Complyng with EMC 89/336/EC LV 73/23/EC

Table of Contents by Page NoINSTALATIONIntroduction Safety Warnings Fuels Venting Technical Data Boiler Location Function Description Fuel Tank Supply lines, pressure - output diagram Circuit Diagram Safety and control succession Malfunction an remedy Conformity declaration Air/oil-supply circuit Main construction parts Component parts list Burner body Top cover Burner flange Burner tube Burner tank Burner tank lid Motor Control box Pump Primary air regulator Manometar Safety valve Pipe Nozzle Temperature regulator Ignition unit Flame ring Cartridge heater Floater Maintenance 3 3 3 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Read the operation instructions carefully, prior to instaling and comissioning the heater All details stated, refering tue instalation and setting into operation must be effected and observed carefully in order to grant an economic operation free of malfunctions. Technical changes in the sense of product improvement reserved. 2

GP

G1P

G2P

G2P+

G3P

INTRODUCTIONThis burners are for commercial or industrial use. The burners should be installed by an experienced instaler specialized with the instalation of oil-fierd appliances. If you pay attention to the following hints, you will be a part of the big circle of satisfied users of: OLUSTERM MULTIFUEL BURNERS

PRECAUTIONSWaste oil may contain many foreign materials. Waste oil may also contain gasoline. Therefore, specific pecautions on the handling and storage of wastw oils areto be observed when using, cleaning and maintailing this heater. Use a scren in a fuunel when pouring oil into storage tank to catch foreign material, i.e., gasket material and sealant fibers, etc.

WARNING:

This appliance is not designated for use in hazardous atmospheres containing chlorinated or halogennated hydrocarbons. Do not expose this unit to rain or moisture. These burners are designet to provide economic disposal of used oils. Used oil is an incosistent fuel and may containwater and/or foreign materials witch may cause the unit to shut down. Asecondary source of heat should always be provided to the building.

WARNING:

Do not attempt to burn any grade of gasoline, paint thinners, or nonapproved fluids. Adeqate ventilation must be provided in any enclosure where storage tanks, pumpe or accessories are installed. Identical to any gas or oil burning appleance, without adequate draft over the fire, thecombustion gases cannot escape the appliance. The flame will lengthen resulting in an oveheated combustion chamber. Even if the heated is installed correctly and adequate draft. Burnign used oil is similar to burning wood. A fine gray ash accumulates in the chamber and flue passage. This accumulation of ash will eventually affect the draft. It is important to remove this ash before the draft is affected.

FUELS:

OLUSTERM burners are designed for fuels as: EL fuel oil,

biodiesel, domestic oil, vegetable oil, wast oils or mixtures.

WARNING: Collect and store your oil continuously and be aware that:Water and Sludge are Not combustible new oil does NOT burn!

WENTING: Faulture to provide proper venting could result in death, serious injury, and/property damage. Units must be installed with a flue connection and a proper vent to the outside of the building. Safe operation of any oil-burning equipment requires a properly operating vent system, correct provision for combustion air, and regular maintenance and inspection. 3

GP

G1P

G2P

G2P+

G3P

TECHNICAL DATA

Technical data Heat output kw Fuel consumption kg/h V Motor data Pover cartrige heater Power supply W A W V W A Rotation Weight Primary air consumption Nozzles Rpm Kg m3/h

GP 25-35 2,4-3,4 230 180 1,2

G1P 43-64 4,2-6,3 230 180 1,2

G2P 60-110 5,8-10,7 230 180 1,2 1000 230 1200 6 2800

G2P+ 60-150 5,8-14,5 230 180 1,2

G3P 130-201 12,5-19,2 230 180 1,2

16 3.1 30609-11

16 5,2 DA-2

16,5 13 2xDA-2

17 18 2xDA-2

19 24 3xDA-2

4

GP

G1P

G2P

G2P+

G3P

BOILER LOCATION

Wall

Boiler

5

GP

G1P

G2P

G2P+

G3P

FUNCTION DESCRIPTIONWhen using synthetic oil - min. Mix it with 10% heating oilfor start safety. When use oil from plants - set oil temperature to max, because flash point is high. When using heating oil EL set oil temperature to min

HOW IT WORKS ?Fuel is pulled from the storage tank by pump into burner tank. A floating switch regulates the level in the burner tank. An additional floating micro switch funcions sa a limit switch which indicates malfuncion in case of overfiling. A contact switch stips the burner in case of overflow in the tank. A thermostat regulates the oil temperature in the burner tankand swiches on the burner automatically as soon as the regulatedtemperature is reached. An additional overheat thermostat prevents overheating with malfunctioning. Then the burner control box (SIEMENS LOA 24) checks the procedure. A special nozzle draws the fuel, by using the passing compressed air, which serves as primary air for the combustion, and atomizes it. The combustion fan delivers secondary air that is mixed with the spray mist at the flame ring. Thereby a perfect combustion and safe operating are guarantieed.

FUEL TANK CAUTION:It is recommended that fuel be at a temperature of 50 F or higher when it enters the pump. At a temperature below 50 F oil becomes more viscous and difficult to pump. Supply of the burner tank may be reduced, resulting in nuisance shutdowns. The storage tank should be no closer than 1,5m and no fartfer then 10m from the burner. If the thank is lower than the boiler and is more then 5m away from burner, then external pump must be used. At the bottom of the supply tank manual valve must be instaled (for water and sludge separation)

WARNING:

Never install suction line at the botton of the supply tank! Suction line must be fitted at 20cm higher from bottom.

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Supply lines, Pressure - output diagram

SUPPLY LINESRead this section carefully before instaling any supply lines.Since a suction line leak is nearly impossibl to find, take your time to assure all connections are leak-free during instalation. Supply lines and fittings are furnished by the installer. With the vacuum gauge mounted on the pump vaccum port, the gauge will indicate any suction line restriction, including a dirty filter. A pump inlet maniford is suoolied for direct conecction of the filter to the inlet of the pump. All piping should be protected from possible damage and be rigidly fastened in place in workmanlike manner.

NOTE: Care must be exercised to ensure leak-free connections.G1 must be no farther than 5m from the supply tank and bottom of the supply tank must be at least 1m higher then a burner, it is wery important that supply line is at least 3/4 or 1 That is only way to obtain constant gravity-feeding of G1 burner.18 17 16 15 14 13 12 11

G3P G2P+

Output (kg/h)

10 9 8 7 6 5 4 3 2 1 0

G2P

Pressure - output diagram

G1P GP

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

1,1

Pressure primary air (bar)

Burner type GP G1P G2P G2P+ G3P

Nozzle 1x30609-11 1xDA-2 2xDA-2 2xDA-2 3xDA-2

Primary air 0,7 0,9 0,9 1,2 1,2

Secondary air 1,5 2 3,5 3,5 4

Factory setting

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Circuit diagram

P F1 S1 maxST B

X4 1 E1

S4 K1

2

S5

165 C

S2 min

X2

X3

X5L1 PO N T1 T2 S3 B4

X1

B1 E1 F1 K1 M1 S1 S2 S4 S5 T1 Y1 X1 X2 X3 X4 X5

Cad cell Heating coil 1100W Regulating thermostat oil Relay Burner motor Micro switch overflow security tank Micro switch niveau regulation (min) Overflow security overflow tank Overheat thermostat OI Transformer Solenoid valve Burner plug Socket burner control Control burner oil tank Oil tank Pump solenoid valve or feeding aggregat

bl br ye gr blk re wh

blue brown yelow green black red white

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Safety and control successionTHERMOSTAT ADJUSTMENTAdjustment thermostatRape seed oil 80-140 C 90-120 C 0 C (not to heat)

Multi oil Heating EL/ Diesel

SAFETY AND CONTROL SUCCESSIONOil preheating Motor Ignition Solenold valve air Photo cell Store lamp -12sta tv

-10sts

-20stn

ta tv ts tn

- Heat-up time - Preliminary ignition time preventilation - Safety time - Post-ignition time

9

Malfunction- Possible cause - RemedyMalfunctionBurner does not ignite or Flame interrups and stops

Possible Causea Heating oil is not combustible due to sludge or water contamination b Oil tank empty c Oil level in burn tank too high d Oil level in burner tank too low e Filter, feeding pump filter clloged, oil or air pipes defective f Solenold valve feedingpump defective g Nozzle clogged or defective h Feeding pump blocked i No current j k l m Motor defective Overheat thermostat has triggered Overheat thermostat continues triggering Photo cell dirty or not pluggend in cor rectly n Burner control defective o No ignition p No comresed air q Compresed air too iow r Solenoid valve defective s Compressor or air pipe defective t Oil too viscous from frost u Distance between storage tank and burner to long v Burner too big or set too high

Remedya Poen drain tap of burner tank. Drain sludge and water or use better heating oil b Refill with oil c Correct oil level by draining through drain tap and readjust if necessary. Float-switch leve setting d Correct oil level (refill) Clean feeding pump filter e Clean filter, feeding pump filter and pipes or repair f Check or raplace solenoid valve feedingpump g Clean or replace nozzle h Remove feeding pumpand clean gear wheel i Switch on plug coupling at burner to heater j replace motor k Unlok overheat thermostat l Change temperature regulator m Clean photo cell, plug it in correctly, replace if defective n Replace burner control o Adjust ignition electrodes and replace if necessary. Check transformer and ignition leads p Conect compressed air and adjust pressure q Verify the compressed air at Compres sor (not below 2 bar) r Check solenoid valve and replace if necessary s Check compressor and air pipe and repair it t Insulate tank and oil tubes u Mount an additional feeding pump v Replace oveheat thermostat at heater and reduce heat load of burner a Clean catridge feeding and at thermo couple in burner tank or replace a Clean feeding pump strainer b Clean filter a Correct measuring of the flame ring b Correct gauge pressure c Make ventilation openings big enough

Burner ignites to late No oil supply to the burner tank Nozzle clogged or carbonized

a Cartrige heater and thermocouple in burner tank incrused or defective a Feeding pump dirty b Filter at the suction line is clogged a Flame ring falsely set b Too muchor too less compressed air c Too little ventilation in the heating room

Each readjustment of quantity, primary or secondary air requires an exaust measuring and adjustment to optimum values- see at factory setting 10

Conformity declarationWe declare, that the ventilated oil burners Gp, G1p, G2p, G2p+, G3p correspond to the basic demand of following directives:

Low tension directiveacoording 73/23/EC in connection with VDE 0700 partie 1 / version 04.88 and DIN VDE 0722 / version 04.83

Electromagnetic compatibilityaccording to directive 89/336/EC in connection with EN 55014 / version 04.93 and EN 50082-1 / version 01.92 Machines directive according directive 98 / 73 / EC

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Air - oil supply circuit

12

Main construction parts

Solenoid valve Manometer Safety vavle Cover burner tank Temperature regulator Burner tank Motor Compressed air conecction Primary air regilator

Control box Burner plug socket Drain cap Overheat thermostat Float switch Overflow tank Secondary air regulator

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Component part list1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Burner body Burner tube Nozzle Seal flange Burner flange O-ring for nozzle Nozzle connection Ignition electrode Flame ring Conecting tube Ignition cable Cartridge heater Photo cell Capacitor Safety valve Pressure gauge Distributor Solenoid valve Primary air regulator Motor Burner control Socket for burner control Fitting panel Fan wheel Jack 7-pol Prise 7-pol Tank lid Relay Overheat thermostat Temperature regulator Float Seals for heating coil Heating coil 1000w Draining Overflow tank Transformer Contact switch Flexible pipes Burner tank Thermostat sensor holder Suction pipe Pump OLUSTERM OLUSTERM Delavan DA-2 OLUSTERM OLUSTERM Delavan Delavan OLUSTERM OLUSTERM OLUSTERM OLUSTERM OLUSTERM SIEMENS QRB 1s Aaco 5 MF Seetry 81888r Mano test 0-2.5 bar OLUSTERM Ceme 5511 Camozzi 004 Aaco 180 w SIEMENS LOA 24 SIEMENS OLUSTERM Termovent Kema&Keur Kema&Keur OLUSTERM SCHRACK C.A.E.M. 165 C C.A.E.M. 0-140 C OLUSTERM OLUSTERM OLUSTERM OLUSTERM OLUSTERM FIDA ELOBAU OLUSTERM OLUSTERM OLUSTERM OLUSTERM ITALPUMP PN-2

14

Heavy oil Burner Pump series PNCHARACTERISTICSApplications: Heavy oil. One pipe and two pipes system. Self-priming. Manometer and vacuumeter connections.

FUNCTIONPressure Return Suction

The suction vacuum generated by the gears sucks up the fuel through the suction line A; it crosses the filter and it is sent under pressure to the pressure adjustment screw RG. The fuel is sent to the nozzle at the pressure value set by RG, only the exceding fuel is sent on the return line R. In the one-pipe system the by-pass screw B is removed and the return R is pluged; the whole fuel is sucked up by the gears without crossing another time through the filter. During the operation it is possible to measure the suction vacuum by the vacuum gauge port V and the pressure by the pressure gauge port P; it is also available on the pump an auxiliary delivery port P1. When the burner stops, instantly the pressure comes down and the spring of the pressure adjustment screw RG moves the piston which stops the oil flow to the line and allows to the fluid to go through the return line R.

CONVERSION 2PIPES-1PIPESYSTEMFor the conversion proceed as follow: Remove the by-pass screw, located inside the return port R. Lock the return port with a steel plug G 1/4 and washerR A

ATTENTION:In two-pipes system oil pump is self-priming, the bleding is obtained through the return line. In one-pipe system the return line is closed by plug, the bleeding must be obtained through the nozzle or opening the pressure gauge port P, to accelerate the way out of the air. 15

PN Technical dataPower consuption-pressure Diagram Pressure - capacity DiagramDiagram considers a wear margin.W 250 225 200 175 150 125 100 75 50 25 0 5 10 15 20 25 30 bar PN 2

Viscosity 20cSt

Speed 2800 rpm

I/h 150 140 130 120 110 100 90 80 70 60 0

Viscosity 20cSt

Speed 2800 rpm

PN 2

5

10

15

20

25

30

bar

Hidraulic DataFactory settings Pressure range Viscosity range Oil temperature Inlet pressure Return pressure Suction height Speed Starting torque Capacity Power consuption Filter Open aria Mesh Weight 15 bar 10 - 28 bar 2 - 200 cSt 0 - 120C 1,5 bar max 1,5 bar max 0,45 bar max 2800 - 3480 rpm 0,10 Nm see graphs see graphs 11 cm2 300 m 1,1 kg

16

MaitenanceWhen setting into operation for the first time, fill up the burner tank by hand to the oil level mark. When the oil level is too high, the float switch switches off the burner automatically. If the oil level is too low, the cartridge heater will be damaged. Wait the burner will start automatically as soon as the fuel has reached the right operation temperature. Post regulation of oil consumption by the primary air regulator Post regulation of smoke number and Co2 , by secondary air regulator Optimum vlues: Smoke number as Bacharach 1 (max.2) Co2 - 10 to 11,5 %

Setting into operation

Regulations

WARNING: Turn off electric power to the unit before doing any serviceor maintenance on the burner. After more than 7 days out of operation: drain settled water and sludge through drain tap in burner tank

Servicing

Weekly:Check the oil level in the supply tank to be certain that enough fuel is available. Inspect flame ring (clean it if necessary) and ignition electrodes (adjust if necessary)

Monthly:Clean pump strainer Remove the four bolts that hold the pump cover, (Be careful, pump is full of oil) Be careful, not to lose or damage the gasket and two O-rings (for pressure and vacuum) Remove the circular strainer and clean it with a solvent and compressed air. Clean photo cell. Clean ignition electrodes and flame ring The electrode porcelain insulators must be free from carbon, oil, dirt, cracks. Otherwise, short circuiting could cause ignition problems. Blow compressed air through nozzle and check ignition electrode distance (picture page 17) NOTE: Be sure NOT to damage the O-ring on the nozzle (lube it before putting back nozzle). If the O-ring appears damaged, replace it. Clean combustion chamber and flueway passages (on the boiler) from ash. Drain settled water and sludge through drain tap in burner tank.

Yearly at begining + end of seasonCarry out monthly servicing as described. Clean catridge heater in burner tank and burner tank Drain settled water and sludge through manual valve of the storage tank 17

GP

G1P

G2P

G2P+

G3P

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TABLE OF CONTENTS BY PAGE NO

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