INSTRUCTION MANUAL

OILFIRED WATER HEATER

TYPE : E1133

CAPACITY : 872 kW

PROD. NO. : E1133-96

ORDER NO. : 51088

ORDERED BY : Ulstein Verft AS

YARD NO./NAME : 300

DELIVERY DATE : 25.06.2013

ULMATEC PYRO AS
6280 SØVIK
NORWAY

PHONE : (47) 70 20 98 70
FAX : (47) 70 20 98 90
EMAIL : pyro@pyro.no
 PYRO OILFIRED WATER HEATER

INDEX LIST INSTRUCTION MANUAL

Contents Page

Installation ...................................................... 3
Startup and test procedure .............................. 4
Technical data................................................. 6
Safety temperature switch............................... 7
Water level pressure switch ............................ 8
Working thermostat ........................................ 9
Oilburner control .......................................... 10
Oilburner ...................................................... 29
List of recommended spareparts ................... 56
Type approval certificate (DNV) .................. 57
Work certificate ............................................ 59
Maintenance of hotwater boiler .................... 60
Oil filter ........................................................ 61

Enclosure:
1. Expansion vessel
2. Oil burner
3. Sanitary pump
4. Drawing: PY-3M-1337 R0
5. Wiring diagram: PY-EL-447 RA
6. Spark arrestor PY-4-295 R0
7. Expansion tank: PY-4-351 R0

2
 PYRO OILFIRED WATER HEATER

INSTALLATION
The heater shall be fastened by screws or by welding on foundation, dimensioned for the heater.
All heaters with burner equipment and automatic control units have been carefully tested and
checked by the manufacturer before delivery.
If, when installing the heater, it should be necessary to dismantle the burner or the automatics to
get the heater in position, it is important that the dismantled equipment is correctly reassembled.
It is important to take notice of the location of the electrical connections, as well as the burner pipe
adjustment in relation to the ignition electrodes, oil nozzle and flame holder. The adjustment
details is shown in the burner manual.
Smoke pipe shall have the same diameter and shall be fitted (mounted) with a minimum of bends.
The pressure safety valves and the expansion tank shall be connected to the boiler.
A shut off valve should be installed on the pipeline between the expansion tank and the boiler (in
case of replacement of the expansion tank.)
Electrical power connections to be arranged in accordance with the enclosed diagrams.

AIR SUPPLY TO THE HEATING PLANT

To ensure satisfactory combustion in the oilburner it is necessary to provide sufficient air supply
to the water heater plant.
This is often solved by the installation of a separate air duct to the burner connection. Such an
arrangement prevents the interference from other environmental air consumers. Approx. 15m3 air
is needed for the combustion of 1 kg. of oil.

OIL PIPE ARRANGEMENT

SINGLE PIPE ARRANGEMENT
Where the bottom of the oil tank is situated on a higher level than the burner pump, a single pipe
from the oil tank to the oilpump suction intake is sufficient.
With single pipe arrangement the bypass plug must be dismantled in such a way that the oil will
circulate in the pump without cracking the shaft sealing (see the enclosed burner manual).
The oil pump is best ventilated by slackening the pressure gauge plug on the pump until the oil
runs without air. A shut off valve should be mounted between the pipeline and the flexible hose (in
case of later removal).

TWO PIPE ARRANGEMENT

Where the oil pump is situated at a higher level than the oil tank, two pipes are necessary. (One
suction pipe and one return pipe).

3
 PYRO OILFIRED WATER HEATER
The suction pipe is conducted from the pump suction side to approx. 10 cm. above the tank bottom
level or other safe connections.
The return pipe is conducted from the pump back to the same tank. (See the enclosed burner
manual).
At the lower end of the suction pipe a back pressure valve (bottom valve) is located either
vertically or horizontally, depending on the pipe connection to the tank. This is in order to prevent
the pump from loosing oil when not operating.
Furthermore shut off valves are fixed to the suction pipe as well as the return pipe between the
pipeline and the flexible hose, in order to facilitate servicing later on.
Dimension of oil pipes shall be in accordance with the table in the burner manual, with respect to
suction height and length.
All oil pump joints shall be carefully tightened to prevent any leakage. With two pipe arrangement
oil pump circulating plug must be in position. The enclosed drawings and instructions shows the
pipe arrangements as well as the pipe dimensions in relation to the pipe length.

INITIAL START OF OIL PUMP

Check that the stop valves are in the open position, then start the burner. After a short internal
ventilation cycle the burner will start.
If the burner should fail to ignite, try once more by pressing the reset button on the control panel.
The burner motor will restart after approx. 1 minute. This is normal because the relay needs this
time to get to the starting position once more.
If the oil do not reach the nozzle at the second attempt, try again by pressing the reset button once
more, and restart the burner. When using a one pipe system it would be necessary to ventilate the
pump.
The enclosed drawings and instructions, with descriptions of the burner and the automatics should
be studied carefully.

4
 PYRO OILFIRED WATER HEATER

START UP AND TEST PROCEDURE

1. Check that all pipe connections are mounted and fixed.

2. Ensure that 2 pc. safety valves and the expansion tank are installed.

3. Fill up the boiler and circuit with water.

4. Start the circulation pumps and check the rotation of the pump motor. Air in the circulation pump
and the system should be ventilated on the highest point of the circuit. Air pockets should be
ventilated when circulating the water and ventilation should be repeated several times.

5. Check the power supply to the boiler, and check rotation of the burner motor.

6. Check that there are no leakages on the fuel oil tubes, and that valves are opened.

7. Check the power supply and Control voltage 230V AC, 24V DC

5
 PYRO OILFIRED WATER HEATER

PLC PANEL OPERATION PROCEDURE

MAIN SCREEN

SETTINGS SCREEN

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 PYRO OILFIRED WATER HEATER
STARTING THE OILBURNER

Set main switch in position 1, and the PLC Ctrl. switch in position PLC.On Panel “Operation screen”
push the button Low-temp Mode or High-temp mode and Oil Burner Auto (The burner begins its
starting cycle (approx.60.sec.)).

OPERATION SCREEN

The burner fan starts the burning chamber preparing period (30.sec.). The air flap will open.

The ignition transformer is activated. The fuel oil solenoid valve opens, and the flame occurs.

The photo-cell activates and surveys the flame.

From the inspection opening it can be observed if the burner flame is sufficient. -See burner manual
for adjustment of burner.

On two step burners, nozzle 2 will open after 15sec. The air flap will open to nozzle 2 set point.

The water heater will now operate automatically on the boiler thermostat, normally adjusted to 65°C
for Low-temp mode and 90°C for High-temp mode.

The temperature for nozzle 2 should be adjusted approx. 5°C lower than nozzle 1.

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 PYRO OILFIRED WATER HEATER

TEST OF EL.HEATING ELEMENTS

From “Settings screen” choose Settings Low Temp buttom

1. Increase the set point on the “Connect El.Heater Section No.”,

2. Push the button El.Heaters Auto, the contactor will connect and ON will be indicated on
panel.

Alternatively the ampere could be checked.

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 PYRO OILFIRED WATER HEATER
START OF EL.CIRULATION PUMPS

Push the button Pumps.

Screen for pumps ctrl. will be open.

Push the button Start ON\OFF for start / test of pumps.

(In normally operation mode push the button St.by ON\OFF Pump No1 will run, if failure
On pump No 1 pump No 2 will start automatic and alarm will be indicated on panel.)
9
 PYRO OILFIRED WATER HEATER

ALARM LIST

Choose Alarm List from Operation screen to reed an acknowledge Alarms

ADJUSTMENT OF WORKING PRESSURE:

In a closed pressurised arrangement, the working pressure on the boiler will be affected by the size
and situation of the expansion vessel likewise the water volume in the system and the adjusted gas
pressure. With cold water in the circuit the pressure to be found on the boiler, should be the static
height from the boiler to the top of the water system plus approx. 0.1 bars.
By cold system, the adjusted gas pressure on the expansion vessel should be the static height from
the expansion vessel to the top of the water system plus 0.1 bars.

SET POINTS/ALARM SENSOR:

Water level pressure switch: 0.2-0.3 bar.
High. temp. safety switch: 95°C.

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 PYRO OILFIRED WATER HEATER

TEST OF WATER LOW LEVEL SAFETY SWITCH:

The water heater is operating as normal.

The set point of the pressure switch is set to 2-3m.W.G. (0.2-0.3bar). Water shall be drained off
the hot water heater until the “pressure switch low water level” is tripping. Alarm function "high
temp. /water level" is indicated on panel.
(Common alarm in control room).

Increase water level to normal value, and the heater restarts.

Alternatively the water level pressure switch could be checked with a pressure pump on the test-
flange connection.

TEST OF THE SAFETY TEMP SWITCH

To perform a test of the safety temp. switch the set point of the safety temperature switch must be
adjusted to a temperature below the working temperature switch.
Reduce the consumption of hot water.
The hot water temperature will increase and the safety temp. switch will stop the boiler. High
temp. /water level alarm will occur (common alarm in control room).
The set point of safety temp. switch should be adjusted to 95°C.
Restart is not possible until water temp. drops 15°C below the set point for the safety temp.
switch, and the safety temp. switch must be manually reset.

TEST FOR FLAME CONTROL

A. When starting:
1. Before starting up, pull the photocell from socket (false flame failure). Photocell shall be kept
in dark.
2. Start the oil burner.
3. Flame ignites.
4. Power supply to the burner should be cut after a delay of 5 sec.
5. The "ignition/flame failure” lights up. Flame failure alarm indicated on panel.
a. Common alarm in the control room.
6. Refit the photocell in socket.
7. The heater plant is restarted by pushing ACK on panel and "Reset Ctrl.Oil Burner".

11
 PYRO OILFIRED WATER HEATER

B. When running:
8. The heater plant is running at normal working temperature.
9. Pull the photocell from its socket, the photocell should be kept in dark.
10. The burner will stop after a time delay of 5 sec.
11. The burner tries one restart after a time delay of approx. 2 min.
12. As in pt. 1-7

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 PYRO OILFIRED WATER HEATER

TECHNICAL DATASHEET

Art.no. E1133

Capacity (kcal/h) 750000

Capacity (kW) 872

El. Heating elements See drawing/wiring diagram

Oil burner type HF740-100-2D

Oil consumption max. (kg/h) 90

Oil viscosity max. C.ST. 50°C 40

Air consumption oil burner max (m3/h) 1350

Water temperature diff inlet/outlet (adjustable) 70 / 90°C

Voltage main/control See wiring diagram

Net. Weight (kG) 3100

Water volume (litres) 1900

Max. working pressure (Bar) 3

Test pressure (Bar) 4,5

Water level pressure switch (Bar) 0,2

Normal working temp. (°C) 80 (adjustable)

Set point safety temp. switch (°C) 95

Plate material H2, DIN17150

Pipe/tube material St.35.8.1, DIN17175

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 SAFETY TEMPERATURE SWITCH
The scale is an indication of the set temperature and can have a small deviation from the actual
value. For an accurate setting use a thermometer and adjust.

Adjustment of the knob:

Electrical connections:

Terminal 1: Entry phase

Terminal 2: Exit phase – heating
Terminal 3: Exit phase cooling

Reset of the safety temp. switch:

Remove the cover and press the red button

64 54 110

14
 WATER LEVEL PRESSURE SWITCH.
Adjustment of the pressure range:
From Pyro AS, the pressure switch is preadjusted to 0.2 bar (i.e. 2.0 M.W.G.)
If a later adjustment is necessary, this is done with a 5mm allen key on the pressure switch body.
The scala on the pressure switch indicates + or -.
The pressure difference is fixed.

The pressure switch connection to the water heater is equipped with a test flange for easier performing the
adjustment.
With water pressure higher than 0,2 bar, the switch 1-3 is connected.
With water pressure lower than 0,2 bar, the switch 1-3 is open, and the alarm (low water level) will appear.

15
WORKING THERMOSTAT

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35
 LIST OF RECOMMENDED SPAREPARTS FOR BOILER E1133
WITH OILBURNER TYPE HF740-100.

Art.no Description Unit Pcs.

2283 Photoresist. Detect QRB3 Pc. 1
RF1530510 Ignition transformer ZM20/10 Pc. 1
831755342 Oil nozzle 10 gph. 45° Pc. 1
831754464 Oil nozzle 6 gph 60° Pc. 1
RF1621080 Ignition cable L=530mm Pc. 2
RF1135010 Ignition electrode Pc. 2
RF1513060 Electric motor 1,5kW 400/690V Pc. 1
RF1461401 Baffle plate 114x40 Pc. 1
RF1661140 Oilpump AJ6 AC 1000 Pc. 1
RF1690080 Air wheel Ø240x102x24V Pc. 1
RF1710145 Oil tube 3/8"x1000mm Pc. 1
RF1523165 Servomotor SQN75.494A21 Pc. 1
RF1618071 Coil for solenoid valve SV04 R3 ¼” Pc. 2
2606 Control box type LAL 2.25 Pc. 1
227145 Temperature sensor TA3171 Pc. 1
22012 Safety thermostat type Trafag 472 Pc. 1
2264-1 Pressure switch MBC5100 Pc. 1
2712-2 Contactor DIL M9-10 230V Pc. 1
2256 Thermohydrometer THR 80.11 Pc. 1
80161 O-ring 249.3x5.7mm EPDM Pc. 1
1734 Safety valve 1 ¼" 3Bar Pc. 1

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38
PYRO AS, GAMLEM, N-6280 SØVIK

WORKS CERTIFICATE
OF HYDRAULIC TEST AND EXAMINATION.

Component Pyro hot water boiler

:
Production no: E1133-96 Art.no: E1133
Pyro order no: 51088 Date: 03.10.2012
Equipment intended for: Ulstein Verft AS

THIS CERTIFICATE IS ISSUED TO CERTIFY THAT THE EQUIPMENT DESCRIBED

HAVE BEEN TESTED BY HYDRAULIC TEST PRESSURE AND VISUALLY
EXAMINED.
NO LEAKAGES OR DEFECTS COULD BE SEEN.

Rated work pressure: 3,0 Bar

Test pressure: 4,5 Bar
Test pressure holding time: 1 Hour
Date of inspection: 07.06.13 Inspected by: Jarle Håskjold
Remarks:

Date: Signature:
07.06.2013 Palmar Bjørnøy

39
 MAINTENANCE OF PYRO HOT WATER BOILERS
WEEKLY:

1. The water level shall be checked. If necessary, refill water.

2. Check that the oilburner operate according to the manual.

(Check the flame through inspection glass when the burner is running.)
See burner manual for possible adjustments.

MONTHLY:
1. The fuel oilfilter in front of the boiler shall be inspected and cleaned. (Change filter cartridge
if necessary).
If the filter is dirty, the filter in the oilpump shall be cleaned. (See burner manual)

2. Check through the inspection glass when the burner is running, if it is coke residue in
combustion chamber, the boiler shall be cleaned.

YEARLY:
Oilfired section:
1. Dismount the burner and the burner plate / cleaning doors.

2. Remove the burner/burnerplate and the cleaning doors and clean the boiler with a brush or
cleaning liquid).

3. Check ceramic plates on the burner plate.

If the plates are worn they have to be changed.
Check gasket for the cleaning doors, change gasket if necessary.

4. Check the burner tube. Clean the tube if necessary (See burner manual).

5. Dismount the burner insert, clean parts and change oilnozzles. Check adjustment (See burner
manual).

6. Check air inlet and blower wheel. Clean if necessary.

7. Check the gas pressure on expansion vessel. When the water is cold, the gas pressure shall be
equal to the static height over the expansion vessel.

8. Filter in the oilpump shall be cleaned.

Instrumentation/
safety valves 1. Check the set point for the thermostats and the pressure switch. See manual.

2. Check that the safety valves are not leaking.

40
 GA Oilfilter for light fuel oil.

Size Type Dimensions Mesh Max.

width flow
A B C D
1/4" 70452/0.1 1/4" 1/4" 61 mm 75 mm 0.1 mm 350 l/h
3/8" 70451/0.1 3/8" 3/8" 61 mm 75 mm 0.1 mm 420 l/ h
1/2" 703120.2 1/2" 1/2" 81 mm 116 mm 0.2 mm 1200 l/h
3/4" 70207/0.2 3/4" 3/4" 96 mm 144 mm 0.2 mm 2000 l/h
1" 70101/0.3 1" 1" 120 mm 181 mm 0.3 mm 2800 l/h
1 1/4" 70502/0.3 1 1/4" 1 1/4" 190 mm 255 mm 0.3 mm 7000 l/h

Test pressure: 2 Bar.

41
’reflex’
Montage-, Betriebs- und Wartungsanleitung
Installation, operating and maintenance instructions

Allgemeine Sicherheitshinweise General safety instructions

’reflex’ Membran-Druckausdehnungsgefäße sind ’reflex’ diaphragm pressure expansion vessels are pressure
Druckgeräte. Eine Membrane teilt das Gefäß in einen devices. They have an gas cushion. A diaphragm separates
Wasser- und einen Gasraum mit Druckpolster. Die ’reflex’ in a gas and a water space. The attached conformity
Konformität im Anhang bescheinigt die Übereinstimmung certification certifies the compliance to the Pressure Equipment
mit der Richtlinie 97/23/EG. Der Umfang der Baugruppe directive 97/23/EC. The scope of the subassembly can be found
ist der Konformitätserklärung zu entnehmen. Die gewählte in the conformity declaration. The technical specification selected
technische Spezifikation zur Erfüllung der grundlegenden to fulfill the fundamental safety requirements of annex I of the
Sicherheitsanforderungen des Anhangs I der Richtlinie 97/23/ directive 97/23/EC can be found on the nameplate or conformity
EG ist dem Typenschild bzw. der Konformitätserklärung zu declaration.
entnehmen.
Montage, Betrieb, Prüfung vor Inbetriebnahme, Mounting, operation, test before operation,
wiederkehrende Prüfungen regular check-up
nach den nationalen Vorschriften, in Deutschland nach According to the governing local regulations. The installation and
der Betriebssicherheitsverordnung. Entsprechend sind the operation to be performed to the art of technique by profes-
Montage und Betrieb nach dem Stand der Technik durch sional installers and authorised technical personnel. Necessary
Fachpersonal und speziell eingewiesenes Personal durch- tests before operation, after fundamental changes in the instal-
zuführen. Erforderliche Prüfungen vor Inbetriebnahme, nach lation and periodic inspection have to be initiated by the user
wesentlichen Veränderungen der Anlage und wiederkehrende acc. to the requirements of the Operational Safety Regulation.
Prüfungen sind vom Betreiber gemäß den Anforderungen der Recommendations regarding periodic check-up: → paragraph
Betriebssicherheitsverordnung zu veranlassen. Empfohlene „periodic check-up“.
Prüffristen siehe Abschnitt „Prüffristen“. Es dürfen nur ’reflex’ Only ’reflex’ without visible external damage to the pressure body
ohne äußere sichtbare Schäden am Druckkörper installiert und may be installed and operated.
betrieben werden.
Veränderungen am ’reflex’, Changes to the ’reflex’
z. B. Schweißarbeiten oder mechanische Verformungen, sind for instance welding operations or mechanical deformations are
unzulässig. Bei Austausch von Teilen sind nur die Originalteile impermissible. Only original parts of the manufacturer may be
des Herstellers zu verwenden. used when replacing parts.
Parameter einhalten Observe the Parameters
Angaben zum Hersteller, Baujahr, Herstellnummer sowie die Details concerning manufacturer, year of manufacture, serial
technischen Daten sind dem Typenschild zu entnehmen. Es sind number and the technical data are provided on the name plate.
geeignete sicherheitstechnische Maßnahmen zu treffen, damit Suitable measures must be taken so that the specified permis-
die angegebenen zulässigen max. und min. Betriebsparameter sible maximum and minimum operating parameters (pressure,
(Druck, Temperatur) nicht über- bzw. unterschritten werden. temperatrue) are adhered to. Exceeding the permissible ope-
Eine Überschreitung des zulässigen Betriebsüberdruckes was- rating pressure of the water and the gas systems both during
ser- und gasseitig, sowohl im Betrieb als auch beim gasseitigen operation and when filling the gas system must be excluded. On
Befüllen, ist auszuschließen. no account must the gas pre-pressure exceed the permissible
Der Vordruck p0 darf keinesfalls den zul. Betriebsüberdruck operating pressure. Even with vessels having a permissible
überschreiten. Selbst bei Gefäßen mit zul. Betriebsüberdruck operating pressure above 4 bar, the gas prepressure for storage
größer 4 bar darf der Vordruck bei Lagerung und Transport nicht and transport may not exceed 4 bar. An inert gas, for instance
mehr als 4 bar betragen. Zur Gasbefüllung ist ein Inertgas, z.B. nitrogen, should be used for the gas charge.
Stickstoff, zu verwenden.
Korrosion/Inkrustation Corrosion/Incrustiation
’reflex’ sind aus Stahl gefertigt, außen beschichtet und innen roh. ’reflex’ vessels are made of steel, coated on the outside and
Ein Abnutzungszuschlag (Korrosionszuschlag) wurde nicht vor- untreated on the inside. No wear allowance (corrosion allo-
gesehen. Der Einsatz darf nur in atmosphärisch geschlossenen wance) has been provided for. They may only be used in atmos-
Systemen mit nicht korrosiven und chemisch nicht aggressiven pherically closed systems with non-corrosive and chemically
und nicht giftigen Wassern erfolgen. Der Zutritt von Luftsauerstoff non-aggressive water. The ingress of amospheric oxygen into
in das gesamte Heiz- und Kühlwassersystem durch Permeation, the entire heating and cooling water system through permeation,
Nachspeisewasser usw. ist im Betrieb zuverlässig zu minimie- water replenishment, etc., must be reliably minimised in opera-
ren. Wasseraufbereitungsanlagen sind nach dem aktuellen tion. Water treatment facilities are to be designed, installed and
Stand der Technik auszulegen, zu installieren und zu betreiben. operated according to state of the art.
Wärmeschutz Thermal protection
In Heizwasseranlagen ist bei Personengefährdung durch zu In heated water systems, a warning instruction must be provided
hohe Oberflächentemperaturen vom Betreiber ein Warnhinweis by the operator near the ’reflex’ if persons are endangered by
in der Nähe des ’reflex’ anzubringen. excessive surface temperatures.
Aufstellungsort Place of installation
Eine ausreichende Tragfähigkeit des Aufstellortes ist unter It must be ensured that the place of installation has an adequate
Beachtung der Vollfüllung des ’reflex’ mit Wasser sicherzustellen. load-carrying capacity, taking into account the 'reflex' will be filled
Für das Entleerungswasser ist ein Ablauf bereitzustellen, erfor- with water. A drain must be provided for the draining water and
derlichenfalls ist eine Kaltwasserzumischung vorzusehen (siehe a cold water admixture facility must be provided if required (see
auch Abschnitt „Montage“). Eine Aufstellung in erdbebengefähr- also the section "Installation"). Installation in earthquake zones
deten Gebieten ist nicht zulässig. is not permissible.

Das Missachten dieser Anleitung, insbesondere der Failure to heed these instructions especially the safety instruc-
Sicherheitshinweise, kann zur Zerstörung und Defekten am tions can result in the destruction of and defects on the ’reflex’,
’reflex’ führen, Personen gefährden sowie die Funktion beein- endanger persons and impair the operation. Any claims for war-
trächtigen. Bei Zuwiderhandlung sind jegliche Ansprüche auf ranty and liability are excluded if these instructions are violated.
Gewährleistung und Haftung ausgeschlossen.
’reflex’ 2

Einsatzbereiche/Betriebsparameter Application, operating parameters

’reflex’ sind zur Druckhaltung und zum Volumen- ’reflex’ are suitable for pressure holding and volume
ausgleich in geschlossenen Heiz-, Solar- und compensation in closed heating water, solar and coo-
Kühlwassersystemen geeignet. ling water systems.

Der Glykolanteil im Wasser darf max. 50% betragen. The glycol content in the water may not exceed 50%.
Bei der Dosierung von Zusätzen sind die Angaben der When dosing additives, the instructions of the manuf-
Hersteller bezüglich der zulässigen Dosiermengen, acturers with regard to the reliable dosing quantities,
insbesondere auch hinsichtlich Korrosion, zu beach- especially with regard to corrosion, must be observed.
ten. ’reflex’ sind für Öl ungeeignet und für Medien der ’reflex’ are unsuitable for oil and are not permitted for
Fluidgruppe 1 nach Richtlinie 97/23/EG (z. B. giftige media of fluid group 1 according to directive 97/23/EC
Medien) nicht zugelassen. Andere als die angege- (e.g. toxic media). Media other than those specified
benen Medien auf Anfrage. on request.

zul. Vorlauftemperatur perm. advance temperature

der Versorgungsanlage: tVorlauf max + 120 °C of the supply system: tsupply max+ 120 °C

min. Betriebstemperatur: tmax - 10 °C min. operating temperature: tmax - 10 °C

(nur bei entsprechendem Frostschutzmittelzusatz) (only with addition of suitable anti-freeze agent)

max. Dauerbetriebstempe- max. continuous operating temperature

ratur an der Membrane: t + 70 °C at the diaphragm: t + 70 °C

zul. Betriebsüberdruck: pmax → Typenschild perm. operating pressure: pmax → type plate

min. Betriebsüberdruck: pmin 0 bar min. operating pressure: pmin 0 bar

Blasenmembrane: ’reflex A, E, G, EN, S,’ Diaphragm: ’reflex A, E, G, EN, S,’

Halbmembrane: ’reflex F, N, NG, S’ Bladder (non-replaceable): ’reflex F, N, NG, S’

Gasraum: Stickstoff Gas space: Nitrogen

(Fluidgruppe 2 (fluid group 2 acc.
nach RL 97/23/EG) to directive RL 97/23/EG)

Wasserraum: Wasser, Water space: Water,

Wasser-/Glyklolgemisch Water-/Glycol mixture
(max. 50% Glykolanteil; (max. 50% glycol fraction;
Fluidgruppe 2 nach RL 97/23/EG) fluid group 2 acc to. direc-
tive RL 97/23/EG)

Montage Installation

Aufstellung in einem frostfreien Raum so, dass eine Install in a frost-free room so that inspection is possi-
allseitige Besichtigung möglich ist, das Gasfüllventil ble from all sides, the gas filling valve and the water
sowie die wasserseitige Absperrung und Entleerung shut-off and discharge are accessible and the name
zugänglich sind und das Typenschild erkennbar bleibt. plate remains visible.
Spannungsfreier (momentenfreier) Einbau erfor-
derlich, keine zusätzlichen Belastungen durch Stress-free installation is required, no additional
Rohrleitungen oder Apparate zulässig. loads due to piplines or equipment!
Wandhalterung für ’reflex’ 8-25 l erforderlich
(für ’reflex’ 8-25 l als Zubehör lieferbar). Wall bracket for ’reflex’ 8-25 l required (for ’reflex’ 8-25 l
Einbaulage: available as accessory).
reflex F senkrecht an den Einbaulage:
vorgesehenen Laschen reflex F vertical with the straps
reflex N, NG 8-25 senkrecht provided
reflex S 2-40 senkrecht reflex N, NG 8-25 vertical
reflex EN 18-80 senkrecht reflex S 2-40 vertical
reflex N, NG 35-80 senkrecht stehend oder reflex EN 18-80 vertical
reflex S 50-80 waagerecht (wobei reflex N, NG 35-80 vertical upright or
Wasseranschluss nach unten)
reflex S 50-80 horizontal (water connection
reflex N, NG, S ab 100 l senkrecht stehend down)
reflex A, E senkrecht stehend reflex N, NG, S ab 100 l vertical upright
reflex G senkrecht stehend reflex A, E vertical upright
reflex G vertical upright
 3 ’reflex’

Gesicherte Absperrung mit Entleerung für Provide secure shut-off with drainage for main-
Wartungsarbeiten vorsehen (extra bestellen). tenance operations (order separately). With larger
Bei größeren Anlagen ist auch die getrennte systems, the separate arrangement of drainage
Anordnung von Entleerung und Absperrung mög- and shut-off is also possible.
lich.
Expansion lines must be dimensioned and
Ausdehnungsleitungen sind nach den nationalen installed according to the requirements of the specific
Vorschriften, in Deutschland nach den Forderungen national regulations, in Germany according to the
der DIN EN 12828, zu dimensionieren und zu installie- requirements of DIN EN 12828. Frost-free conditions
ren. Auf Frostfreiheit ist unbedingt zu achten. are essential.
Einbindung in den Kreislauf vorzugsweise auf der Incorporate in the circuit preferably on the suction
Saugseite der Umwälzpumpe im Rücklauf zum side of the circulating pump in the return to the boiler,
Heizkessel, Solarkollektor oder zur Kältemaschine. solar collector or refrigeration machine. An in-line
Bei Rücklauftemperaturen > 70 °C ist ein ’V Vorschalt- vessel is required with return temperatures > 70 °C,
gefäß’ erforderlich, bei Rücklauftemperaturen < 0 °C and it is recommended at return temperatures < 0 °C.
wird es empfohlen.
Nachspeiseleitungen sind in das zirkulierende Replenishment lines must be incorporated in the
Anlagenwasser, nicht in die Aus-dehnungsleitung ein- circulating plant water, not in the expansion line.
zubinden.

Beispiel einer Heizungsanlage Beispiel ’reflex N’

Example of a heating system Example ’reflex N’
Gasfüllventil
Gas filling valve

gesicherte Absperrung
protected shut-off with
Wasseranschluss
Water connection
pSV
Entleerung
Drain
H[m]
Statische Höhe
Static height Zubehör
Accessory
t
Nachspeisung
Replenishment
’reflex’

’reflex V Vorschaltgefäß’ nur für gesicherte Absperrung mit

’reflex V In-line vessel’ only for Entleerung
t > 70°C protected shut-off with drain
t < 0°C

Inbetriebnahme Start-up

’reflex’ wasserseitig absperren und entleeren. Shut off ’reflex’ water system and drain. The expan-
Die Ausdehnungsleitung ist zu spülen und von sion line is flushed and cleaned of coarse dirt.
Grobschmutz zu befreien.
’reflex’ 4

Achtung! Attention!
Den zulässigen Betriebsdruck Do not exceed the maximum operating
(→ Typenschild) keinesfalls überschreiten. pressure (acc. to name plate). The vessel
Das Gefäß kann bersten. might burst.

Bei falscher Einstellung des Vordruckes If the preset pressure is incorrectly set, the
und des Anlagenfülldruckes ist die Funktion operation of the ’reflex’ is not guaranteed
des ’reflex’ nicht bzw. nur unzureichend or only insufficiently so.
gewährleistet.

Vordruck p0 am Gasventil auf Mindest- Setting pre-pressure p0 to minimum

betriebsdruck der Anlage einstellen operating pressure of the System
- Erff. werksseitig eingestellten - If necessary reset factory-set pre-
Vordruck p0 auf geforderten Wert pressure p0 to required value (minimum
(Mindestbetriebsdruck der Anlage) operating pressure of plant, release gas
neu einstellen, bei zu hohem Druck if pressure is too high at gas-filling valve,
am Gasfüllventil Gas ablassen, bei fill with gas e.g. using a nitrogen cylinder,
zu geringem Druck Gas z.B. mittels if pressure is too low
Stickstoffflasche auffüllen. - Enter newly set pre-pressure on the
- Neu eingestellten Vordruck p0 auf dem name plate
Typenschild eintragen. - Calculation of pre-pressure p0
- Berechnung des Vordruckes p0:

p0 [bar] = H[m] + 0,2 bar1) + p2) + pP3) p0 [bar] = H[m] + 0,2 bar1) + p2) + pP3)
10 10
1) Empfehlung 1) Recommendation
2) Verdampfungsdruck bei Heißwasseranlagen 2) Evaporation pressure with hot water systems
> 100 °C > 100 °C
3) Differenzdruck Umwälzpumpe, nur bei Einbau 3) Differential press. circulation pump, only to be
des ’reflex’ auf der Druckseite der considered if ’reflex’ is installed on the press.
Umwälzpumpe berücksichtigen side of the circulation pump

p0 ≥ 1 bar (Empfehlung auch für geringer p0 ≥ 1 bar (Recommendation also for lower
berechnete Werte) calculation values)

Absperrung vorsichtig öffnen, Carefully open shut-off, carefully bleed the

die Ausdehnungsleitung sorgfältig expansion line and close the drain.
entlüften und die Entleerung schließen.

Fülldruck pF durch wasserseitiges Befüllen Apply filling pressure pF by filling on the

aufbringen. water side.
Achtung: Beim Füllen aus Trinkwassernetzen Caution: When filling from potable water
unbedingt die nationalen Vorschriften, in systems it is imperative to
Deutschland die Sicherheitshinweise der observe the safety instruc-
DIN 1988 T4, zum Schutz des Trinkwassers tions and the specific natio-
beachten. nal regulations for the pro-
tection of potable water, in
pF [bar] ≥ p0 + 0,3 bar Germany the safety instruc-
tions of DIN 1988 Part 4.
im entlüfteten Zustand.
pF [bar] ≥ p0 + 0,3 bar
Enddruck pe wasserseitig nachfüllen
(Beispiel Heizungsanlage) in the bled state.
- Anlage auf max. Vorlauftemperatur
fahren (thermische Entgasung) Replenish final pressure pe
- Umwälzpumpen ausschalten, Anlage on the water side (example
nachentlüften heating system)
- Wasser nachspeisen bis zum Enddruck pe - Run system to maximum
advance temperature
pe [bar] ≤ pSV - 0,5 bar (thermal degassing)
- Switch off circulation
pumps, re-bleed system
- Replenish water up to
the final pressure pe

pe [bar] ≤ pSV - 0,5 bar

Das ’reflex’ ist jetzt betriebsbereit. The ’reflex’ is now ready for operation.
 5 ’reflex’
Wartung Maintenance
Es ist eine jährliche Wartung erforderlich. Annual maintenance is required.
Äußere Überprüfung External check
Beschädigungen (z.B. Korrosion) am ’reflex’ sichtbar? Bei Damage (for instance corrosion) visible? In the case of
Großgefäßen im Zweifelsfall Reflex-Servicedienst ein- large vessels involve service; replace smaller vessels.
schalten; bei Kleingefäßen Austausch.
Membranprüfung Diaphragm inspection
Stickstoffventil kurz betätigen, falls Wasser entweicht: Briefly actuate the nitrogen valve. If water escapes:
bei ’reflex N, NG, EN, S, F’: Austausch ’reflex N, NG, EN, S, F’: Exchange
bei ’reflex A, E, G’: Reflex-Servicedienst einschalten und ’reflex A, E, G’: Inform Reflex service and exchange blad-
Blasenmembrane austauschen der diaphragm
Überprüfung der Wasserqualität Checking the water quality
Die Anforderungen an geschlossene Heiz- und The requirements on closed heating and cooling
Kühlkreisläufe sind zu erfüllen. circuits must be met.
Druckeinstellung Pressure setting
Anlage bei konstanter Temperatur fahren und beaufsich- Run constant temperature with system operation and con-
tigen. tinuously monitor the system.
1. ’reflex’ wasserseitig absperren, falls der Druck im 1. Isolate reflex vessel from water system, in case the
’reflex’ > 4 bar, dann zunächst Druck am Gasventil auf pressure in ’reflex’ > 4 bar then, first reduce pressure
4 bar reduzieren, on gas filling valve to 4 bar,
2. wasserseitig entleeren 2. Drain waterside
Vordruck p0 einstellen → Inbetriebnahme Pre-set pressure p0 setting → Start-up
Gasfüllventil und, falls vorhanden, Gasmanometer auf Check gas filling valve and, if available, gas press. gauge for leaks,
Dichtheit prüfen, bei Wartungsarbeiten am Gasfüllventil ist when conducting maintenance operations on the gas filling valve
das Gefäß zusätzlich gasseitig zu entleeren. the vessel gas system must be drained in addition.
Fülldruck pF einstellen → Inbetriebnahme Filling pressure pF setting → Start-up
Enddruck pe einstellen → Inbetriebnahme Final pressure pe setting → Start-up
Das ’reflex’ ist jetzt wieder betriebsbereit. Das ’reflex’ ist jetzt wieder betriebsbereit.
Demontage Disassembly
Vor der Prüfung oder Demontage des ’reflex’ bzw. drucktra- Before any check-up or disassembling of the vessel as well
gender Teile ist ’reflex’ drucklos zu machen: as the parts which exposed to pressure, the ’reflex’ vessel
1. ’reflex’ wasserseitig absperren, falls der Druck im needs to be pressure-less:
’reflex’ > 4 bar dann zunächst Druck am Gasventil auf 1. Isolate reflex vessel from water system, in case the
4 bar reduzieren, pressure in ’reflex’ > 4 bar, then first reduce pressure on
2. Wasserseitig entleeren, gas filling valve to 4 bar,
3. Gasseitig am Gasventil drucklos machen 2. Drain water side,
Neubefüllung → Inbetriebnahme 3. Gas-side through gas valve to be pressure-less
Bei Nichtbeachtung besteht die Gefahr der Zerstörung der For re-filling vessel → Start-up
Membrane. Not following instructions can result in diaphragm failure.
Prüfung vor Inbetriebnahme Test before operation
Die jeweiligen nationalen Vorschriften für den Betrieb The specific governing local regulations for the operation of
von Druckgeräten sind in jedem Fall zu beachten. pressure equipment have to be considered in any case.
In Deutschland ist die Betriebssicherheitsverordnung In Germany the Operational Safety Regulation § 14 and
§14 und hier insbesondere §14 (3) Nr. 6 zu beachten. especially § 14 (3) No. 6 has to be followed.

Prüffristen Periodic check-up

Eingruppierung der ’reflex’ in Diagramm 2 des Anhangs II Classification of the 'reflex' in Chart 2 of annex II of the
der Richtlinie 97/23/EG sowie empfohlene maximale directive 97/23/EC and recommended maximum inspection
Prüffristen (in Deutschland unter Berücksichtigung der intervals (in Germany taking account of the Operational
Betriebssicherheitsverordnung § 15): Safety Regulation § 15):
Gültig bei strikter Einhaltung der ’reflex’ Montage-, Valid with strict adherence to the 'reflex' installation, ope-
Betriebs- und Wartungsanleitung und Betrieb bei Druck- rating and maintenance instructions and operation with
und Vorlauftemperaturschwankungen vergleichbar einer pressure and flow temperature fluctuations comparable to
witterungsgeführten Fahrweise: an atmospherically guided mode of operation:
äußere Prüfung: keine Forderung nach § 15 (6) external inspection: no requirement acc. to § 15 (6)
innere Prüfung: internal inspection:
- Höchstfrist nach § 15 (5) bei ’reflex N, NG, EN, S, F’; - maximum interval acc. to § 15 (5) with ’reflex N, NG, EN,
sind geeignete Ersatzmaßnahmen zu ergreifen (z. B. S, F’; appropriate substitute measures must be taken
Wanddickenmessung und Vergleich mit konstruktiven (e.g. wall thickness measurement and comparison with
Vorgaben; diese können beim Hersteller angefordert design specifications; these can be obtained from the
werden) bzw. manufacturer) or
- Höchstfrist nach § 15 (5) bei ’reflex A, E, G’ mit - maximum interval acc. to § 15 (5) with ’reflex A, E, G’
Blasenmembrane und Dokumentation der jährlichen with bladder diaphragm and documentation of the annual
Wartungsarbeiten. maintenance work.
Festigkeitsprüfung: Höchstfrist nach § 15 (5) ggf. in Strength test: maximum interval acc. to § 15 (5)
Verbindung mit § 15 (10) if so in connection with § 15 (10)
Die tatsächlichen Fristen muss der Betreiber auf The actual intervals must be laid down by the
Grundlage einer sicherheitstechnischen Bewertung, operator on the basis of a safety evaluation,
unter Beachtung der realen Betriebsverhältnisse, der taking due account of the actual operating
Erfahrung mit Betriebsweise und Beschickungsgut conditions, the experience with operation
und unter Berücksichtigung der gültigen nationalen mode and operating medium and the applica-
Vorschriften für den Betrieb von Druckgeräten festlegen. ble national regulations for the operation of pressure equipment.
 Anhang 1
’reflex’ Annex 1

Konformitätserklärung für eine Baugruppe Konstruktion, Fertigung, Prüfung von Druckgeräten

Declaration of conformity of an assembly Design – Manufacturing – Product Verification

Angewandtes Konformitätsbewertungsverfahren nach Richtlinie für Druckgeräte

97/23/EG des Europäischen Parlaments und des Rates vom 29. Mai 1997
Operative Conformity Assessment according to Pressure Equipment Directive
97/23/EC of the European Parliament and the Council of 29 May 1997

Membran-Druckausdehnungsgefäße: ’reflex F’, ’N’, ’NG’, ’EN’, ’S’, ’G’,

universell einsetzbar in Heiz-, Solar- und Kühlwassersystemen
Diaphragm Pressure Expansion vessels: ’reflex F’, ’N’, ’NG’, ’EN’, ’S’, ’G’,
for operation in heating, solar and cooling systems

Angaben zu Behälter, Seriennummer, Typ und Betriebsgrenzen gemäß Typenschild

Data about vessel, serial no., type and working limits according to name plate
Beschickungsgut Wasser / Inertgas gemäß Typenschild
Operating medium Water / Inertgas according to name plate
Druckgeräterichtlinie, prEN 13831:2000
Normen, Regelwerk
gemäß Typenschild
Pressure Equipment Directive, prEN 13831:2000
Standards
according to name plate
Druckgerät Baugruppe nach Richtlinie 97/23/EG Artikel 3 Abs.
2.2 bestehend aus: Behälter, Membrane, Ventil und
Manometer (soweit vorhanden)
Pressure equipment assembly acc. to Directive 97/23/EC article 3 para-
graph 2.2 consisting of: vessel, diaphragm, valve and
manometer (as available)
Fluidgruppe
2
Fluid group
Konformitätsbewertungsverfahren nach Modul B+D ’reflex N, NG, EN, S, G’
Conformity assessment acc. to module A ’reflex F’
Kennzeichnung gem. Richtlinie 97/23/EG CE 0045 ’reflex N, NG, EN, S, G’
Label acc. to Directive 97/23/EC CE ’reflex F’
Zertifikat-Nr. der EG-Baumusterprüfung → Anhang 2
Certificate No. of EC Type Approval → annex 2
Zertifikat-Nr. der Bewertung des QS-Systems (Modul D)
07 202 1403 Z 0836/9/D0045
Certificate No. of certification of QS-System (module D)
Benannte Stelle für Bewertung des QS-Systems TÜV Nord Systems GmbH + Co. KG
Notified Body for certification of QS-System Große Bahnstraße 31, 22525 Hamburg
Registrier-Nr. der Benannten Stelle
0045
Registration No. of the Notified Body
Hersteller: Der Hersteller erklärt, daß die Baugruppe die
Manufacturer: Anforderungen der Richtlinie 97/23/EG erfüllt.
Reflex Winkelmann The manufacturer herewith certifies this assembly is in
GmbH + Co. KG conformity with directive 97/23/EC.
Gersteinstraße 19
59227 Ahlen - Germany
Telefon: +49 23 82 / 70 69 - 0
Telefax: +49 23 82 / 70 69 - 588 Manfred Nussbaumer Volker Mauel
E-Mail: info@reflex.de Mitglieder der Geschäftsführung / Members of the Management
Anhang 2
Annex 2
’reflex’

Zertifikat-Nr. der EG-Baumusterprüfung

Certificate No. of EG type approval

Typ Zertifikat-Nr.
Type Certificate No.
’reflex N’ 8 - 25 Liter 3 bar - 120 °C 04 202 1 450 06 00094
35 Liter 3 bar - 120 °C 07 202 1403 Z 0471/0/D0045
50 - 140 Liter 6 bar - 120 °C 04 202 1 932 01 00029
200 - 1.000 Liter 6 bar - 120 °C 04 202 1 932 01 00031
’reflex NG’ 18 - 35 Liter 3 bar - 120 °C 04 202 1 450 06 00121 A
12 - 35 Liter 6 bar - 120 °C 07 202 1403 Z 0492/8/D0045
50 - 140 Liter 6 bar - 120 °C 04 202 1 450 05 00700
’reflex EN’ 18 - 80 Liter 3 bar - 120 °C 07 202 1 450 06 00357
’reflex S’ 8 - 25 Liter 10 bar - 120 °C 04 202 1 932 01 00106
33 Liter 10 bar - 120 °C 04 202 1 932 01 00099
40 Liter 10 bar - 120 °C 04 202 1 450 03 00245
50 - 600 Liter 10 bar - 120 °C 04 202 4 450 02 00655
’reflex A’ 150 - 350 Liter 6 bar - 120 °C 04 202 1 932 01 00048 Rev. 1 A
’reflex E’ 400 - 1.000 Liter 6 bar - 120 °C 04 202 1 932 01 00030 Rev. 1 A
’reflex G’ 80 (Ø 480) Liter 10 bar - 120 °C 04 202 1 932 01 00082
80 (Ø 450) Liter 40 bar - 120 °C 04 202 1 450 02 00413
80 (Ø 450) - 1.000 (Ø 750) Liter 10 bar - 120 °C 04 202 1 450 02 00078 A
80 (Ø 450) - 1.000 (Ø 750) Liter 16 bar - 120 °C 04 202 1 450 02 00155 A
100 - 1.000 (Ø 740) Liter 10 bar - 120 °C 07 202 1 450 06 00355
100 - 1.000 (Ø 740) Liter 16 bar - 120 °C 07 202 1 450 06 00356
400 - 1.000 (Ø 740) Liter 6 bar - 120 °C 07 202 1 450 06 00354
400 - 1.000 (Ø 750) Liter 6 bar - 120 °C 04 202 1 450 02 00079 A
400 - 1.000 (Ø 750) Liter 25 bar - 120 °C 04 202 1 450 02 00215
1.000 (Ø 1000) - 5.000 Liter 6 bar - 120 °C 04 202 1 450 02 00716
1.000 (Ø 1000) - 5.000 Liter 10 bar - 120 °C 04 202 1 450 02 00717
1.000 (Ø 1000) - 5.000 Liter 16 bar - 120 °C 04 202 1 450 03 00954
1.000 (Ø 1000) - 5.000 Liter 25 bar - 120 °C 04 202 1 450 03 00955

A Auslaufmodell
Discontinued model
 MANUAL FOR INSTALLATION,
OPERATION AND MAINTENANCE

Type FREMO HF-740-P

Approvals:

DSB 001-296 and 297

1 REV.C.11.04.2011
2 REV.C.11.04.2011
CONTENTS:

Preface ……………………………………………………. Page 4

Specification ……………………………………................ Page 6

Mounting and connections ……………………………….. Page 10

Adjustments ..…………………………………………….. Page 12

Maintenance …………………………………………….... Page 16

Components …………………………………………….... Page 17

Spareparts list ……………………..…………………….... Page 18

Troubleshooting ………………………………………….. Page 19

Nozzle capacity ………………….……………………….. Page 22

Length and diameter of flame ..…………………………… Page 23

Appendix …………………………………………………. Page 24

3 REV.C.11.04.2011
 PREFACE
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE
DELIVERED TO THE USER.

INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL
FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.

THE USER WILL FIND FURTHER INFORMATIONS ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND
SECTION OF THIS MANUAL. WE HIGHLY COMMEND TO READ IT.

CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1) GENERAL INTRODUCTION 2) SPECIAL INSTRUCTIONS FOR BURNERS

The equipment must be installed in compliance with the *The burner should be installed in a suitable room, with
regulations in force, following the manufacturer’s ventilation openings complying with the requirements of
instructions, by qualified personnel. the regulations in force, and sufficient for good
Qualified personnel means those having technical combustion.
knowledge in the field of components for civil or industrial * Only burners designed according to the regulations in
heating systems, sanitary hot water generation and force should be used.
particularly service centres authorised by the * This burner should be employed exclusively for the use
manufacturer. for which it was designed.
Improper installation may cause injury to people and * Before connecting the burner, make sure that the unit
animals, or damage to property, for which the rating is the same as delivery mains (electricity, gas oil, or
manufacturer cannot be held liable. other fuel). *Observe caution with hot burner components.
* Remove all packaging material and inspect the These are, usually, near to the flame and the fuel pre-
equipment for integrity. heating system, they become hot during the unit operation
In case of any doubt, do not use the unit - contact the and will remain hot for some time after the burner has
supplier. The packaging materials (wooden crate, nails, stopped.
fastening devices, plastic bags, foamed polystyrene, etc),
should not be left within the reach of children, as they may * When the decision is made to discontinue the use of the
prove harmful. burner, the user shall have qualified personnel carry out
* Before any cleaning or servicing operation, disconnect the following operations:
the unit from the mains by turning the master switch OFF, a) Remove the power supply by disconnecting the power
and/or through the cut-out devices that are provided. cord from the mains.
* Make sure that inlet or exhaust grilles are unobstructed. b) Disconnect the fuel supply by means of the hand-
* In case of breakdown and/or defective unit operation, operated shut-off valve and remove the control
disconnect the unit. Make no attempt to repair the unit or handwheels from their spindles.
take any direct action. Special warnings
Contact qualified personnel only. * Make sure that the burner has, on installation, been
Units shall be repaired exclusively by a servicing centre, firmly secured to the appliance, so that the flame is
duly authorised by the manufacturer, with original spare generated inside the appliance firebox.
parts. Failure to comply with the above instructions is likely * Before the burner is started and, thereafter, at least once
to impair the unit’s safety. To ensure equipment efficiency a year, have qualified personnel perform the following
and proper operation, it is essential that maintenance operations:
operations are performed by qualified personnel at regular
a) set the burner fuel flow rate depending on the heat input
intervals, following the manufacturer’s instructions.
of the appliance;
* When a decision is made to discontinue the use of the
equipment, those parts likely to constitute sources of b) set the flow rate of the combustion-supporting air to
danger shall be made harmless. obtain a combustion efficiency level at least equal to the
* In case the equipment is to be sold or transferred to lower level required by the regulations in force;
another user, or in case the original user should move and c) check the unit operation for proper combustion, to avoid
leave the unit behind, make sure that these instructions any harmful or polluting unburnt gases in excess of the
accompany the equipment at all times so that they can be limits permitted by the regulations in force;
consulted by the new owner and/or the installer. d) make sure that control and safety devices are operating
* For all the units that have been modified or have options properly;
fitted then original accessory equipment only shall be e) make sure that exhaust ducts intended to discharge the
used. products of combustion are operating properly;
* This unit shall be employed exclusively for the use for f) on completion of setting and adjustment operations,
which it is meant. Any other use shall be considered as make sure that all mechanical locking devices of controls
improper and, therefore, dangerous. have been duly tightened;
The manufacturer shall not be held liable, by agreement or g) make sure that a copy of the burner use and
otherwise, for damages resulting from improper maintenance instructions is available in the boiler room.
installation, use and failure to comply with the instructions * In case of repeated burner shut-downs, do not continue
supplied by the manufacturer. resetting the unit manually. Contact qualified personnel to
take care of such defects.
* The unit shall be operated and serviced by qualified
personnel only, in compliance with the regulations in force.

4 REV.C.11.04.2011
 SPECIAL INSTRUCTIONS FOR USING GAS
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL
USED 3A) ELECTRICAL CONNECTION * Have qualified personnel inspect the installation to
ensure that:
* For safety reasons the unit must be efficiently earthed a) the gas delivery line and train are in compliance with the
and installed as required by current safety regulations. regulations and provisions in force;
* It is vital that all saftey requirements are met. In case of b) all gas connections are tight;
any doubt, ask for an accurate inspection of electrics by
c) the boiler room ventilation openings are such that they
qualified personnel, since the manufacturer cannot be
ensure the air supply flow required by the current
held liable for damages that may be caused by failure to
regulations,
correctly earth the equipment.
and in any case are sufficient for proper combustion.
* Qualified personnel must inspect the system to make
sure that it is adequate to take the maximum power
* Do not use gas pipes to earth electrical equipment.
used by the equipment shown on the equipment rating
plate. In particular, make sure that the system cable
cross section is adequate for the power absorbed by * Never leave the burner connected when not in use.
the unit. Always shut the gas valve off.
* No adaptors, multiple outlet sockets and/or extension
cables are permitted to connect the unit to the electric * In case of prolonged absence of the user, the main gas
mains. An omnipolar switch shall be provided for delivery valve to the burner should be shut off.
connection to mains, as required by the current safety
regulations.
Precautions if you can smell gas
The use of any power-operated component implies
observance of a few basic rules, for example: a) do not operate electric switches, the telephone, or any
- do not touch the unit with wet or damp parts of the other item likely to generate sparks;
body and/ or with bare feet;
- do not pull electric cables; b) immediately open doors and windows to create an air
- do not leave the equipment exposed to weather (rain, flow to purge the room;
sun, etc.) unless expressly required to do so;
- do not allow children or inexperienced persons to use c)close the gas valves;
equipment;
* The unit input cable shall not be replaced by the user. d)contact qualified personnel.
In case of damage to the cable, switch off the unit and
contact qualified personnel to replace. * Do not obstruct the ventilation openings of the room
where gas appliances are installed, to avoid dangerous
* When the unit is out of use for some time the electric
conditions such as the development of toxic or
switch supplying all the power-driven components in the
explosive mixtures
system (i.e. pumps, burner, etc.) should be switched off.

3B) FIRING WITH GAS, OIL OR OTHER FUELS

GENERAL
* The burner shall be installed by qualified personnel and
in compliance with regulations and provisions in force;
wrong installation can cause injuries to people and
animals, or damage to property, for which the
manufacturer cannot be held liable.
* Before installation, it is recommended that all the fuel
supply system pipes be carefully cleaned inside, to
remove foreign matter that might impair the burner
operation.
* Before the burner is commissioned, qualified personnel
should inspect the following:

a) the fuel supply system, for proper sealing;

b) the fuel flow rate, to make sure that it has been set
based on the firing rate required of the burner;
c) the burner firing system, to make sure that it is supplied
for the designed fuel type;
d) the fuel supply pressure, to make sure that it is included
in the range shown on the rating plate;
e) the fuel supply system, to make sure that the system
dimensions are adequate to the burner firing rate, and that
the system is equipped with all the safety and control
devices required by the regulations in force.
* When the burner is to remain idle for some time, the fuel
supply tap or taps should be closed.

5 REV.C.11.04.2011
 PART I: INSTALLATION MANUAL

SPECIFICATIONS

Burners HF-740-70-2D HF-740-100-2D

Output min kW 215 320

max kW 840 1200
Fuel Light oil Light oil
Oil rate min kg/h 18 27
max kg/h 70 100
Pump pressure 18 bar 18 bar
Electric supply 400/690V 400/690V
Electric consumption
Fan motor 1,1 kW 1,5 kW
Amperes
Protection IP55 IP55
Weight kg 70 70
Operation 2-stage 2-stage

6 REV.C.11.04.2011
7 REV.C.11.04.2011
8 REV.C.11.04.2011
9 REV.C.11.04.2011
MOUNTINGS AND CONNECTIONS
Packing
The burners are despatched in cardboard packages of dimensions: 800 x 600 x 900mm (L x H x B)

Packaging cases of this type are affected by humidity and must not be stacked.
The following are placed in each packing case:
1 burner, electrical wired
1 burner head
1 blast tube
2 flexible oil hoses
1 gasket to be fitted between the burner and the boiler
1 this manual
When disposing of the burner packing and if the packing is scrapped, follow the procedures laid down in the
current legislation regarding disposal of materials.

When unwrapping the burner, please protect the electrical connections.

Assemble the burner head and blast tube.

Fitting the burner to the boiler

Attach the burners flange to the boiler as shown in figur 1.

Key
1) Burner
2) Fixing nut
3) Washer
4) Seal
5) Stud bolt
6) Sigthglass
7) Blast tube

Fig 1
Green connector

Supply connector B5 = Operation nozzle 2 (3), green

lamp/meter. Connected according to
demand.
Brown/black connector
T6 = Thermostat nozzle 2 (3), high flame
T7 = Not connected
L1 = Control current 1-phase T8 = Thermostat nozzle 2 (3), high flame
≡ = Earth
N = Control current 1-fas Black connector
T1 = Operation thermostat
T2 = Operation thermostat
L1 = Motor 3-phase
S3 = External fault warning, red light.
≡ = Earth
Connected according to demand.
N = Motor 3-phase
B4 = Operation nozzle 1, green lamp/meter
L2 = Motor 3-phase
Connected according to demand.
(3) For burners with 3 nozzles.

RESPECT BASIC SAFETY RULES. MAKE SURE OF THE CONNECTION TP THE EARTHING SYSTEM. DO NOT
REVERSE THE PHASE AND NEUTRAL CONNECTIONS. FIT A DIFFERENTIAL THERMAL MAGNET SWITCH
ADEQUATE FOR CONNECTION TO THE MAINS.

10 REV.C.11.04.2011
DETERMINING THE LIGHT OIL SUPPLY PIPES DIAMETER

Fig 2 Fig 3

SUNTEC AJ 6 Fig 2 SUNTEC AJ 6 Fig 3

H (m) L (m) H (m) L (m)
Ø10 Ø12 Ø14 Ø16 Ø10 Ø12 Ø14 Ø16
0 5 13 27 47 0 5 13 27 47
0,5 6 15 3 52 0,5 4 12 23 41
1,0 7 17 33 58 1,0 3 10 20 36
2,0 9 21 40 70 2,0 2 6 13 24
3,0 10 24 47 80 3,0 0 3 7 13
4,0 12 28 53 92 4,0 0 0 0 2

SUNTEC J 7 Fig 2 SUNTEC J 7 Fig 3

H (m) L (m) H (m) L (m)
Ø10 Ø12 Ø14 Ø16 Ø10 Ø12 Ø14 Ø16
0 2 7 16 29 0 7 16 29 76
0,5 2 8 18 33 0,5 6 14 26 67
1,0 3 10 20 37 1,0 5 12 22 58
2,0 4 12 25 44 2,0 2 7 14 40
3,0 5 14 29 52 3,0 0 3 7 21
4,0 6 17 33 59 4,0 0 0 0 3

L = pipeline length in metres

Single pipe system

The burners leave the factory ready for a 2 pipes supply
system. It is however possible to transform them for a
single pipe supply system (advisable in the case of a
gravity feed system).
See appendix for details of the operations to be carried
out.

11 REV.C.11.04.2011
ADJUSTMENTS

Ligth oil rate setting

The fuel flow rate is set choosing a properly dimensioned nozzle for the first and second stage and setting the inlet pressure
gauge connection.

Starting the burner

Prior to carrying out the adjustment the burner, proceed as follows:
• Start the burner, light up the photoresistance after the opening of the solenoid valve and let the air escape from the
pressure gauge connection.
• Prior to start up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would cause
the pump seal to break.

Note: all pumps are delivered with a pressure of 18 bars. The amount of oil at low flame must not be less than
minimum burner effect.

Key
EV Solenoid valve
M Manometer
P Pump

Fig. 8

Air rate adjustment

The burner is delivered with set-values for the servocontrol and the oilpump.

1. Remove the servocontrol cover.

2. Start the burner and let it run in low flame mode.
3. Set the air rate in low flame with the proper cam. For less air turn the cam to the right, for more to the left.
4. Take the burner to high flame mode.
5. Set the air rate in high flame with the proper cam. For less air turn the cam to the right, for more to the left.
6. The third cam drives the opening of the fuel solenoid valve for the second stage. It must be set to an intermediate
position between the two other cams. Turning to the right gives an earlier activation of nozzle 2 (at operation from low
to high flame) and a later cutout of nozzle 2 (at operation from high to low flame).
7. Refit the servocontrol cover.

12 REV.C.11.04.2011
 10

Siemens stillmotor

1 = Scale 0 - 90°
2 = Indication of position of airdamper
3 = Closed airdamper Blue cam
5 = Air setting adjustment nozzle 1 Orange cam
9 = Air setting adjustment nozzle 2 Red cam
nd
10 = Auxiliary cam for 2 solenoid valve Black cam

General basic adjustment

Airdamper motor stage 1 Low flame 10° (Orange)

Airdamper motor stage 2 Solenoid valve 15° (Black)
Airdamper motor stage 2 Air high flame 35° (Red)
Airdamper motor closed airdamper Stagnation 0° (Blue)

13 REV.C.11.04.2011
 Blast tube

Combustion head

Fastening screw

At low capacity and high pressure in the combustion chamber, there shall be only a small opening
between the combustion head and the blast tube. Loosen the fastening screw and adjust the blast tube
forward so that the distance “A” increases. If the burner leaves soot even with the air damper fully
open, adjust the blast tube backwards. Normally the burner is set up with 2/3 of the input on nozzle 1
and 1/3 on nozzle 2. The spray angle is 60 ° on nozzle 1 and 45 ° on nozzle 2.
The pump pressure is set at 12 bar. Check that pipes and fittings are not leaking.

14 REV.C.11.04.2011
 Part lI: OPERATION MANUAL

LIMITATIONS OF USE

THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY
CONNECTED TO A HEAT GENERATOR (I.E. BOILER, HOT AIR GENERATOR, FURNACE, ETC.). ANY OTHER USE IS
TO BE CONSIDERED IMPROPER AND THEREFORE DANGEROUS.

THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF
IT TO QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING CARRIED OUT BY A SERVICE CENTRE
AUTHORISED BY THE MANUFACTURER OF THE BURNER.
A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL
AND SAFETY UNITS (THERMOSTATS, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF
THE BURNER.

ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION
OPERATION OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TEMPERING WITH THESE (I.E. DISCONNECTION,
EVEN PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE
BURNER).

NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.

IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED
PERSONNEL WHO WILL PROCEED.

WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR
(COUPLING FLANGE) CAN BECOME VERY HOT. AVOID TOUCHING THEM TO NOT GET BURNT.

OPERATION

1. Activate the buttons for low and high flame.

2. Check the flame control device is not locked, in this case press the reset button. The controller will now
start the burner start-up cycle.
3. The air damper will go into full open position during pre-purge, and the fan motor starts.
4. At the end of the pre-purge til air damper will og back to ignition position, and the 1st stage solenoid valve
is energised.
5. The ignition transformer is activated and remains on for some time after the flame is lit (post ignition time).
6. The burner is on in the low flame stage, and after some time activates the 2nd solenoid valve and goes to
high flame. As the system demands, the burner either stays in high flame or goes back to low flame.

15 REV.C.11.04.2011
 PART lll: MAINTENANCE

At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to
carry out the maintenance at the end of each heating season; in case of continuous operation the maintenance must be
carried out every 6 months.

WARNING: All operations on the burner must be carried out with the power disconnected!

PERIODICAL OPERATIONS
z Check the cartridge of the fuel filter. Replace if necessary.
z Check the flexible hoses for leaks.
z Check the filter in the oilpump and replace if necessary.
z Dismantle, check and clean the combustion head. Respect dimensions shown in figure on page 14.
z Check and clean the ignition electrodes and their ceramic insulators. Replace if necessary.

z Dismantle and replace the nozzle Important: use solvents and not metallic or sharp objects to clean!
z After the maintenance refit the burner parts. Ignite the flame and check the shape. Replace the nozzle if the shape of the
flame is abnormal. In case of intensive use of the burner, the nozzle must be replaced before working season.
z Check and clean the photoresistor, replace if necessary. If in doubt, check the ionisation current.

16 REV.C.11.04.2011
17 REV.C.11.04.2011
 Sparepartslist for burner HF-740-70-P

Part Number Pos number Description Pcs

RF 1020010 1 Fan house 1

RF 1020015 2 Cover 1
RF 1470410 3 Grid 1
RF 1020016 4 Hingeplate 1
RF 1020018 5 Hingepivot 2
2606 6 Flame control device LAL2.25 1
2283 7 Photoresistor QRB 3 1
8 Screw M10x40 1
RF 1155010 10 Flange gasket 1
RF 1523165 11 Air damper actuator SQN75.494A21 1
RF 1107100 12 Air damper 1
RF 1513055 13 Electric motor MEZ 1,1kW 400 / 690V 1
RF 1020017 14 Motor flange 1
RF 1690070 15 Fan 215x102x19 V 1
RF 1661140 16 Oil pump, Suntec AJ6 AC 1000 1
RF 1127010 17 Assembed coupling, motor – oil pump 1
RF 1107122 18 Nozzle line 435mm 1
RF 1970410 19 Bushing 2
RF 1610500 21 Safety solenoid valve 1
RF 1471111 22 Adapter sleeve / electrode holder 1
RF 1135010 23 Ignition electrode 2
RF 1621080 24 Ignition leads 530mm 2
RF 1461401 25 Flame schrod 114 x 40 1
RF 1610500 26 Solenoid valve 2
RF 1471310 27 Solenoid valve block 1
RF 1207110 28 Oil pipe 10mm 1
RF 1177010 29 Connection GE-10LR ¼” 1
RF 1177010 30 Connection GE-10LR ¼” 1
RF 1177010 33 Connection GE-10LR ¼” 1
RF 1530510 34 Ignition transformer ZM 20/10 1
RF 1710145 35 Flexible oil hoses 1m ⅜”x⅜” 2
RF 1197022 37 Blast tube Ф160x350mm 1

18 REV.C.11.04.2011
 Sparepartslist for burner HF-740-100-P

Part Number Pos number Description Pcs

RF 1020010 1 Fan house 1

RF 1020015 2 Cover 1
RF 1470410 3 Grid 1
RF 1020016 4 Hingeplate 1
RF 1020018 5 Hingepivot 2
2606 6 Flame control device LAL2.25 1
2283 7 Photoresistor QRB 3 1
8 Screw M10x40 1
RF 1155010 10 Flange gasket 1
RF 1523165 11 Air damper actuator SQN75.494A21 1
RF 1107100 12 Air damper 1
RF 1513060 13 Electric motor MEZ 1,5kW 400 / 690V 1
RF 1020017 14 Motor flange 1
RF 1690080 15 Fan 240x102x24 V 1
RF 1661140 16 Oil pump, Suntec AJ6 AC 1000 1
RF 1127020 17 Assembed coupling, motor – oil pump 1
RF 1107140 18 Nozzle line 413mm 1
RF 1970410 19 Bushing 2
RF 1610500 21 Safety solenoid valve 1
RF 1471111 22 Adapter sleeve / electrode holder 1
RF 1135010 23 Ignition electrode 2
RF 1621080 24 Ignition leads 530mm 2
RF 1461401 25 Flame schrod 114 x 40 1
RF 1610500 26 Solenoid valve 2
RF 1471310 27 Solenoid valve block 1
RF 1207110 28 Oil pipe 10mm 1
RF 1177010 29 Connection GE-10LR ¼” 1
RF 1177010 30 Connection GE-10LR ¼” 1
RF 1177010 33 Connection GE-10LR ¼” 1
RF 1530510 34 Ignition transformer ZM 20/10 1
RF 1710145 35 Flexible oil hoses 1m ⅜”x⅜” 2
RF 1197024 37 Blast tube Ф175x350mm 1

19 REV.C.11.04.2011
TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Reset by pushing reset button
Flame safeguard locked-out.
momentarily.

Check with voltmeter on terminals on

Power disconnected or
control cabinet terminals or L1, L2, or L3 of
improper voltage supplied.
motor starter.

Operating controls not Jumper control circuit terminals. If

calling for heat. burner starts check controls and wiring.

Overload tripped out on Reset. Check motor current for

motor starter. possible overload.
Blower motor does not operate.
Power on light will not be on. Check for
voltage on fuse holder. Replace fuse if
Blown power supply fuses. correct voltage is not measured. Check
fuses back up the line if power not on
panel.
If the voltage checks okay to starter coil,
Defective motor starter.
replace coil.

Defective flame safeguard. Replay faulty unit.

Voltage checks okay to proper motor

Defective motor.
terminals. Replace motor.

Power is disconnected or
Check with voltmeter at motor.
improper voltage supplied.

Overload tripped out on Reset. Check motor current for

motor starter. possible overload.
Oil pump motor does not operate.
Voltage checks okay to relay coil.
Defective motor starter coil.
Replace coil.

Disconnect pump coupling. If motor runs,

Pump will not turn. pump may be stuck or bypass system
closed (if used).

Voltage checks okay to proper motor

Defective motor.
terminals. Replace motor.

Motor runs but no attempt to ignite

Auxiliary contact on motor
main oil flame. Starter operates. Clean contact.
starter dirty.
Or lock-out occurs in pre-purge run up.

Motor runs but no attempt to

Defective. Flame safeguard unit. Replace with new unit.
ignite main oil flame.

Oil spray impinges on floor of combustion

chamber or side of burner air tube -
Oil accumulation continues to position nozzles correctly. Check nozzles
Lock-out occurs in pre-purge
burn after burner is off. for correct flame pattern, nozzle spray
angle, and height from floor Main Oil
valve failure - replaces.

20 REV.C.11.04.2011
TROUBLE PROBABLE CAUSE REMEDY
No oil in tank. Fill tank.

Manual valve closed in

Open valve.
suction line.

Open pump gauge port and wait for pump

No oil in supply line (pump air to prime itself or fill line from tee in high
bound). point. (Caution: do not run pump more than
2 mins. without oil).

Oil solenoid does not open. Defective - Replace.

Pump not running. Connect and tighten coupling.

Motor runs but oil does not ignite.

Nozzle line blocked. Clean out.

Nozzle blocked. Clean or replace.

Low pump pressure nozzles do

Adjust pump pressure setting.
not atomise.

Check oil ignition transformer and

Ignition spark missing or weak.
wires. Check electrode setting.

Pump will not prime or produce

Defective pump.
pressure when filled - replace.

Replace unit. Contact cleaning not

Faulty flame safeguard unit.
No ignition. recommended by manufacturer.

Defective ignition transformer.

Replace if defective.
Beware high voltage.

Flame not bright enough Too much or too little air.

Failure to prove main oil flame. (smoky or blows away). Adjust per instructions.

Defective nozzle or spinner blades bent

Flame pattern irregular.
irregularly.

Oil flame ignites and proves, but Defective flame safeguard unit. Replace.
safety switch locks out during run.
Air in oil line causes delayed oil
Bleed air from oil line.
flow.

Improper electrode setting. Check setting.

Too much air. Reduce air and adjust.

Burner ignites with a puff.
Defective nozzle(s). Replace.

Delayed spark. Replace ignition transformer.

21 REV.C.11.04.2011
TROUBLE PROBABLE CAUSE REMEDY

Run separate flame wire. If this corrects

Flame wires open. Check
trouble replace flame wire or check for shorts
microamperes.
and open circuits.
Failure to prove pilot flame on gas.
Dirty U.V. cell. Clean.
Run separate wires to U.V. cell - if flame
Open or grounded U.V. cell wires.
proves replace wires.
Flame not bright enough Too much or too little air.
(smoky or blows away). Adjust per instructions.
Failure to prove main oil flame.
Defective nozzle or spinner blades bent
Flame pattern irregular.
irregularly.

Manual valve not open. Open manual valve.

Regulator damaged, too much gas pressure

Defective regulator. or regulator vent line is plugged - correct or
replace.
Pilot proves but main gas flame does not
light. See individual burner material list for gas
Inadequate gas pressure.
pressure requirements at control train inlet.

Replace it. Manufacturer does not

Faulty flame safeguard unit.
recommend contact cleaning.

Defective flame safeguard unit. Replace.

Oil flame ignites and proves, but safety
switch locks out during run. Air in oil line causes delayed oil
Bleed air from oil line.
flow.

Too small pilot flame. Increase pilot gas pressure.

Check gas company regulator Vent orifice to

Line pressure drops when main
valve may be opened smaller to slow down
valve opens.
valve opening speed.

Burner ignites with a puff.

Improper electrode setting (oil). Check setting.

Too much air (gas or oil). Reduce air and adjust.

Defective nozzle (s) (oil). Replace.

Delayed spark (oil). Replace ignition transformer.

Adjust for softer flame by closing air inlet

Too much air (roaring noise very
louver. Flame should remain blue with orange
sharp blue flame).
tips.
Open air louver and adjust primary air
Too little air - heavy pulsations (yellow
sleeve. Check for dirty fan or clogged air
Gas burner ignites but is noisy and or lazy blue flame).
pulsates. inlet.
Too little gas - similar to "too much
Adjust input.
air".

Too much gas - similar to "too

Adjust input.
little air".

22 REV.C.11.04.2011
 Nozzle capacity in kg/h during changing working pressure

Light oil: Specific weight 0,85 v/25 ºC and viscosity 1,3º E v/20 ºC

Nozzle Pump pressure, bar

GPH 7 9 10 12 14 16 18 19 21 24 28 32 35
0,50 1,6 1,8 1,9 2,1 2,3 2,4 2,6 2,7 2,8 3,0 3,2 3,4 3,6
0,60 1,9 2,2 2,3 2,5 2,7 2,7 3,1 3,2 3,3 3,6 3,9 4,1 4,3
0,75 2,4 2,7 2,9 3,2 3,4 3,7 3,9 4,0 4,2 4,5 4,8 5,2 5,4
0,85 2,7 3,1 3,3 3,6 3,9 4,1 4,4 4,5 4,7 5,1 5,5 5,9 6,1
1,00 3,2 3,7 3,9 4,2 4,6 4,9 5,2 5,3 5,6 6,0 6,4 6,9 7,2
1,20 3,9 4,4 4,6 5,1 5,5 5,8 6,2 6,4 6,7 7,1 7,7 8,3 8,7
1,35 4,3 4,9 5,2 5,7 6,1 6,6 7,0 7,2 7,5 8,0 8,7 9,3 9,7
1,50 4,8 5,5 5,8 6,3 6,8 7,2 7,7 8,0 8,4 8,9 9,7 10,3 10,8
1,65 5,3 6,0 6,3 7,0 7,5 8,3 8,5 8,8 9,2 9,8 10,6 11,4 11,9
1,75 5,6 6,4 6,7 7,4 8,0 8,5 9,0 9,3 9,7 10,4 11,3 12,1 12,6
2,00 6,4 7,7 7,7 8,4 9,1 9,7 10,3 10,6 11,1 11,9 12,9 13,8 14,4
2,25 7,2 8,2 8,7 9,5 10,2 10,9 11,6 11,9 12,5 13,4 14,5 15,5 16,2
2,50 8,0 9,1 9,6 10,5 11,4 12,2 12,9 13,3 13,9 14,9 16,1 17,2 18,00
3,00 9,7 10,9 11,5 12,6 13,7 14,6 15,4 15,9 16,7 17,9 19,3 20,7 21,6
3,50 11,3 12,8 13,5 14,8 15,9 17,0 18,0 18,6 19,5 20,8 22,5 24,1 25,2
4,00 12,9 14,6 15,4 16,9 18,2 19,5 20,6 21,2 22,3 23,8 25,7 27,5 28,8
4,50 14,5 16,4 17,3 19,0 20,5 21,9 23,2 23,9 25,1 26,8 29,0 31,0 32,4
5,00 16,1 18,2 19,2 21,1 22,8 24,3 25,7 26,5 27,8 29,8 32,2 34,4 36,0
5,50 17,7 20,1 21,1 23,2 25,0 26,8 28,3 29,2 30,6 32,7 35,4 37,9 39,6
6,00 19,3 21,9 23,1 25,3 27,3 29,2 30,9 31,9 33,4 35,7 38,6 41,3 43,2
6,50 21 24 25 27 30 32 34 35 36 39 42 45 47
7,00 23 26 27 30 32 34 36 37 39 42 45 48 50
7,50 24 27 29 32 34 37 39 40 42 45 48 52 54
8,00 26 29 31 34 36 39 41 43 45 48 52 55 58
9,00 29 33 35 38 41 44 46 48 50 54 58 62 65
10,00 32 37 38 42 46 49 52 53 56 60 64 69 72
11,00 35 40 42 46 50 54 57 58 61 66 71 76 79
12,00 39 44 46 51 55 58 62 64 67 72 77 83 87
13,00 42 47 50 55 59 63 67 69 72 77 84 90 94
14,00 45 51 54 59 64 68 72 74 78 83 90 96 101
15,00 48 55 58 63 68 73 77 80 84 89 97 103 108
16,00 52 58 62 67 73 78 82 85 89 95 103 110 115
17,00 55 62 65 72 77 83 88 90 95 101 109 117 123
18,00 58 66 69 76 82 88 93 96 100 107 116 124 130
20,00 64 73 77 84 91 97 103 106 11 119 129 138 144
22,00 71 80 85 93 100 107 113 117 122 131 142 152 159
24,00 77 88 92 101 109 117 124 127 134 143 154 165 173
26,00 84 95 100 110 118 127 134 138 145 155 167 179 187
28,00 90 102 108 118 127 136 144 149 156 167 180 193 202
30,00 97 109 115 126 137 146 154 159 167 179 193 207 216
32,00 103 117 123 135 146 156 165 170 178 191 206 220 231
35,00 113 128 135 148 159 170 180 186 195 208 225 241 252
40,00 129 146 154 169 182 195 206 212 223 238 257 275 288
45,00 145 164 173 190 205 219 232 239 250 268 290 310 324
50,00 161 182 192 211 227 243 257 265 278 298 322 344 360

23 REV.C.11.04.2011
 The diagram shows diameter and length of the flame for oilburners with capacity 25 – 250 kg oil per hour.
The shape of the flame is dependent on the angle of the nozzle, opening of the air damper and the shape of the combustion chamber.
The shaded areas is based on experience, whereas the highest values are for heavy oil.

24
REV.C.11.04.2011
Diameter of flame (cm) Length of flame (cm)
Capacity kg oil/h
 APPENDIX: COMPONENTS CHARACTERISTICS

SUNTEC OIL PUMPS AJ6 PAGE 25

STATEMENT OF CONFORMITY PAGE 28
CONTROL FORM FOR OIL BURNERS PAGE 29

25 REV.C.11.04.2011
26 REV.C.11.04.2011
27 REV.C.11.04.2011
NOTES FOR USE AND MAINTENANCE OF FUEL PUMPS

z Make sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and
damage to the pump and burner motor could result.
z Do not use fuel with additives to avoid possible formation over time of compounds which may deposit between the gear
teeth, thus obstructing them.
z After filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of
the tank, thus avoiding the possibility that they might be sucked into the pump.
z On initial commissioning a "dry” operation is foreseen for a considerable length of time (for example, when there is a long
suction line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet.
z Care must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear
on the joint, noise and overloading the gears.
z Pipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal
junctions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The
number of junctions should be kept to a minimum as they are a possible source of leakage.
z Do not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These
could deposit on the pump filter or the nozzle, reducing efficiency. Always use o-rings or mechanical seal (copper or
aluminium gaskets) junctions if possible.
z Filter must be thoroughly cleaned at least once in a season to ensure correct working of the fuel unit. To remove the filter,
unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted with the feet toward the pump
body. If the gasket between cover and pump housing should be damaged, it must be replaced. An external filter should
always be installed in the suction line upstream the fuel unit.

28 REV.C.11.04.2011
 STATEMENT OF CONFORMITY

Producer: Fremo as
Helgerovn 7

3290 Stavern
Norway

Product groupe: 001/85 11000 Oil burners

Type: FREMO HF-740…

Data: 1100 – 1500 W 230/400V – 50 Hz
Other spec.: Cl. I

Produced according to the following standards:

EN 50165: Electrical equipment of non-electric appliances for household

and similar purpose- Safety requirements.
EN 60335-1: Safety of household and similar electrical appliances – Part 1:
General requirements (IEC 60335-1 : 1991, modified)
EN 230: Monoblock oil burners-Safety, control and regulation devices and safety
times.

Additional information:
The certified equipment is in conformity with present statutory rules and technical guidelines in Norway
regarding safety and Electromagnetic Compatibility (EMC).
It should be noted that marketing of equipment which demands official registration in Norway has to be
marketed by a company registered in the “Norske Direktoratet for Produkt og Elektrisk Sikkerhet”.

This conformity is translated on basis of DSB technical approval with number 001-295, 296, 297, 298,
299, 300 and 301, as well as NEMKO certificate No. P96101207

Fremo as

29 REV.C.11.04.2011
 Control form for oil burners

Customer: Service company:

Name:
Adress:
Postal adr:
Burner: Boiler:
Model: No: Model: Capacity:
Mounted by: Date: Mounted by: Date:
Data at Air Air Oil Oil O2 CO2 CO NOx Temp Temp Draugth Effici Foto-
start-up pressure press. pressure pressure flue- boiler / ency resistor/
combust. burner before burner gas pressure UV cell
chamber burner pump

Stage mbar mbar bar bar % % ppm ppm °C °C mbar % μamp

Low
High
Nozzle 1 Nozzle size: GPH Angle: º
Nozzle 2 Nozzle size: GPH Angle: º
Data
Routine
check
Date:

Date: Executed tasks: Sign:

Service engineer:

30 REV.C.11.04.2011
31 REV.C.11.04.2011
Tlf 33 19 65 00 Pb.38
Fax 33 19 65 01 Helgeroveien 7
3291 STAVERN
fremo@fremo.com www.fremo.com

32 REV.C.11.04.2011
 GRUNDFOS INSTRUCTIONS

UP, UPS, UPSD

MEDIUM
2

Hmax 2... 12 (m)

 3

t1 >= t2
t1°C -25 -10 0 10 25 40 80 110
Max.
t2°C -25 -10 0 10 25 40 40 40
4

1 3

5 6
5
6

! +§

1 2 3 4
 7

1˜ Min. 3 mm

Off
On
L N

Click

5 6 7
8
 9

1 2

3a 3b

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