH FEED FROM THE TOP OF THE TANK
1 Serbatoio 7 Return pipe
3 Mesh filter 8 Automatic shut-off device with
4 Pompa burner off
0002900740N2

6 Suction pipe 9 Unidirectional valve

P

10 Foot valve

H Total L.
H

1 10 4 Meters
7 9 Meters Øi 14 mm
6
1 30
1,5 35
2 35
8 3
2,5 40
3 40
Value P = 3.5 m (Max)

INTAKE SUPPLY SYSTEM

1 Serbatoio 6 Suction pipe
3 Mesh filter 7 Return pipe
4 Pompa 10 Foot valve
H Total L.
Meters
4 Meters
Øi 14 mm Øi 16 mm
0,5 26 45
1 22 38
6 1,5 19 31
7 2 14 25
2,5 11 19
H

3
1 N.B. Comply with the regulations in force for any components missing in the
0002900740N3

10 pipelines.
H = Difference in level between minimum level in tank and pump axis
L = Deduct 0.25 m for each elbow or gate.

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TBL 130 - 160 - 210

GRAVITY SUPPLY SYSTEM
1 Serbatoio 6 Suction pipe
2 Feeding pipe 7 Burner return pipe
3 Mesh filter 8 Automatic shut-off device with burner

0002900740N1
1 4 Pompa off
5 Degasificatore 9 Unidirectional valve

H Total L.
H

2 Meters
4
9 7 Meters Øi 16 mm
1 40
6 1,5 45
5 2 45
8 3 2,5 50
3 50

SIPHON FEED SYSTEM WITH FEED FROM THE TOP OF THE TANK
1 Serbatoio 7 Return pipe
3 Mesh filter 8 Automatic shut-off device with burner
4 Pompa off
0002900740N2

6 Suction pipe 9 Unidirectional valve

P

10 Foot valve
H Total L.
H

Meters
1 10 4
7 9 Meters Øi 16 mm
6 1 40
1,5 45
2 45
8 3 2,5 50
3 50
Value P = 3.5 m (Max)

INTAKE SUPPLY SYSTEM

1 Serbatoio 6 Suction pipe
3 Mesh filter 7 Return pipe
4 Pompa 10 Foot valve
H Total L.
Meters
Meters
4 Øi 14 mm Øi 16 mm
0,5 36 55
1 30 48
1,5 25 41
6 2 20 32
7 2,5 15 24
H

3 3 10 15
1 3,5 4 7,5
0002900740N3

10 N.B. Comply with the regulations in force for any components missing in the
pipelines.
H = Difference in level between minimum level in tank and pump axis
L = Deduct 0.25 m for each elbow or gate.

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TBL 260
GRAVITY SUPPLY SYSTEM
1 Serbatoio 6 Suction pipe
2 Feeding pipe 7 Burner return pipe
3 Mesh filter 8 Automatic shut-off device with
4 Pompa burner off

0002900740N1
1 5 Degasificatore 9 Unidirectional valve

H Total L.
H

2
4 Meters
9 7 Meters Øi 16 mm
1 30
6
1,5 35
5 2 35
8 3
2,5 40
3 40

SIPHON FEED SYSTEM WITH FEED FROM THE TOP OF THE TANK
1 Serbatoio 7 Return pipe
3 Mesh filter 8 Automatic shut-off device with burner
4 Pompa off
0002900740N2

6 Suction pipe 9 Unidirectional valve

P

10 Foot valve
H Total L.
H

1 10 Meters
4
7 9 Meters Øi 16 mm
6
1 30
1,5 35
2 35
8 3
2,5 40
3 40
Dimension = 3.5 m (Max)

INTAKE SUPPLY SYSTEM

1 Serbatoio 6 Suction pipe
3 Mesh filter 7 Return pipe
4 Pompa 10 Foot valve
H Total L.
Meters
4 Meters
Øi. 16 mm Øi. 18 mm
0,5 21 34
1 18 29
6 1,5 15 24
7 2 11,5 19
2,5 8,5 14
H

3
1 3 5,5 9
0002900740N3

3,5 - 3,5
10
N.B. Comply with the regulations in force for any components missing in the
pipelines.
H = Difference in level between minimum level in tank and pump axis
L = Deduct 0.25 m for each elbow or gate.

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 ENGLISH

AUXILIARY PUMP
In some cases (excessive distance or differences in level) the
system must be implemented with a "loop" supply circuit with an
auxiliary pump, avoiding to connect the burner pump directly to
the tank.
In this case, the auxiliary pump can be started when the burner
starts and stopped when it stops.
The electric wiring of the auxiliary pump is made by connecting
the coil (230V) which controls the pump remote control switch in
parallel to the motor-fan remote switch coil.
Always follow the instructions below:
• The auxiliary pump must be installed as close as possible to the
liquid to be sucked.
• The head must be suitable for the relative plant.
• We recommend a flow rate equal at least to that of the burner
pump.
• The connection pipes must be dimensioned based on the flow
rate of the auxiliary pump.
• Avoid electrically connecting the auxiliary pump directly to the
remote control switch of the burner.

BLOCK DIAGRAM OF HYDRAULIC CIRCUIT

1 Foot valve
2 Possible air regulation servomotor
3 2nd stage nozzle
4 1st stage nozzle
5 Normally closed safety valve 5 7 4
6 12-bar pump
7 Normally closed valve
8 Hydraulic air control jack
A Intake
B Return
6
Hydraulic circuit loss of head: 3
TBL 85P - 85P DACA 1 bar A 7
TBL 105P - 105P DACA 1.5 bar
TBL 130P - 130P DACA 1.5 bar 8
TBL 160P - 160P DACA 2 bar B 2
0002901470

TBL 210P - 210P DACA 2.5 bar

TBL 260P - 260P DACA 5 bar
1 M

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ENGLISH

ELECTRICAL CONNECTIONS
1

0002934780a
• It is advisable to make all connections with flexible electric wire.
• The power lines must be distanced from the hot parts.
• The burner installation is allowed only in environments with
pollution degree 2 as indicated in annex M of the EN 60335-
1:2008-07 regulation.
• Make sure that the power line to which the unit will be connected,
has frequency and voltage values suitable for the burner.
• The three-phase or single-phase power supply line must have
a switch with fuses. The standards also require a switch on the
burner's power line located outside the boiler room where it can
be accessed easily.
• The main line, the relevant switch with fuses and the possible
limiter must be suitable to support the maximum current
absorbed by the burner.
• For the mains supply connection is required an omnipolar switch 1
with a contact opening gap equal or above 3 mm in accordance
with current safety regulations.
• Refer to the wiring diagram for electrical connections (line and
thermostats). 4
• Remove the external insulating seal of the supply pipe necessary
for the connection, preventing the cable to touch metal parts.
CAUTION / WARNINGS
Only professionally qualified personnel may open the
5
burner electrical switchboard.
To carry out the connection of the burner to the power supply line
proceed as follows:
• Remove the cover by unscrewing the screws (1), without
removing the transparent door. In this way the burner’s electrical
3 2
panel can be accessed.
• Undo the screws (2) and, after removing the cable retaining
plate (3), make the two 4- and 7-pole connectors go through

0002934780b
the hole. Connect the power supply cables (4) to the contactor,
secure the ground cable (5) and tighten the relating cable gland.
• Reposition the cable clamp plate. Turn the cam (6) so that the
plate exerts sufficient pressure on the cables, then tighten the
screws that fasten the plate. Finally, connect the related plugs
and modulation command cable, if installed.
0002934780c

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CAUTION / WARNINGS

0002934780d1
The housings for the cables for the plugs are provided 8
respectively for cable Ø 9.5÷10 mm and Ø 8.5÷9 mm, 7
this ensures the protection rating is IP 54 (Standard IEC
EN60529) for the electrical panel.
• To reclose the electrical panel lid, fix the screws (1) with a
torque of about 5 Nm to ensure the correct seal.
To gain access to the control panel (8), slide the transparent
door (7) for a short distance following the direction on the arrow
indicated in the figure exerting slight pressure with a tool (e.g. a
screwdriver) following the arrows' direction and slide it for a short
distance to separate it from the cover.
• To secure the transparent door on the panel properly, position
the hooks at their hooking points (9), slide the door in the
direction indicated by the arrow until you hear a click that
ensures its seal.
CAUTION / WARNINGS
Only professionally qualified personnel may open the
burner electrical switchboard.

0002934780e
9

9
9

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ENGLISH

OPERATING DESCRIPTION The ignition phase is repeated in this manner and, if the flame
reignites normally, the burner will return to normal operation.
When the two-stage burner is installed on a boiler for the Otherwise the equipment will shut-down automatically.
production of hot water for heating purposes, it must be connected If the program is interrupted, due to a power supply failure,
so it can operate under normal conditions with both flames, manual action or the intervention of the thermostat, during the pre-
completely stopping, without operating with single-stage, when wash stage, the programmer returns to its starting position and
the predefined temperature is reached. automatically repeats the entire burner ignition sequence.
To obtain this operating condition, do not install the second stage
IMPORTANT
thermostat and make a direct connection (bridge) between the
The LMO 44 device goes into lock-out after three repetitions
respective equipment terminals.
of the ignition cycle.
Thereby only the burner's capacity for ignition at a reduced flow
rate will be used for a soft start, which is an essential condition for IMPORTANT
boilers with pressurized and vacuum combustion chambers. The selection of the nozzles depending on the total flow
The burner's command (on or off) is dependent on the operating rate (2 nozzles in operation) must be made accounting for
or safety thermostats. the flow rate values that correspond to the fuel operating
Closing the main switch and the ON / OFF switch of the electric pressure of 12 bar.
panel, if the thermostats are closed, the voltage reaches the It is possible to vary widely the ratio between the first and
command and control equipment which starts operating. second stage by replacing the nozzles.
This switches on the fan motor and the ignition transformer.
The fan motor starts fan rotation, which performs a wash with air in 6 5 3 4
I
the combustion chamber and, at the same time, the pump makes II
the fuel circulate in the pipes, expelling any air bubbles through
the return line.
This pre-washing phase ends with the opening of the safety
solenoid valve and the 1st stage, making it possible for the fuel to
reach the 1st stage nozzle at a pressure of 12 bar and exit in the OIL
combustion chamber finely atomized. 2 7
The fuel atomised by the nozzle is set on fire by the spark present

sinottico_TBL85210P
between the electrodes as soon as the motor starts.
During first stage ignition, the combustion air delivery is determined
by the adjustment of the control hydraulic jack (0002935420).
If an air regulation servomotor is used, see the 1st stage cam 1 8
adjustment drawing 0002935210. 1 ON / OFF main switch.
If the flame appears in a normal manner, once the safety time 2 Voltage warning light
foreseen by the electric equipment has passed, it activates the 3 Fan operation warning light
2nd stage solenoid valve (closed, in stand-by). 4 Transformer ON warning light
If an air regulation servomotor is used, see the 2st stage cam 5 1st stage operation warning light
adjustment drawing (0002935210). 6 2nd stage operation warning light
The opening of the 2nd stage valve makes it possible for the fuel 7 Equipment shut-down warning light
to reach, at a pressure of 16 bar, the 2nd stage nozzle closure 8 Equipment release button
devices.
The pressure acts on the 2nd stage nozzle closure device that,
up to a pressure of 12 bar, prevents the fuel from flowing to the
second nozzle.
The piston stroke can be adjusted by turning the screw with the
lock nut in order for the burner to be fully operational.
Since the flame appears in the combustion chamber, the burner is
controlled by photoresistors and thermostats.
The control equipment follows the program and switches the
ignition transformer off.
When the temperature or pressure in the boiler reaches the value
to which the thermostat or pressure switch is calibrated, the
burner stops.
Vice versa if the temperature or pressure descends below the
calibration values of boiler's thermostat or pressure switch, the
burner restarts.
If during the operation the flame is interrupted for at least a
second, the photoresistor activates and cuts out the power supply
to the relay, thus closing the fuel shut-off solenoids.
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FIRST HYDRAULIC CIRCUIT FILLING • Now press on the mobile part of the motor remote control switch
in order to start up the motor and therefore the pump. Wait until
the pump has sucked in an amount of lubricant equal to 1 or 2
FUEL PIPES
glassfuls, then stop. This operation will prevent the pump from
After checking that the protective caps on the pump fittings have operating dry and will increase the suction power.
been removed, proceed as follows:
• Turn the switch on the burner to the “O” position to avoid the DANGER / ATTENTION
burner automatic activation. Pump operating at 2800 r.p.m. must not work dry otherwise
• Turn to "on" position the switch (1) on the synoptic panel, they will jam (seizure) within a very short time.
making sure that the thermostat line switch (2) is set to "O". • Attach the flexible hose to the intake pipe and open any gate
• Make sure that the line voltage coincides with the one indicated valves fitted on this pipe and any other shut-off element on the
in the burner's identification plate. Make sure that the motor fuel pipes.
rotates anti-clockwise, by observing the burner from the pump • Now press on the mobile part of the motor remote control switch
side. The rotation direction can be determined also looking at to start up the pump that extracts the fuel from the tank.
the direction of fan rotation through the inspection window on • When you see fuel coming out of the return line (not yet
the back of the scroll. To start up the motor, close the remote connected), stop.
control switch manually by pressing on the mobile part for a few DANGER / ATTENTION
seconds and watch the sense of rotation of the fan. If the pipe is long, it may be necessary to bleed the air out
• If it is necessary to reverse the rotation direction, reverse the through the cap; if the pump is not fitted with a cap, remove
two phases on the line input terminals (L1_L2_L3). the pressure gauge connector cap.
DANGER / ATTENTION • Connect the flexible return hose to the pipe and open any gate
To positively determine the direction of rotation, wait until the valves fitted on this pipe. The burner is now ready to start up.
fan turns very slowly because it is quite easy to misinterpret
the direction of rotation.
• Detach, if already attached, the flexible hoses from the intake
and return pipes.
• Dip the end of the flexible intake hose in a tin containing either
lubricant or diesel (do not use low-viscosity products such as
petrol, kerosene, etc.).

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STARTING UP AND REGULATION be based on the colour of the flame.

• Regulate to obtain a light orange flame avoiding a red flame
Before starting up, make sure that: with smoke, or a white flame with air excess.
• Check that the nozzles fitted on the burner are suitable for the • Air regulation should be performed to allow a certain amount of
boiler capacity. If necessary, replace them with suitable ones. carbon dioxide (CO2) in the fumes, which may vary from a min.
In no case should the quantity of fuel delivered exceed the of 10% to a max. of 13% with a fume index not exceeding 6 of
maximum amount required by the boiler and the maximum the Bacharach scale.
amount allowed for the burner.
CAUTION / WARNINGS
• Make sure that the mains voltage corresponds to the
manufacturer's requirements and that all electrical connections With a hydraulic jack,
made at the installation site are effected properly as illustrated When switching on the burner for the first time, shut downs
in our wiring diagram. may be experienced during the transition from the first to
• Make sure that the combustion products may be freely vented the second stage, due to the presence of air in the jack
through the boiler and flue dampers. circuit.
• Check that there is water in the boiler and that the gate valves Slightly loosen the nut blocking the jack pipe, carry out a
of the system are open. few operating cycles until there is fuel discharge from jack
• Make sure that there is fuel in the tank. connection nut.
• Check that all the gate valves fitted on the fuel suction and Tighten the nut when the operation is finished.
return pipes are open; the same applies to any other fuel shut-
off devices.
• Avoid second stage operation. Set the switch on the electrical
panel to the first stage position. If the burner does not have
the first and second stage switch, disconnect the thermostat to
avoid activating the second stage, if installed.
• Slightly open the air regulator and let in an amount of air
deemed necessary for burner operation with the 1st stage and
lock it in this position.
• Set the air adjustment device on the combustion head in an
intermediate position.(refer to the chapter Air regulation on the
combustion head).
• Turn on the main switch and the one on the control panel, (S1),
if provided.
• The programmer starts executing the preset program, activating
the devices comprising the burner.
• The equipment will start as described in the chapter
“OPERATION DESCRIPTION”.
• With the burner operating in the first stage, adjust now the
amount of air necessary for ensuring efficient combustion.
• We recommend keeping the air quantity at a low level when
working in the first stage output to ensure perfect ignition even
in the most difficult conditions.
• After adjusting the first stage air, disconnecting the current
from the main switch, close the electric circuit commanding the
second stage activation and move the switch on the electrical
panel to second stage.
• If the electrical panel does not have the first and second stage
switch, connect the terminals of the 2nd stage thermostat with
each other on the boiler terminal block.
• Working on the screw limiting pin stroke for the models with
hydraulic jack (0002935420), or on the second stage air
regulation cam for the models with servomotor (0002935210),
set the second stage air damper opening at the position
considered suitable for the desired fuel delivery.
• Now the equipment is activated again and will automatically
switch to the second stage according to the program set by the
programmer.
• Regulate the air quantity to ensure a good combustion.
• Check combustion with special instruments.
• If the appropriate instruments are not available, judgement can
22 / 38
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CONTROLS • Keep the photoresistor darkened to restart the burner, but if the
After starting the burner, check the safety devices, photoresistor, photoresistor does see the light within the time preset by the
lock components, thermostats. control device, the burner will lock-out.
• The photoresistor is the device controlling the flame and • The equipment can only be reset manually by pressing the
therefore must be able to intervene if the flame turns off during specific button.
operation. • To check the thermostats’ efficiency, increase the boiler water
• The burner must lock out and remain in that condition when, temperature up to at least 50° C.
during the ignition sequence in the time pre-set by the control • Act on the thermostat control knob to lower the temperature
device, the flame does not appear regularly. until the burner stops.
• The lock-out causes the immediate stop of the motor and • The thermostat should activate within a maximum range of 10°
burner and the switching on of the corresponding lock-out light C with respect to the boiler thermometer; if not, change the
indication. setting on the thermostat scale to match that of the thermometer.
Proceed as follows to check the efficiency of the photoresistor and
the relating lock-out warning light:
• Start the burner.
• After ignition, remove the photoresistor, pulling it out of its
housing, to simulate absence of flame by darkening the
photoresistor blocking off the window in the photoresistor
support with a cloth
• The burner flame must go out.

DIAGRAM FOR REGULATING THE ELECTRODE DISK DISTANCE

After having installed the nozzle, check the correct position of the electrodes
and disk according to the following values, indicated in millimetres.
After each operation on the head, make sure to comply with the indicated
values.
DANGER / ATTENTION
To prevent damage to the support, carry out nozzle assembly and
disassembly tasks with the aid of a wrench and counter-wrench.
DANGER / ATTENTION
For narrow combustion chambers, it is recommended to use nozzles
with a 45° atomisation angle.
1 - Diffuser
2 - Flame disc
3 - Nozzle holder sleeve
4 - Ignition electrode
5 - Nozzle
Recommended
A B C D E
nozzles
TBL 85 P / P
2 ÷ 2,5 19 5 2÷3 7,5 ÷ 8,5
DACA
TBL 105 P / MONARCH PLP
2 ÷ 2,5 19 5 2÷3 7,5 ÷ 8,5
P DACA 60°
TBL 130 P /
2 ÷ 2,5 19 5 2÷3 7,5 ÷ 8,5
P DACA
TBL 160 P /
2 ÷ 2,5 19 5 2÷3 7,5 ÷ 8,5
P DACA
STEINEN SS 45°
TBL 210 P /
12 ÷ 12,5 29 15 2÷3 7,5 ÷ 8,5
P DACA
MONARCH PLP
TBL 260 P /
0,5 ÷ 1 19 5 4÷5 7÷8 60° - HV 45° -
P DACA
STEINEN SS 45°

* TBL260P After any operation on the combustion

head, check the connection of the extensions on the
electrodes.

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AIR REGULATION ON THE COMBUSTION HEAD

The combustion head is equipped with a regulation device that
makes it possible to open or close the air passage between the
disk and the head.
Closing the air passage increases the pressure upstream of the
disk also with low flow rates.
The high speed and turbulence of the air provides for its greater
penetration into the fuel and therefore an excellent mixture and
flame stability.
It may be necessary to have high air pressure upstream of the
disc, so as to prevent flame pulses. This condition is indispensable
when the burner operates on pressurised combustion chamber
and/or with high heating load.
Therefore the air regulation device on the combustion head must
be set to such position as to always obtain, behind the disc, a very
high pressure value.
To do this fasten the device in an intermediate position on the
head air closure, and act on the air damper by increasing the fan
intake flow; needless to say that this condition must occur when
the burner is working at the maximum capacity required by the
system. Model X Index value (15)
Correct the position of the device that closes the air of the TBL 85P - P DACA 100 ÷ 64 1÷5
TBL 105P - P DACA 103 ÷ 67 1÷5
combustion head, moving it forward or backward, in order to
TBL 130P - P DACA 103 ÷ 67 1÷5
obtain an air flow suitable for the supply with the air damper
TBL 160P - P DACA 127,5 ÷ 91,5 1÷5
considerably open. TBL 210P - P DACA 132 ÷ 96 1÷5
TBL 260P - P DACA 132 ÷ 96 1÷5

DANGER / ATTENTION
The adjustments are indicative only; position the combustion
head according to the characteristics of the combustion
chamber.

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DETAILS OF PUMPS
1 Solenoid valve (normally closed) AJ4 - AJ6

8894_1
2 Pressure gauge connector and air vent (1/8”G) 2
3 Pressure adjusting screw
3.1 Remove the nut to access the pressure adjusting screw (11- 3
14 bar)
4 Return
6
4.1 Return with inner by-pass dowel
5 Suction
6 Delivery to nozzle
7 Vacuum gauge connector (1/8”G)
7.1 Vacuum gauge connector and internal by-pass dowel
CAUTION / WARNINGS
The pump is preset at a pressure of 12 bar
7.1
G7A 4.1 5

7 5
AN 47 - 57 - 67 - 77 - 97
4.1 5
2 2
Made in Italy

6
3
0005060115

3
2 4.1

6 0002900331

7 6

25 / 38
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OSCILLATING JACK
ADJUSTMENT OF FIRST STAGE AIR DUMPER POSITION
• To increase the flow rate, turn ring nut (3) anticlockwise using
the counter wrench on the body (1) of the jack to avoid putting
excessive stress on the eyelet pin (9).
• This operation lowers the body (1) and favours the opening of
the first stage air damper (7).
• To decrease the air flow rate, turn ring nut (4) clockwise, using
always the counter-wrench on the body of the jack.
• In this case, the body (1) move upwards and favours air damper
closing (7).
• Once the first stage air regulation is complete, lock the two ring
nuts (3) and (4).
ADJUSTMENT OF SECOND STAGE AIR DUMPER
POSITION
• Loosen lock nut (6).
• To increase second stage flow rate, undo the screw (5) so as
to lengthen the hydraulic piston stroke. Perform the operation in
the reverse order to reduce it.
• After second stage air flow adjustment is completed, tighten nut
(6).
DANGER / ATTENTION
To avoid damaging the eyelet (9), carry out all the adjustment
operations with wrench and counter-wrench.

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SERVOMOTOR CAMS ADJUSTMENT

SQN 72.2B4A20
SQN72.2B4A20 4
I II III IV
To adjust the setting of the cams used, use the corresponding
rings (I - II - III). The scale on the ring indicates the reference scale
of the rotation angle set for each cam.
1 Motor-camshaft coupling On/Off pin
2 Reference scale
3 Position indicator
4 Adjustable camshaft
I 2nd stage air regulation cam (80°)
II Total air closure (burner stopped) (0°)
III 1st stage air regulation cam (20°)
IV 2nd stage valve activation cam (40°)
1

3
I II III IV

0002935210

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CONTROL AND COMMAND EQUIPMENT LMO...

OPERATION.
The reset button «EK...» is the main element to access all diagnostics functions RED
(activation and deactivation) and serves to unlock the command and control device.
YELLOW
The multi-coloured «LED» indicates the command and control device status during
GREEN
both operation and diagnostics functions.

Both «LED» and «EK...» are positioned under the transparent button. Pressing this button, you reset the command and control equipment.
There are two diagnostics choices:
1. Visual indication directly on the reset button: operation and diagnostics of device status.
2. Diagnostics with interface: in this case the OCI400 connecting cable is necessary and it can be connected to a PC with ACS400
software, or to gas analysers of different manufacturers.
VISUAL INDICATION.
During operation, the command and control equipment phase is indicated on the reset button. The table lists all colour sequences and
their meaning. To activate the diagnostics function, hold the reset button down for at least 3 seconds. A quick red flashing indicates that
the function is active. Likewise, hold the reset button down for at least 3 seconds to deactivate the function (the switching will be indicated
with a flashing yellow light).

Operating position Operating position

Diagnostics PC interface / diagnostic

>3s analyser

7101z03e0305
Colour code table EK
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxxx

Condition Colour sequence Colours

Waiting time, other intermediate conditions ........ No light
Fuel oil preheating "ON", max waiting time 5 s. (tw) . . . . . . . . . Fixed Yellow continuous
Ignition phase Intermittent yellow
Correct operation, current strength of flame detector Green
above the minimum allowed
Incorrect operation, current strength of flame detector Intermittent green
below the minimum allowed value
Decrease in power supply voltage Alternating Yellow and Red
Burner shut down condition Red
Fault indication (see colour key) Intermittent red
Extraneous light upon burner start-up Alternating Green and Red
Quick flashing for diagnostics Quick flashing red
NO LIGHT. RED. YELLOW. GREEN.

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MALFUNCTION AND LOCK CAUSE DIAGNOSTICS.

In the event of a burner lock-out, the red light on the reset button will be fixed.
To activate the diagnosis phase (red light blinking fast) press the button for more than 3 seconds. The table below indicates the meaning
of the block or fault cause according to the number of flashings (always red).
Holding the reset button down for at least 3 seconds, the diagnostics function will be interrupted.
The diagram below shows the operations to be carried out to activate the diagnostic functions even with communication interface through
the "OCI400" connection cable.

7130z04e/0602
OCI400
Operating position Operating position Operating position

Diagnostics Colour code table PC interface /

diagnostic analyser
On
Flashing Reset
EK EK EK

>3s xxxx xxxx

>3s <3s
xxxx xxxx
xxxx xxxx
xxxx xxxx
xxxx xxxx
xxxx xxxx

Visual indication "AL” to terminal 10 Possible causes

2 blinks On No flame at the end of the safe ignition time<TSA>
●● - Fuel valves malfunctioning
- Flame detector malfunctioning
- Incorrect burner calibration, no fuel
- No ignition faulty ignition transformer
3 blinks On Available
●●●
4 blinks On Extraneous light during the ignition phase
●●●●
5 blinks On Available
●●●●●
6 blinks On Available
●●●●●●
7 blinks On No flame signal during normal operation, ignition repetition (limitation of ignition repetitions
●●●●●●● to max 3)
- Fuel valve fault or incorrect grounding
- Incorrect burner calibration
8 blinks On Fuel pre-heading anomalous time
●●●●●●●●
9 blinks On Available
●●●●●●●●●
10 blinks On Wiring problems or internal device damages
●●●●●●●●●●

• During the fault-finding time, the device is disabled.

• - The burner is off.
• - The alarm signal AL “is on terminal 10 which is under voltage.
• Press the lockout reset button for about 1 second (< 3 seconds) to reactivate the device and start a new cycle.

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MAINTENANCE

0002935140
10 11
Analyse combustion gases and check that the emission values
are correct at least once a year, in compliance with current law.
• Clean air dampers, the air pressure switch with pressure port
and the relevant pipe, if any.
• Check the electrode condition. Replace them, if necessary.
• Clean the photocell. Replace it, if necessary.
• Have the burner and the chimney cleaned by specialised 24
personnel (stove repairer); a clean burner is more efficient, lasts
longer and is quieter.
• Check that the fuel filter is clean. Replace it, if necessary.
• Check that all components of the combustion head are in good
condition, have not been deformed and are free from deposits Fig.1

deriving from the installation environment and/or from poor

combustion.
• Analyse combustion gases and check emissions values.
If it is necessary to clean the outside of the combustion head, take
out its components according to the procedure described:
• Disconnect the diesel hoses (24) from the connectors beneath
the head unit (mind the dripping).
• Undo the two screws (11) and turn the burner around the pin
(10) inside the specific hinge (figure 1).
• After pulling out the ignition cables (14) from the relating 14
6
electrodes, undo completely the locking nuts (6) from mixing
unit.
• Lift up the mixing unit (18) until the pipes come out and then

0002935150
pull the mixing unit out completely in the direction indicated by
the arrow.
• Complete the maintenance operations, proceed with the
assembly of the mixing unit by carrying out the above operations
0002935160

in reverse order, after checking that the ignition electrodes and

the flame disk are correctly positioned.
DANGER / ATTENTION
When closing the burner, gently pull the two ignition cables
towards the electrical panel, putting them slightly in tension,
then arrange them in their housing on the scroll. This will
ensure that the two cables do not get damaged by the fan 18
during burner operation.
0002935170

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MAINTENANCE TIME

Part description Action to be performed Diesel

COMBUSTION HEAD
VISUAL INSPECTION OF THE INTEGRITY OF CERAMICS. TIP GRINDING, CHECK
ELECTRODES YEARLY
DISTANCE, CHECK ELECTRICAL CONNECTION
FLAME DISC INTEGRITY VISUAL CHECK FOR ANY DEFORMATIONS, CLEANING, YEARLY
COMBUSTION HEAD COMPONENTS INTEGRITY VISUAL CHECK FOR ANY DEFORMATIONS, CLEANING, YEARLY
LIQUID FUEL NOZZLES REPLACEMENT YEARLY
INSULATING GASKET SEAL VISUAL INSPECTION AND POSSIBLE REPLACEMENT YEARLY
AIR LINE
AIR GRILLE/DAMPERS CLEANING YEAR
AIR DAMPER BEARINGS GREASING, (Note: apply only on burners with bearings requiring lubrication) YEAR
FAN FAN AND SCROLL CLEANING, DRIVE SHAFT GREASING YEAR
AIR PRESSURE SWITCH CLEANING YEAR
AIR PRESSURE PORT AND PIPES CLEANING YEAR
SAFETY COMPONENTS
FLAME SENSOR CLEANING YEAR
VARIOUS COMPONENTS
ELECTRIC MOTORS COOLING FAN CLEANING, BEARING NOISE CHECK YEAR
CHECK OF WEAR AND OPERATION, GREASING OF SLIDING BLOCK AND
MECHANICAL CAM YEAR
SCREWS
LEVERS/TIE-RODS/BALL JOINTS CHECK OF ANY WEAR, COMPONENT LUBRICATION YEAR
ELECTRICAL SYSTEM CHECK OF CONNECTIONS AND TERMINAL TIGHTENING YEAR
INVERTER COOLING FAN CLEANING AND TERMINAL TIGHTENING YEAR
CO PROBE CLEANING AND CALIBRATION YEAR
O2 PROBE CLEANING AND CALIBRATION YEAR
FUEL LINE
HOSES REPLACEMENT 5 YEARS
PUMP FILTER CLEANING YEAR
LINE FILTER FILTERING ELEMENT CLEANING / REPLACEMENT YEAR
COMBUSTION PARAMETERS
CO CONTROL COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
CO2 CONTROL COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
BACHARACH SMOKE INDEX CONTROL COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
NOX CONTROL COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
SMOKE TEMPERATURE CONTROL COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
DELIVERY/SCAVENGE OIL PRESSURE
COMPARISON WITH VALUES RECORDED AT SYSTEM START-UP YEAR
CONTROL

IMPORTANT
In case of heavy-duty operation or when using special fuels, the maintenance intervals must be reduced adapting them to the real
operating conditions, according to the indications of the maintenance technician.

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EXPECTED LIFESPAN
The expected lifespan of burners and relevant components depends very much from the type of application on which the burner is
installed, from cycles of delivered power, from the conditions of the environment in which it is located, from maintenance frequency and
mode, etc.
Standards about safety components provide for a project expected lifespan expressed in cycles and/or years of operation.
Such components ensure the correct operation in standard (*) operating conditions, with periodic maintenance according to the instructions
contained in the manual.
The table below shows the project expected lifespan of the main safety components; approximately, operating cycles correspond to the
burner activations.
When this expected lifespan limit has almost been reached the component must be replaced with an original spare part .
IMPORTANT
warranty conditions (laid down in contracts and/or delivery or payment notes, if necessary) are independent and do not refer to the
expected lifespan stated below.
(*) “Normal” operating conditions means applications on water boilers and steam generators or industrial applications compliant with the
standard EN 746, in environments with temperatures within the limits provided for in this manual and with pollution degree 2 in compliance
with annex M of the standard EN 60335-1.

Project expected lifespan

Safety component
Operating cycles Years of operation
Control box 250 000 10
Flame sensor (1) n.a. 10,000 operating hours
Seal control 250 000 10
Gas pressure switch 50 000 10
Air pressure switch 250 000 10
Gas pressure regulator (1) n.a. 15
Gas valves (with seal check) Until the first seal fault signal
Gas valves (without seal check) ( 2) 250 000 10
Servomotors 250 000 10
5 (every year for fuel oil burners or in the
Liquid fuel hoses n.a.
presence of biodiesel in diesel/kerosene)
Liquid fuel valves 250 000 10
Air fan impeller 50,000 activations 10

(1) The characteristics can degrade over time; during the annual maintenance the sensor must be checked and in case of flame signal
degradation must be replaced.
(2) Using normal mains gas.

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INSTRUCTIONS FOR DETERMINING THE CAUSE LEADING TO IRREGULARITIES IN THE

OPERATION AND THEIR ELIMINATION
IRREGULARITY POSSIBLE CAUSE REMEDY
The equipment locks out with the flame 1 Photoresistor severed or fouled with 1 Clean or replace.
on (red lamp on). The fault is in the flame smoke. 2 Check all the smoke ducts in the
control device. 2 Insufficient draught. boiler and in the chimney.
3 Flame detector circuit interrupted in 3 Replace the equipment.
the equipment. 4 Clean.
4 Dirty flame disk and diffuser.

1 Ignition circuit severed.

2 The ignition transformer cables are
discharging to ground.
3 The ignition transformer leads are not 1 Check the entire circuit.
The equipment goes into lock-out spraying properly connected. 2 Replace.
liquid fuel but the flame does not ignite 4 Ignition transformer is faulty. 3 Restore the connection.
(red light on). 5 The electrode faces are not at the 4 Replace.
right distance. 5 Return to the required position.
6 Electrodes discharge to earth 6 Clean and if necessary replace them.
because they are dirty or their
insulation is cracked: check also the
porcelain insulator terminals.

1 Adjust.
1 Pump pressure is not regular. 2 Drain water from the tank using a
2 Water in the fuel. suitable pump. Never use the burner
The equipment goes to lock-out without 3 Too much combustion air. pump for this purpose.
spraying fuel. 4 Air passage between flame disk and 3 Reduce combustion air.
diffuser excessively closed. 4 Correct the position of the
5 Nozzle worn out or dirty. combustion head adjusting device.
5 Clean or replace.

1 Thermostats (boiler or room) or 1 Raise the thermostats settings, or

pressure switches are open. wait that the contacts close for natural
2 Photoresistor in short circuit. decrease of temperature or pressure.
3 Absence of line voltage, main 2 Replace it.
The burner does not start.(The equipment switch open, meter switch tripped or 3 Activate switches or wait for power to
does not perform the start up program). absence of line voltage. return.
4 Thermostat line not wired according 4 Check the connections and
to diagram or open thermostats. thermostats.
5 Equipment internal fault. 5 Replace it.

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IRREGULARITY POSSIBLE CAUSE REMEDY

Defective flame with sparks. 1 Spraying pressure is too low. 1 Restore it at the required value.
2 Too much combustion air. 2 Reduce combustion air
3 Nozzle inefficient because dirty or 3 Clean or replace.
worn. 4 Drain water from the tank using a
4 Water in the fuel. suitable pump. Never use the burner
pump for this purpose.

1 Insufficient combustion air flow. 1 Increase combustion air.

2 Nozzle inefficient because dirty or 2 Clean or replace.
worn. 3 Decrease diesel flow rate to suit
3 Nozzle capacity too low with respect the chamber (thermal power will
to combustion chamber volume. obviously be lower than necessary)
Flame not properly shaped with presence 4 Combustion chamber unsuitably or replace the boiler.
of smoke and soot. designed or too small. 4 Increase nozzle flow by replacing it.
5 Unsuitable refractory coating (it 5 Modify it, carefully abiding by
reduces excessively the space of the the instructions given by boiler
flame). manufacturer.
6 Boiler or chimney ducts blocked. 6 Arrange for cleaning.
7 Spraying pressure is low. 7 Restore it at the required value.

1 Excessive draught, only when there 1 Adjust the suction fan speed by
is an extractor in the chimney. changing the pulley diameter.
2 Nozzle inefficient because dirty or 2 Clean or replace.
worn. 3 Drain water from the tank using a
Defective flame, flickering or protruding suitable pump. Never use the burner
3 Water in the fuel.
from combustion orifice. pump for this purpose.
4 Dirty flame disk.
5 Too much combustion air. 4 Clean.
6 Air passage between flame disk and 5 Reduce combustion air.
diffuser excessively closed. 6 Correct the position of the
combustion head regulating device.

1 Boiler operating temperature too low

(below the dew point). 1 Increase the operating temperature.
Corrosion inside the boiler. 2 Smoke temperature too low, 2 Increase diesel flow rate is the boiler
approximately below 130 °C for allows it.
diesel.

1 Excessive cooling of smoke

(approximately below 130°C) in the 1 Improve insulation and close any
Soot at chimney outlet. chimney, for an outside chimney not opening letting cold air into the
adequately heat insulated or cold air chimney.
infiltration.

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NOZZLE FLOW RATE TABLE

Nozzle Pump pressure in bar Nozzle
G.P.H. 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 G.P.H.
0,40 1,18 1,27 1,36 1,44 1,52 1,59 1,67 1,73 1,80 1,86 1,92 1,98 2,04 2,10 2,15 2,20 2,25 2,31 2,36 2,40 2,45 0,40
0,50 1,47 1,59 1,70 1,80 1,90 1,99 2,08 2,17 2,25 2,33 2,40 2,48 2,55 2,62 2,69 2,75 2,82 2,88 2,94 3,00 3,05 0,50
0,60 1,77 1,91 2,04 2,16 2,28 2,39 2,50 2,60 2,70 2,79 2,88 2,97 3,06 3,14 3,22 3,30 3,38 3,46 3,53 3,61 3,68 0,60
0,65 1,91 2,07 2,21 2,34 2,47 2,59 2,71 2,82 2,92 3,03 3,12 3,22 3,31 3,41 3,49 3,58 3,66 3,75 3,83 3,91 3,98 0,65
0,75 2,20 2,38 2,55 2,70 2,85 2,99 3,12 3,25 3,37 3,49 3,61 3,72 3,82 3,93 4,03 4,13 4,23 4,32 4,42 4,51 4,60 0,75
0,85 2,50 2,70 2,89 3,06 3,23 3,39 3,54 3,68 3,82 3,96 4,09 4,21 4,33 4,45 4,57 4,68 4,79 4,90 5,00 5,11 5,21 0,85
1,00 2,94 3,18 3,40 3,61 3,80 3,99 4,16 4,33 4,50 4,65 4,81 4,96 5,10 5,24 5,37 5,51 5,64 5,76 5,89 6,01 6,13 1,00
1,10 3,24 3,50 3,74 3,97 4,18 4,38 4,58 4,77 4,95 5,12 5,29 5,45 5,61 5,76 5,91 6,06 6,20 6,34 6,48 6,61 6,74 1,10
1,20 3,53 3,82 4,08 4,33 4,56 4,78 5,00 5,20 5,40 5,59 5,77 5,95 6,12 6,29 6,45 6,61 6,76 6,92 7,07 7,21 7,35 1,20
1,25 3,68 3,97 4,25 4,50 4,75 5,00 5,20 5,40 5,60 5,80 6,00 6,20 6,35 6,55 6,70 6,85 7,05 7,20 7,35 7,50 7,65 1,25
1,35 3,97 4,29 4,59 4,87 5,13 5,38 5,62 5,85 6,07 6,28 6,49 6,69 6,88 7,07 7,26 7,44 7,61 7,78 7,95 8,11 8,27 1,35
1,50 4,42 4,77 5,10 5,41 5,70 5,90 6,24 6,50 6,75 6,98 7,21 7,43 7,65 7,86 8,06 8,26 8,46 8,65 8,83 9,01 9,19 1,50
1,65 4,86 5,25 5,61 5,95 6,27 6,58 6,87 7,15 7,42 7,68 7,93 8,18 8,41 8,64 8,87 9,09 9,30 9,51 9,71 9,92 10,11 1,65
1,75 5,15 5,56 5,95 6,31 6,65 6,98 7,29 7,58 7,87 8,15 8,41 8,67 8,92 9,17 9,41 9,64 9,86 10,09 10,30 10,52 10,72 1,75
2,00 5,89 6,30 6,80 7,21 7,60 7,97 8,33 8,67 8,99 9,31 9,61 9,91 10,20 10,48 10,75 11,01 11,27 11,53 11,78 12,02 12,26 2,00
2,25 6,62 7,15 7,65 8,15 8,55 8,97 9,37 9,75 10,12 10,47, 10,85 11,15 11,47 11,79 12,09 12,39 12,68 12,97 13,25 13,52 13,79 2,25
2,50 7,36 7,95 8,50 9,01 9,50 9,97 10,41 10,83 11,24 11,64 12,02 12,39 12,75 13,10 13,44 13,77 14,09 14,41 14,72 15,02 15,32 2,50
3,00 8,83 9,54 10,20 10,82 11,40 11,96 12,49 13,00 13,49 13,96 14,42 14,87 15,30 15,72 16,12 16,52 16,91 17,29 17,66 18,03 18,35 3,00
3,50 10,30 11,13 11,90 12,62 13,30 13,95 14,57 15,17 15,74 16,29 16,83 17,34 17,85 18,34 18,81 19,28 19,73 20,17 20,61 21,03 21,45 3,50
4,00 11,77 12,72 13,60 14,42 15,20 15,94 16,65 17,33 17,99 18,62 19,23 19,82 20,40 20,95 21,50 22,03 22,55 23,06 23,55 24,04 24,51 4,00
4,50 13,25 14,31 15,30 16,22 17,10 17,94 18,73 19,50 20,24 20,95 21,63 22,30 22,95 23,57 24,19 24,78 25,37 25,94 26,49 27,04 27,58 4,50
5,00 14,72 15,90 17,00 18,03 19,00 19,93 20,82 21,67 22,48 23,27 24,04 24,78 25,49 26,19 26,87 27,54 28,19 28,82 29,44 30,05 30,64 5,00
5,5 16,19 17,49 18,70 19,83 20,90 21,92 22,90 23,83 24,73 25,60 26,44 27,25 28,04 28,81 29,56 30,29 31,00 31,70 32,38 33,05 33,70 5,5
6,00 17,66 19,00 20,40 21,63 22,80 23,92 24,98 26,00 26,98 27,93 28,84 29,73 30,59 31,43 32,25 33,04 33,82 34,58 35,33 36,05 36,77 6,00
6,50 19,13 20,67 22,10 23,44 23,70 25,91 27,06 28,17 29,23 30,26 31,25 32,21 33,14 34,05 34,94 35,80 36,64 37,46 38,27 39,06 39,83 6,50
7,00 20,60 22,26 23,79 25,24 26,60 27,60 29,14 30,33 31,48 32,58 33,65 34,69 35,69 36,67 37,62 38,55 39,46 40,35 41,21 42,06 42,90 7,00
7,50 22,07 23,85 25,49 27,04 28,50 29,90 31,22 32,50 33,73 34,91 36,05 37,16 38,24 39,29 40,31 41,31 42,28 43,23 44,16 45,07 45,96 7,50
8,30 24,43 26,39 28,21 29,93 31,54 33,08 34,55 35,97 37,32 38,63 39,90 41,13 42,32 43,48 44,61 45,71 46,79 47,84 48,87 49,88 50,86 8,30
9,50 27,96 30,21 32,29 34,25 36,10 37,87 39,55 41,17 42,72 44,22 45,67 47,07 48,44 48,77 51,06 52,32 53,55 54,76 55,93 57,09 58,22 9,50
10,50 30,90 33,39 35,69 37,86 40,06 41,73 43,74 45,41 47,20 48,90 50,50 52,00 53,50 55,00 56,40 57,80 59,20 60,50 61,80 63,10 64,30 10,50
12,00 35,32 38,20 40,80 43,30 45,60 47,80 50,00 52,00 54,00 55,90 57,70 59,50 61,20 62,90 64,50 66,10 67,60 69,20 70,70 72,10 73,60 12,00
13,80 40,62 43,90 46,90 49,80 52,40 55,00 57,50 59,80 62,10 64,20 66,30 68,40 70,40 72,30 74,30 76,00 77,80 79,50 81,30 82,90 84,60 13,80
15,30 45,03 48,60 52,00 55,20 58,10 61,00 63,70 66,30 68,80 71,10 73,60 75,80 78,00 80,20 82,20 84,30 86,20 88,20 90,10 91,90 93,80 15,30
17,50 55,51 55,60 59,50 63,10 66,50 69,80 72,90 75,80 78,70 81,50 84,10 86,70 89,20 91,70 94,10 96,40 98,60 100,90 103,00 105,20 107,20 17,50
19,50 57,40 62,00 66,30 70,30 74,10 77,70 81,20 84,50 87,70 90,80 93,70 96,60 99,40 102,20 104,80 107,40 109,90 112,40 114,80 117,20 119,50 19,50
21,50 63,20 68,40 73,10 77,50 81,70 85,70 89,50 93,20 96,70 100,10 103,40 106,50 109,60 112,60 115,60 118,40 121,20 123,90 126,60 129,20 131,80 21,50
24,00 70,64 76,30 81,60 86,50 91,20 95,70 99,90 104,00 107,90 111,70 115,40 118,90 122,40 125,70 129,00 132,20 135,30 138,30 141,30 144,20 147,10 24,00
28,00 82,41 89,00 95,20 101,00 106,40 111,60 116,60 121,30 125,90 130,30 134,60 138,70 142,80 146,70 150,50 154,20 157,80 161,40 164,90 168,30 171,60 28,00
30,00 88,30 95,40 102,00 108,20 114,00 119,60 124,90 130,00 134,90 139,60 144,20 148,70 153,00 157,20 161,20 165,20 169,10 172,90 176,60 180,30 183,80 30,00
G.P.H. Nozzle output flow-rate G.P.H.

1 mbar = 10 mmCA = 100 Pa

1 kW = 860 kcal
Diesel density =0.820 / 0.830 PCI = 10150
PCI Lower Calorific Value
In order to select the nozzle it is necessary to know the pump operating pressure (in bar) and the fuel flow rate to be delivered (in kg/h).
In the vertical column of the used pump pressure it is possible to find the required fuel flow rate (choose the value which was rounded
down).
Next to the flow rate value found, look at the border of the same horizontal line in the column “Nozzles”, to find the corresponding Nozzle
expressed in G.P.H.

Example
Pump pressure: 12 bars
Required capacity: 15 bars
Flow rate indicated on the diagram: 14.57 kg/h
Calculated nozzle: 3.50 G.P.H.

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WIRING DIAGRAMS

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A1 APPARECCHIATURA Wire series colour

B1 PHOTORESISTOR / IONISATION ELECTRODE / UV GNYE GREEN / YELLOW
PHOTOCELL BU BLUE
F1 THERMAL RELAY BN BROWN
FU1÷4 FUSES BK BLACK
H0 EXTERNAL LOCK INDICATOR LIGHT/ AUXILIARY HEATING BK* BLACK CONNECTOR WITH OVERPRINT
ELEMENT OPERATION LAMP
L1 - L2- L3 Phases
H1 OPERATION INDICATOR LIGHT N - Neutral
H2 LOCK-OUT WARNING LIGHT
Ground
H17 FAN OPERATION INDICATOR LIGHT
H18 “2ND STAGE OPERATION LIGHT“
H19 MAIN VALVE OPERATION INDICATOR LIGHT
H23 TRANSFORMER OPERATION INDICATOR LIGHT
K1 FAN MOTOR CONTACTOR
KE EXTERNAL CONTACTOR
MV FAN MOTOR
P1 “HOUR METER“
S1 START/STOP SWITCH
S2 RELEASE BUTTON
S8 1st/2nd STAGE SWITCH
SG MAIN SWITCH
T2 2ND STAGE THERMOSTAT
TC BOILER THERMOSTAT
TS SAFETY THERMOSTAT
X1 BURNER TERMINAL BOARD
X1B/S POWER SUPPLY CONNECTOR
X2B/S 2nd STAGE CONNECTOR
X9 TRANSFORMER CONNECTOR
X10 MOTOR CONNECTOR
Y1/Y2 1st / 2nd STAGE SOLENOID VALVES
Y10 AIR SERVOMOTOR
YS SAFETY SOLENOID VALVE
Z1 FILTRO

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 BALTUR S.P.A.
Via Ferrarese, 10
44042 Cento (Fe) - Italy
Tel. +39 051-6843711
Fax. +39 051-6857527/28
www.baltur.it
[email protected]

Il presente catalogo riveste carattere puramente indicativo. La casa, pertanto, si riserva ogni possibilità di modifica dei dati tecnici e di quant'altro in esso riportato.
Information contained in this catalogue is not binding. The manufacturer reserves the right to change the technical data and any other data it contains.