TECHNICAL MANUAL

IBSM series
HEAVY OIL fuel
MECHANICAL CAM regulation
AIR COMPRESSED atomization

MODEL: IBSM550NV SERIAL NUMBER: 2566

YEAR OF CONSTRUCTION: 2017

POWER SUPPLY: 380/220V – 50Hz

FUEL TYPE 1:NAFTA VISCOSITY: 50°E 50°C
POWER MIN: 157 Kg/h POWER MAX: 470 Kg/h
2
 INDEX

Cap. Description Pag.

Introduction 4
1.0 User warnings for the use of the burner 5
1.1 Directives and standards applied 5
1.2 General warnings and operational safety 6
1.3 Special warnings before starting the burner 7
1.4 Power supply 7
1.5 Heavy fuel oil supply 7
1.6 Refractory 8
2.0 IBSM general description 9
3.0 Lance 10
3.1 Nozzle maintenance 10
3.2 Nozzle curve 11
4.0 Disassembly and assembly procedures 12
4.1 Standard pilot disassembly procedure and inspection cover 12
4.2 Heavy oil lance and accessories disassembly/replacement procedure 12
4.3 Centering lance 14
4.4 Flame disc disassembly/replacement procedure 14
4.5 NAFTA control valve 15
4.6 Disassembly / replacement procedure for liquid fuel regulation valve 16
4.7 Pump seal replacement procedure 17
5.0 Position of ignition electrodes with pilot 18
6.0 Pressure regulation of oil safety switches 18
7 Start procedure for a light oil burner 19
7.1 HP electric pump starting procedure with fuel oil 21
7.2 Adjustment and start-up with mechanical adjustment casing SQM5 .. 24
8 Failures and solutions 25
9 P&ID 27
10 Wiring diagram (attached) 27
11 Data sheet LAL (attached) 27
12 Data sheet RWF (attached) 27
13 Data sheet KM3 (attached) 27
14 Certificate of conformity (attached) 27
15 Warranty certificate (attached) 27
16 Spare parts 28

3
 Introduction

Energy Bruciatori Industriali s.r.l. shall not be held responsible for any issues arising from activities carried out by
unqualified personnel.
It must be highlighted that an incorrect installation of the burner and of the power and fuel supply parts may
cause damage to persons, things or other; for which the manufacturer is not held responsible.
The data shown in the manual are representative only and the technical department reserves the right to change, if
necessary, the data contained in this document.
For further information or for special applications, please contact our technical department or visit our website
www.energybruciatori.com.
The information contained in this manual and any attachments is only intended for the recipient(s); and as such, any
duplication, distribution or any other use of the information is explicitly forbidden.

Furthermore, before proceeding with the installation, it is important to ensure that:

1) The chimney (cross-section and height) is carried out following the exact instructions of the boiler manufacturer.
Nevertheless, the following considerations are always useful:
a) the boiler-chimney connector must be very short and rising at a considerable angle towards the chimney;
b) external sheet metal or asbestos cement chimneys, without a suitable insulating coating, are not recommended since
they,could cause condensation as well as soot at the outlet.
Furthermore, the low temperature reached in these chimneys cannot ensure a good air draught;
c) along the whole length of the flue pipe there must not be any air infiltration;
d) the top must be free from any adjacent obstacles and the cowl must be placed in such a way as to allow free outlet of
combustion gases;
e) for mountain locations, the chimney section must be enlarged by 10% for every 500 metres above sea level; bear in
mind that depending on the height above sea level, the efficiency of the burner fan decreases and as a consequence the
maximum output of the burner is also reduced. The approximate values are given in the table below.

Altitude Reduction in the output of the fan (%)

according to the barometric height
1.000 m - 6%
1.500 m - 11%
2.000 m - 16%
2.500 m - 21%
3.000 m - 27%
3.500 m - 32%

f) When the installation of a refractory coating is required in the combustion chamber (provided that the boiler type
requires it), it must be arranged around the burner combustion opening in accordance with the instructions given by the
boiler manufacturer.
g) The burner power supply line must be set up as shown in our diagram and the electrical connections on the burner
have been made suitable for the mains voltage.
h) The fuel pipes must be set up as shown in our diagrams.
i) Ensure that the burner nozzle enters the combustion chamber according to the instructions of the boiler manufacturer.

4
 1.0 User warnings for the use of the burner

1.1 Directives and standards applied

Light oil burner

European directives:
- 2006/95/EEC (Low Voltage Directive);
- 2004/108/EEC (Electromagnetic Compatibility Directive).
Harmonized standards:
- IEC/EN 60335-1 (Safety of household and similar electrical appliances)
Part I : General requirements;
- EN 50165 Electrical equipment of non-electrical appliances for household and similar purposes. Safety
requirements.
National standards:
- UNI 7824 – Monoblock nebulizer burners for liquid fuels. Characteristics and test methods.

Heavy oil burner

European directives:
- 2006/95/EEC (Low Voltage Directive);
- 2004/108/EEC (Electromagnetic Compatibility Directive).
Harmonized standards:
- IEC/EN 60335-1 (Safety of household and similar electrical appliances)
Part I : General requirements;
- EN 50165 Electrical equipment of non-electrical appliances for household and similar purposes. Safety
requirements.
National standards:
- UNI 7824 – Monoblock nebulizer burners for liquid fuels. Characteristics and test methods.

5
 1.2 General warnings and operation safety measures

- The user manual is an integral part of the product and must be delivered to the user.
- Carefully read the warnings contained in the manual as they provide important information concerning the safe
installation, use and maintenance of the burner.
- The burner installation must be carried out by qualified professionals and in accordance with national and
international regulations and standards currently in force, according to the specifications and the instructions of
the manufacturer.

Warning:
It is highlighted that the incorrect installation of the burner, of the power and fuel supply parts may
cause damage to persons, things or other; for which the manufacturer is not responsible.

 Before carrying out any cleaning or maintenance work, ensure that the personnel employed is professionally
qualified. Then disconnect the device from the power supply by pressing on the switch of the system and/or
through the specific interception units for power supply, gas or liquid fuel.
 Do not obstruct the air intake and heat dissipation grids.
 In the case of a failure and/or poor performance of the burner, turn the burner off and do not try to repair it.
Always contact qualified professionals to carry out repairs. The repair must be carried out by a service centre
that has been authorised by ENERGY, using only original spare parts. Failure in respecting this may
compromise the safety of the burner itself. To guarantee the functioning and the efficiency of the burner, regular
maintenance must be carried out by qualified personnel according to the instructions supplied by the
manufacturer.
 If the burner is not being used, the parts that could be potential sources of danger should be made safe.
 This burner is only to be used for its intended use, i.e. it can only be used with boilers, hot air generators, ovens
or other similar furnaces, and it must be located in a sheltered place away from the elements. Any other use is
to be considered inappropriate and therefore dangerous; hence, any contractual or extra contractual
responsibility on the manufacturer’s part is to be excluded for damages caused by installation errors and use
errors, or a lack of observance of the instructions provided by that same manufacturer.,
 The place in which the boiler is installed must have openings that are large enough to allow for an air inlet from
outside of around 30 m3/s. Particular attention must be paid to the air intake of monoblock burners.
 Before connecting the burner, ensure that the nominal values correspond to those of the supply line (electrical,
gas, heavy oil, light oil, etc).
 Do not touch the hot parts of the burner, such as for example, the fuel pre-heating system (which becomes hot
during the operation and which remains hot, even if the burner is not used for a prolonged period of time) or the
burner areas which are close to the flame. If the burner must be switched off for a longer period of time,
qualified personnel must proceed as indicated below:
 Disconnect the power supply by unplugging the power cable from the master switch.
 Close off the fuel supply via the manual interception valve by removing the control wheels from their slots.
OPEN THE MANUAL VALVES AGAIN BEFORE PROVIDING POWER SUPPLY TO THE MASTER SWITCH.


6
 1.3 Specific warnings before switching on the burner and/or operationss to be carried out
regularly

The following operations must be carried out by qualified personnel during the start-up process and must be
subsequently maintained at least twice a year:
 Adjust the fuel flow rate according to the heat generator requirement.
 Regulate the air flow rate to obtain a fuel yield value which is at least equal to the specified value, or to the
value set by the current specifications.
 Carry out combustion analyses from the flue gas outlet chimney, in order to avoid the formation of harmful or
polluting unburned fuel beyond the limits allowed by the existing regulations.
 Check the functionality of the regulation and safety systems.
 Check the functionality of the outlet duct of the fumes produced by the combustion.
 Check at the end of the adjustments that all the mechanical blocking systems of the regulation devices are
blocked. Check also if they are oiled where it is required.
 In the case of repeated burner blocks, do not insist with manual resetting but, contact qualified professionals
instead to resolve the issue.
1. Operation and maintenance must be carried out by professionally qualified personnel only, in accordance with
the existing regulations.

1.4 Power supply

The electrical characteristics of all the accessories of the combustion system must be checked (motors, resistances,
solenoid valves, servo controls, coils, electrical panels) to ensure that they are compatible with the energy supply
used by the system (voltage, frequency, current) and that the protection devices against short circuits and
overcurrents have been installed.

1.5 Types of fuel: with heavy oil

HEAVY OIL:

The supply of the thrust unit must be guaranteed by gravity (through a service tank) or through a ring pump (see the
installation diagrams). It is also important to ensure, though the temperature control, an excellent flow through the
piping, avoiding cavitation in the thrust pumps.
The pour point must be higher than the minimum room temperature (preheating with hot wire and/or steam tracing, if
needed). The viscosity must not be higher than that indicated in our table.
The fuel requires to be heated according to its viscosity.
All standard Energy burners are dimensioned with heavy oil having an 9600 kcal/kg LHV and an average viscosity of
50 °E at 50 °C.
For different technical values, please contact our technical department.
With heavy oils, the filters must be equipped with preheating resistances

energybruciatori@energybruciatori.com
angelo.milano@energybruciatori.com
rocco.zifarone@energybruciatori.com

7
 1.6 Refractory coating

The coating of the combustion chamber with refractory material allows a very high temperature around the
flame thus facilitating combustion. It also protects the parts of the boiler which are not wet.

It is advisable to use good quality refractory material, which can resist temperatures that exceed 1.500°C
(>70% alumina).

The following is to be avoided:

1. Never use an excessive lining, as this is always isolating, decreasing, the heat exchange and hence the output of
the boiler.
2. Never use an arrangement which considerably reduces the furnace volume as this hinders good combustion
because of a lack of space. Remember that today boiler manufacturers tend to avoid installating a refractory
lining. In any case, the boiler manufacturer’s instructions must be respected for the installation of the lining.
Installation of the refractory lining around the combustion burner opening must be carried out in accordance with
the constructor of the same.

Flame tube burner

+ 20/30 mm to diameter

8
 2.0 IBSM general description

The burners of the IBSM range are monoblock burners with regulation of combustion air in suction. Monoblock
because it has a high performance impeller and a high efficiency motor inside the casing. They are made of
pickled sheet steel, valid for operation with any type of fuel. Suitable for any boiler, in particular for smoking
pipes, both hot water and steam with capacity from 960 kW to 12700 kW. It has an easy installation with
simple connections and a large inspection door for easy maintenance. The IBSM burner is compact and
economical; is the right compromise between performance, reliability and price. The whole range is CE
certified in compliance with current safety and emissions regulations.

Range di funzionamento

Fuel Range
Olio 1:3
Gas 1:4

Index
1 Quadro elettrico
2 Camma meccanica
3 Specula
4 Fotocellula
5 Pressostato aria
6 Scambiatore elettrico
7 PT100
8 Pistone
9 Elettropompa
10 Trasformatore
11 Trasformatore
12 Valvola nafta

9
 3 Lance

Energy lances are always calibrated and tested at our workshop, in order to preserve and verify the integrity of
the product.
The test is carried out with diesel at an operating pressure of 30 bar, in order to check the tightness of all the
components.

If the liquid fuel is dense naphtha, a 90 W hot wire (standard voltage 220V) is inserted in order to keep the fluid
entering temperature constant.

The lances are always calibrated with a dynamometer in order to allow the rod to withdraw and let the liquid
fuel pass inside the nozzle.

A = Return heavy oil with connection ½”G and calibration 8 bar min 18 bar max
B = Inlet heavy oil with connection ½”G and calibration a 20 – 22 bar
C = Inlet compressed air qith connection ½”G and calibration 2 - 3 bar fixed

NB.
The lances are always calibrated with a dynamometer in order to allow the rod to withdraw and let the liquid
fuel pass inside the nozzle.
Make sure the compressed air is clean.

3.1 Nozzle maintenance

The nozzle must be cleaned using only solvents (diesel, petrol, trichlorethylene, petroleum, etc.) and compressed air as
the use of metal tools will definitively compromise its efficiency.
The nozzle undergoes a wear and tear during the operation due to the passage of the fuel, so it must be replaced when
the need arises (abnormal combustion, delay in ignition, etc.).
The frequency of these substitutions is mainly linked to the quality of the fuel used (presence of impurities, suspended
solids) and to overheating by refraction of the refractory in the breaks or stops of the burner.

10
 3.2 Nozzle curve

NOZZLE 45° 600 Kg

Below the nozzle curve of 600 Kg with Range: 1÷3

Pump pressure recommended: 23 bar

Pmin of works: 7/9 bar

Pmax of works: 17/19 bar

NOTE: The curve was made at a pressure of 23 bar. To reach the maximum capacity, install the nozzle according to
the stove's power.
NOTE: For ranges other than 1 ÷ 3 contact the Ns. technical office.

11
 4 Disassembly and assembly procedures

4.1 Standard pilot disassembly procedure and inspection cover

Cover and pilot valve disassembly

1 Remove the cover by loosening the screws with a 5/6mm Allen wrench according to the size of the burner.
Make use of the 2 handles and take care with the electrical connections of the air pressure switch
2 Extract the 2 red electrode ignition cables
3 With a 27mm wrench, unscrew the fixing nut of the pilot valve located inside the burner. Remove the standard
pilot valve

4.2 Heavy oil lance and accessories disassembly/replacement procedure

LANCE disassembly procedure for a dual burner

1. Carry out procedure 6.1.1

2. Remove the connecting pin of the electromagnet control fork by using the control lever of the lance
3. Carefully unscrew the hydraulic fittings of the supply and return fuel hoses to the lance with a 27/32mm wrench
(see the diagram above). Insert hydraulic stoppers and/or stoppers made out of material stoppers into the ends
of the fittings to prevent drips or the inflow of air into the circuit

12
 4. Unscrew the 4 fixing screws of the lance fixing plate with a 5/6mm Allen wrench according to the size of the
burner
5. Unscrew the centering device with a 19mm wrench and take the lance out of the burner.

Foto 2 Foto1

NOZZLE disassembly PROCEDURE

1. Remove the lance by following the procedure shown above

2. Pull the control lever in the direction of the nozzle (by using a 10 mm plate to keep the position, see photograph
2) so as to open completely the exit hole of the fuel for the whole duration of the operation. Unscrew the nozzle
with a 43mm wrench, using a tube wrench preferably (photograph 1)
3. Once the nozzle has been removed from its seat, thoroughly clean the thread so as to eliminate any scale
which could cause damage and fuel losses
4. Taking care not to damage the O-ring, insert the nozzle and tighten by hand until almost touching the lance tube
in order to feel any impurities in the thread and to avoid damaging the nozzle or the lance. When the end is
almost reached, use the wrench to close the nozzle.

1 FIXIN SLEEVE
2 GASKET VITON
3 ROD OPENING AND CLOSING NOZZLE
4 CLOSING CAP
5 LOADING TUBE
6 HOLLOW SPINE
7 LOADING BUSHING
8 PROTECTION SPINE

Lance Gaco seal replacement PROCEDURE

1. Close the supply and return shut-off valves and check that there is no pressure
2. Unscrew the hexagonal cap with a 30mm wrench
3. Remove the Gaco seal with the screwdriver
4. Cover the 6Ma thread with insulating tape
5. Insert the new greased Gaco seal
6. Replace the hexagonal cap
7. Open the shut-off valves
8. Check the copper gasket, if you see fuel there tighten or replace the copper washer

13
 4.3 Lance centering

If the burner is solely a light oil or a heavy oil burner, it will be made up of a ring with adjustable and removable spacers,
that can be disassembled with a 19mm wrench.

4.4 Flame disc disassembly/replacement procedure

Flame disc disassembly PROCEDURE for a dual burner

1. Carry out the gas head disassembly/replacement procedure

2. Remove the eyepiece from the gas combustion head
3. Using an 5mm Allen wrench, loosen the 2 screws of the disc holder and remove the disc with the disc holder
4. Remove the disc from the 2/3 fixing tabs with a 5mm Allen wrench
5. Measure the eyepiece of the burner plate, in order to maintain the same height and distances between the disc
and the nozzle
6. Check that the disc is perfectly perpendicular to the eyepiece if it is a liquid fuel burner. If if it is a gas fuel burner
make sure the disc is perpendicular to the head

For installation, follow the above steps in reverse order.

Periodically check:
that the disc diffuser is in good condition, any cracks may cause incorrect combustion.

14
 4.5 Heavy oil regulation valve

The control valve is used to regulate the flow of fuel oil

on the burner return
This is necessary to guarantee the correct flow to the
nozzle and to have the power required by the burner

Pressure
To adjust the pressure by turning it to the right (clockwise) the adjusting screw will increase the pressure while to reduce
the pressure turn to the left (counterclockwise)

15
 4.6 Liquid fuel regulation valve disassembly/replacement procedure

Oil regulation valve replacement PROCEDURE

1. Disconnect the fuel hoses with the circuit switched off

2. Unscrew the 6x70 screws on the fixing bracket (7.1) and replace the valve with a new one
3. Reconnect the fuel hoses
4. After having checked that all of the manual fuel valves are in the correct position, start the burner and calibrate
the valve by following the procedure on page 14

Perodically replace the lip seal, check the efficiency of the bearing (replace if necessary), and check the spring and
the sliding action of the small piston.
Before replacing the valve, follow the steps outlined below to avoid damages to the fuel pumps or to the
connection hoses.

16
 4.7 Procedura sostituzione tenuta pompa

1 stop ring
2 sliding ring
3 counter ring

We advise that you periodically check seal of the pumps to avoid fuel leaks.

Seal replacement PROCEDURE

1. Unscrew the hollow nut of the pump body and slide the seal that need to be replaced off the shaft
2. Get the counter ring and its gasket to potrude from the hollow nut
3. Clean the pump shaft and the nut’s internal seat thoroughly
4. Take the new seal out of the packaging while taking care not to soil or damage the contact surfaces
5. Insert the counter ring in the seat of the hollow nut while making sure that it fits perfectly into the back surface of
the nut
6. Lightly lubricate the shaft and insert the positioning collar
7. Check the X height and tighten the fastening screws of the collar
8. Fit the sliding head onto the shaft and position it in such a way that it does not interfere with the spring
(screwing the hollow nut to the pump body within 60 seconds from the insertion of the sliding head)

Note:
The pump shaft must not have any abrasions or scoring in the action area of the seal. the shaft. Polish the shaft if
any of the above mentioned are found.
When the sliding head is placed, the internal bellows create a vacuum and block the shaft. This is why the nut must
be screwed onto the pump body straight away.

17
 5 Position of the ignition electrodes with pilot valve

The pilot valve without air premixer can be used as a solution only for the smaller sized burners, such as IBSR 4, IBSR5
and IBSR6.

The burner pilot can operate either with methane or with LPG (the latter can be used with heavy oil burners, where
methane is not available).

The pilot burner’s natural gas or LPG flow rate is regulated via the limiting device for the electromagnetic valves in order
to guarantee the pressure indicated in the test report. The pressure is measured on the pressure gauge downstream of
the electromagnetic valves.
It is important to check that this value is kept as a decrease in pressure completely prevents ignition, while an excessive
pressure causes the flame to tear-off, with a consequent shutdown due to the lack of flame.

As a standard, the standard pilot valve is placed by technicians at approximately 30 mm from the disc in order to allow
for the correct ignition of both a liquid fuel and a gas fuel burner.

6 Regulation of the oil safety pressure switch

The safety devices used to manage a considerable pressure difference are 2

pressure switches.

The minimum pressure switch (which is optional, only on customer request)

monitors the discharge pressure and must be calibrated regularly in the workshop at
a pressure of around 19 bar.
The pressure switch is inserted into the catenary of the electric safety measures; if
the pump pressure falls below the this level, the pressure switch turns the burner
and pump off.

The maximum pressure switch (which is included in the optional accessories kit for
adaptation to UNI-267 standard) monitors the pressure on return and must be calibrated
regularly in the workhop at a pressure of around 19 bar.
The pressure switch is inserted into the catenary of the electric safety measures; if the pressure on return surpasses this
level, the pressure switch turns the burner and the pump off.

As both pressure switches can cause damage to the operation of the burner and boiler, if not correctly calibrated, Energy
Bruciatori Industriali has decided that after having calibrated them and having tested the hydraulic circuit in the
workshop, all the pressure switches will be sealed with red putty in order to avoid any tampering.

WARNING: Energy Bruciatori Industriali shall not be held liable for any modifications and/or tampering on the pressure
switch safety measures.

18
 7.0 Start procedure for a light oil burner

Carry out the following steps to adjust the supply pressure of the nozzle
(Return pressure regulation PROCEDURE)

1. Establish the regulation of the fuel flow rate by referring to the flow rate/pressure diagram of the nozzle
installed, in order to set the lower and higher limits while considering the minimum/maximum ratio of the nozzle
(which normally has a ratio of 1:3);
2. Switch off the burner and unscrew the cap on the valve (3)
3. Regulation of the minimum pressure (MIN):
- Operate the servomotor control and position to a minimum;
- Start the fuel thrust unit in order to keep the circuit under pressure;
- Loosen the lock nut;
Adjust the pressure through the pin screw (4) , “approximate values: 6 – 9 bar ”, lock the nut (5)
4. Regulation of the maximum pressure (MAX),:
- Loosen the locking pin next to the cam disc (7.3);
Adjust the cam of the disc by using the screw (7.5) in order to obtain the required pressure on the return
manometer, “approximate values 15 – 19 bar”, tighten the locking dowel (7.4)
5. Bring the servocontrol back to minimum to check the pressure on the return manometer and correct the
pressure by using the screw pin (2) of the control valve. This procedure must be repeated several times as the
action of the eccentric changes the minimum/maximum ratio (by increasing the MAX pressure, the MIN
pressure decreases and viceversa), remount the cap.

Adjustments can be made while the burner is switched on, as long as the fuel/combustion air ratio has already been
adjusted so as not to form unburnt material. Nevertheless, the operation must be carried out during the combustion
optimization phase by using at the right time the dowels of the air flow control cam, while checking the emissions
from the chimney (CO2 - CO - NO - SO2 - O2 etc.).

To start the burner:

To start the burner:

- Insert the main switch into the electrical panel;

- Ensure that the opening function of all the shut-off valves is working properly;
- Reset the boiler safety interlocks;
- Check that the power indicator of the modulation unit is in the minimum position;
- Ensure that the oil circuit is full;
- Ensure that the rotation directions of the pumps and the motors are correct;
- Activate the ring pump (if any), when the pressure of the ring is stable and therefore when the oil circuit is full,
activate the burner switch.

19
Before conveying power to the electrical panel, check that:
- The supply voltage of the power is correct;
- The supply voltage of the auxiliaries.

Also check:
- The calibrations of the electronic cam (refer to the Siemens LMV manual);
- That everything corresponds to the wiring diagram;
- The configurations set on the electronic cam;
- That the rotation direction of the fan is correct.

At this stage:

- Index all the servocontrols/actuators;

- Set the safety locks of the boiler to low values to try them out immediately. Increase them once the boiler is
ready to function. Try the low level with steam burners.
- Check that the rotation direction of the light oil pump is correct.

WARNING: check that the valves are open!

- Open the intake valve;
- Open the return valve in tank or vent;
- Close the bypass;
- Allow the air to escape;
- Open the bypass and close the return valve in tank;

- Check the pump seal (see chapter. 7.1.4)

- Check that the pump pressure is between 21 to 23 bar at the minimum of the burner and around 23 bar at the
maximum of the burner;
- Opening of the air blades of about 10° set on LMV. Ensure that there are about 3.0 bar in the tank (measure
this with a micromanometer on the plate of the burner);

- Check that the position of the fuel actuator is at 0° on the LMV and set a pressure of around 7 bar as a
minimum on the fuel control valve;

- In manual mode, increase the opening of the fuel actuator up to the maximum and then set a maximum
pressure of 18 bar.
NOTE: once the burner has been started and brought up to maximum capacity, check the output of the nozzle
and compare it with the relative curves provided by Energy (see chapter 7.1.5)
Calibrate the air pressure switch to -20 mmH2O of the pressure in the tank;

- Calibrate the fuel minimum pressure switch to 19 bar;

- Calibrate the fuel maximum pressure switch to 19 bar;

- Calibrate the ignition pilot valve. To calibrate the pilot valve, we advise you to use the function called
ProgramStop on the LMV (see the specific chapter and/or the Siemens LMV manual);
The parameters that need to be respected in order to obtain a good calibration are the following, taken with the
micromanometer:
- Air 1.6 mbar;
- Increase R1 until the pressure gets up to 2 mbar;
- Operate R2 to bring the final pressure up to 2.4 mbar.

- At this stage the boiler can be heated in order to carry out a combustion curve to then set the maximum of the
burner. Start to establish 10 points of the combustion curve.

20
 7.1 Procedura di avviamento elettropompa HP con olio combustibile

SERIE VD R – Regulation and integrated bypass

Rotation direction: l = Anticlockwise

D = Clockwise

The rotation direction can only be changed in the

factory!

Pumps with internal gears up to 40 bar

(Direction D=clockwise Energy standard)
Viscosity: 6mm2 sek-1 ati 20°C

n = 1400 min-1 n = 2800 min-1

Discharge l/h Discharge l/h
Maxi.
Per.
hp Pump Net
internal at at at at at at RPM Weight
Series Article No. Article No. (min -1) (kg)
9 30 40 9 30 40 Gear
VBH R I I
bar bar bar bar bar bar Rotor
at at
Size Shaft
Size I/D I/D
Ø Ø
3
VBHR P 1000 700 600 011/0037 - - - - 56 18 /4" - 1680 7,3
3
VBHR M 1500 1200 1000 011/0038 - - - - 56 18 /4" - 1680 7,3
3
VBHR G 2000 1700 1400 011/0039 - - - - 56 18 /4" - 1680 7,3

1
VBHGR P 3000 2200 2000 011/0049 - - - - 75 22 1" 1) /4" 1400 18,6
1
VBHGR PZ 3700 3000 2700 011/0090 - - - - 75 22 1" 1) /4" 1400 18,6
1
VBHGR M 4500 3600 3200 011/0050 - - - - 75 22 1" 1) /4" 1400 18,6
1
VBHGR G 6000 4800 - 011/0051 - - - - 75 22 1" 1) /4" 1400 18,6

* To guarantee the correct operation of the pump, all the connections must be dimensioned based
on the principles of fluid mechanics and must conform to the conditions given in the place of
installation! The dimension of the pump connections and/or the device are not indicative of the
size of the connector to be used.

Before start-up, ensure that:

- The pump and the motor are paired up without tensions and that the coupling rotates freely;
- The locking of the shafts via the pins has been carried out;
- The shut off valves are in the correct operational position;
- The rotation directions of the pumps and motors are correct.

IMPORTANT:
- The pump must NOT run dry.
- The pump must NOT turn in the opposite direction to that indicated in the specification.
- Never close the valves on the heavy oil or light oil thrust unit.

CHECK THE WHOLE SYSTEM BEFORE STARTING THE BURNER.

Information: the regulator (C) of the High Pressure control valve must always be calibrated to a lower pressure than
the pump regulator (A).
Warning: if the information above is not respected, the mechanical energy developed from inside the pump
transforms into thermal energy which overheats the gears considerably and causes them to break

21
 Start pump PROCEDURE:

1. Activate the thrust pump, by purging the air from the specific manual vent valves
2. Once it is full, adjust the pressure of the thrust pump and of the ring pump (if there is one). Do not feed the
electric heater if the barrel is not full of heavy oil, as this breaks the resistor
3. After having checked that all the coupling and accessories are perfectly sealed, activate the electric heater
(regulating the temperature according to the fuel, see the temperature/viscosity table). Once the temperature is
reached, check the pressures and the seal of the couplings again
4. Unscrew the tap of the regulator (A) with a 6 mm hex wrench, turn the internal screws in clockwise direction
until you you cannot tighten them anymore,then loosen them by 2 anticlockwise turns
5. Mount a manometer of 0-40 bar on point (B)
6. Unscrew the cap (C) and loosen the screws with a 6mm hex wrench in order to release the tension of the spring
of the regulation valve
7. Put the pump motor into action and check the rotation direction
8. Screw the hex screw in a clockwise direction until you read 23 bar on the manometer (B)

Ajusting pressure:

1. The regulator (1) is incorporated into the pump.

Loosen and remove the cap (2)
2. Adjust the pressure (3) with the screwdriver or the 6mm hex wrench
(clockwise direction = increases the pressure; anticlockwise direction = decreases the pressure)
3. Close the cap (check the coupling).

INDEX

A = INTAKE
S = THRUST
M = MANOMETER
V = VACUUM GAUGE

NOTE: perfect adjustment is as follows:

- Regulate the operating pressure of the pump overflow valve at 30 bar,
- Regulate the operating pressure of the high pressure valve at 23 bar.

It is important to check the pressure of the valve (it must be at 23 bar) while the burner is at maximum
capacity, as at low capacity a decrease of the pump pressure can be observed due to the large quantity
of heavy oil recirculated from the nozzle.

ALL THE HEAVY OIL AND LIGHT OIL THRUST UNITS ARE TESTED AND ADJUSTED IN OUR WORKSHOP IN
ACCORDANCE WITH THE ABOVE-MENTIONED INDICATIONS.

22
 PUMP VERSION PUMP VERSION WITH
WITH INTERNAL ADJUSTAMENT HIGH PRESSURE VALVE

We advise that self-cleaning filters, equipped with preheating resistances are mounted when using heavy oils.

The rotation direction of the pump must always be contrary to the fuel feed tube (if you look at it from the
motor casing side it must be in the clockwise direction – only for DC pumps).

The KRAL pump can be fitted on demand or on some specific appliances and is advised mainly for appliances that use
heavy oil that is particularly dense and viscous.

7.1.4 Viscosity curve for heavy oil

23
 7.2 Regulation and start procedure with an SQM5.mchanical control box

The Energy control box contains a SIEMENS SQM5..servomotor + a cylinder with individually adjustable screws via a
5mm Allen screw. The servomotor is located outside the control box.
One side of the cylinder manages the regulation of the air and oil through a series of driving gears and levers, while the
other side manages the regulation of the gas, also through the use of driving gears and levers.
The gas regulation valve is calibrated at the factory to an opening of approximately 15°. The higher postitions must be
calibrated through the optimization of the combustion; this must be done with an analysis tool by qualified personnel.
Combustion optmization is achieved by tweaking the air and gas dowels of the regulation cam.

To obtain more air, the air dowels that act upon the air bearing must be turned in a clockwise direction. However, to
increase gas flow, the gas dowels that act upon the gas lever must be turned anticlockwise.
To set the oil regulation valve, see chapter 7.1.
For information on the start procedure, read chapter 7 which focuses on the different types of fuel.

REGULATION SQM5…

1. Switch off the voltage

2. Set white motor cams on 0
(triangular indicator on motor)
3. Insert voltage
4. If the dial is not at the "correct" minimum adjust the
micro (2) at zero (or about)
5. Set the micro (3) to 20
6. Set the micro (4) to 110
7. Set the micro (1) to 130

24
 8.0 Troubleshooting
OBSERVATIONS
Common problems
The burner motor will not start.
Interruption of the gas supply, gas tap Open the gas tap and inform the supply
closed
Defective control device
Lack of air
The motor starts, but after the
pre-ventilation at full load the
burner locks-out
The motor starts, but after
around 10 secs of pre-
ventilation at full load the
burner locks-out
Flame failure
The motor starts, start-up is
normal but after a short time a
lock-out occurs
For execution with a valve
proving check
The motor starts, the start-up
phase is normal but after a
short time the burner shuts-off
(it does not go into lock-out)
Shut-off after the flame appears
The pilot flame is formed but
the burner stops during the
loading phase
Fuel pump
It does not transport fuel
Very loud mechanical noise
POSSIBLE CAUSE SOLUTIONS
Lack of voltage Re-establish the circuit
Defective fuse Replace it
Defective motor Replace it
Interruption of the control circuit Look for the interruption point and then
insert or unlock the boiler safety thermostat
company if the lack of gas is prolonged
Replace it
Defective air pressure switch or air Replace it
needs to be regulated Adjust the combustion air
The contact of the air pressure switch Regulate the pressure switch correctly, and
does not go into operating position or if necessary, replace it
falls (air pressure is too low)
Dirty fan Clean the fan
The fan rotates in the wrong direction Invert the direction
The electromagnetic valve does not Change the valve or repair the current flow,
open, the coil is defective or the cable check the voltage under the power supply
is defective terminal of the device
Leak from the electromagnetic valve Eliminate the leak
Pressure loss when the valve opens Clean or replace the filter cartridge
due to a blocked filter
Dirty filter Clean the filter
The stabilizer is working too slowly Check the vent opening
Defective meter, collection of water in Inform the gas company
the low pipes
Defective pump Replace it
Loss of flow Replace the pump
Loss from the suction valve Take it apart and clean it, or replace it if
necessary
The suction tube is not airtight Make it airtight by checking the closure or
the mounting axis
The on-off valves are closed Open them
Dirty filter Clean it
Filter leak Replace it
Leaks from the oil pipeline Tighten the fittings and allow the air to
escape
The pump is taking in air Tighten the fittings and allow the air to
escape
Excessive suction vacuum Clean the filters and open the valves
completely
25
Shut-off after the flame appears
The pilot flame is formed but the
burner stops during the loading
phase
Flame failure
The burner starts but shuts-off
straight after in “lock-out” mode
Flame
Noisy flame
Smoky flame
Nozzle
Irregular pulverization
Dirty filter Clean the filter
The stabilizer is working too slowly Check the vent opening
Defective meter, collection of water in Inform the gas company
the low pipes
Dirty photocell Clean the photocell with a clean cloth
Photcell connections are incorrect or Check the connections or replace the
the photocell is defective photocell
The flame is too weak Check the calibration of the
combustion
The flame detection axis of the Check the reading axis with a
photocell is not aligned or is covered projection of light from the photocell
holder and correct the position
Insufficient heating of the liquid fuel or Increase the heating temperature of
water in the liquid fuel the fuel, and remove the water from
the filter, the piping and the cistern
Air/fuel balance is not correct Repeat the regulation of the fuel again
Dirty, worn or defective nozzle Clean it or replace it if necessary
Insufficient pulverization pressure Check the pulverization pressure on
the thrust pump
Insufficient heating of the fuel or water Increase the heating of the fuel by
in the liquid fuel bringing it to the value shown in the
Viscosity-Temperature diagram.
Eliminate the water from the
exchanger and the cistern.
Incorrect balance between comburant Repeat the regulation
air and fuel
Insufficient pulverization pressure Check the pulverization pressure.
Repeat the regulation of the pressure
after having checked that the filter is
clean
The nozzle is dirty or damaged Clean or replace the nozzle

(*) If further information is required, please contact our technical department.

(**)Management and maintenance must be carried out by qualified personnel only, in accordance with current
regulations.
NOTE: For further information and explanations, refer to the Siemens LMV51…/LMV52…manual

26
 9 P&ID

Attached 1

10 Wiring diagram

Attached 2

11 Data sheet LAL

Attached 3

12 Data sheet RWF

Attached 4

13 Data sheet KM3

Attached 5

14 Certificate of conformity

Attached 6

15 Warranty certificate

Attached 7

27
 16 Spare parts

Burner:

28
Pos. Vecchio Codice Nuovo codice Q.tà Descrizione

1 1 PISTON BORING 32 STROKE 20 mm DOUBLE EFFECT

2 1-00000253 07.24.60008 1 IGNITION TRASFORMER 33% 7333 220V 50Hz
3 2-00000178 29.02.00080 1 STANDARD PILOT WITH ELECTRODE
4 indicate burner serial number 1 FLAME TUBE
5 indicate burner serial number 1 FLAME DISK
6 indicate burner serial number 1 NOZZLE GG3 45°
6 indicate burner serial number 1 NOZZLE SONY 150G
7 --- 17.07.00080 1 PT 100 WITH COCKPIT L80 mm 3 FILI
8 1 FILTER Y ¾”
9 1-00000205 17.03.00025 1 ELECTRICAL RESISTANCE 25 KW
10 1-00000095 03.08.22006 2 PILOT ELECTROVALVE E6G 3/8” 220V 50/60Hz
11 1-00000118 08.02.00031 1 PHOTORESISTOR QRB 3
12 --- 03.03.00022 1 SAFETY ELECTROVALVE 1/2" 2VIE
13 1 HIGH TEMP. TERMOSTAT APV9
14 1-00000205 17.03.00025 1 ELECTRICAL RESISTANCE 15 KW
HEAVY OIL PUMP 1500 lt 3 TUBE WITH INTERNAL REGULATION. +
15 1
RESISTANCE
16 --- 07.18.02003 1 ELECTRICAL MOTOR 3 KW B5 220/380V 50 Hz 2P
17 1-00000288 17.08.00038 1 REGULATION FLOW VALVE 3/8"
18 1 SERVOCONTROL AIR / HEAVY OIL 15 Nw + AGA58.4
19 1-00002488 08.06.40010 1 DIGITAL REGULATOR RWF50
20 1 TEMPERATURE REGULATOR KM3
21 1 FLAME CONTROL LAL2.25 – 220v WITH BASE
22 1-00000176 25.06.00080 1 OBLO 'complete with seeger and or
23 1-00000315 16.01.00050 1 GLASS INSPECTION ø 50 mm with or and seeger
24 1 IMPELLER RD TYPE GR560
25 1-00000175 07.18.12015 1 ELECTRICAL MOTOR 25Kw B5 380/420V 50 Hz 2P
26 1 DIFFERENTIAL PRESSURE SWITCH DG6U-3

29