OPERATING AND MAINTENANCE

INSTRUCTIONS FOR LIGHT OIL

BURNERS
Burners without preheating
Junior Pro 1
‰ J10
‰ J18
Junior Pro 2
‰ J20
‰ J45
‰ J50
Burners with preheating
Junior Pro 1
‰ LJ10
‰ LJ18
Junior Pro 2
‰ LJ20
‰ LJ45
‰ LJ50
Read these instructions carefully before installation, commissioning or maintenance of
the burner!

OILON HOME OY
P.O. Box 5, 15801 Lahti
Visiting address:
Tarmontie 4,
15860 Hollola
Tel. (03) 85 761
fax (03) 857 6239
[email protected]
www.oilon.com
10090943EN
Table of Contents

1. Conventions in this Manual............................................................................................................1

2. General ..........................................................................................................................................2
3. Burner Technical Data ...................................................................................................................4
3.1. Exploded View (Junior Pro 1 LJ10) .....................................................................................4
3.2. Parts List ..............................................................................................................................5
3.3. General ................................................................................................................................7
3.4. Capacity Table .....................................................................................................................7
3.5. Name Plate ..........................................................................................................................8
4. Burner Installation ..........................................................................................................................9
4.1. Burner Mounting ..................................................................................................................9
4.2. Hinged Burner Housing .....................................................................................................10
4.3. Electric Connections ..........................................................................................................10
4.4. Connecting the Burner to the Mains ..................................................................................10
4.5. Connecting the Burner to Oil Supply Line .........................................................................11
5. Fuel System .................................................................................................................................12
5.1. Oil Pipes.............................................................................................................................12
5.2. Oil Pumps ..........................................................................................................................13
6. Burner Operation..........................................................................................................................14
6.1. Operating Scheme, Oil Pump BFP 21 L3..........................................................................14
6.2. Operating Scheme, Oil Pump AS 47C ..............................................................................14
6.3. Burner Operation Principle ................................................................................................15
7. Burner Adjustment .......................................................................................................................17
7.1. Capacity Regulation...........................................................................................................17
7.1.1. Nozzle Selection ...................................................................................................17
7.1.2. Oil Pump Pressure Regulation .............................................................................18
7.1.3. Calculation of Burner Capacity ............................................................................18
7.2. Nozzle Table ......................................................................................................................19
7.3. Nozzle and Ignition Electrode Settings..............................................................................20
7.4. Change of nozzle...............................................................................................................20
7.5. Adjusting the Air Velocity in the Combustion Head J50, LJ50 ..........................................21
7.6. Adjusting the Distance and Centrality of the Nozzle .........................................................22
7.7. Combustion Air Adjustment ...............................................................................................23
7.8. Flame Inspection ...............................................................................................................24
8. Control Unit BHO 64.A/LOA 24.173A27 ......................................................................................25
8.1. Time Sequence Diagram (Control Program) .....................................................................25
8.2. Control Functions in the Event of Faults............................................................................26
8.3. Technical Data of Control Unit...........................................................................................26
8.4. Current through Flame Detector........................................................................................26
8.5. Measurement of Flame Signal...........................................................................................27
9. Maintenance.................................................................................................................................28
10. Fault Conditions and Procedures.................................................................................................29

Electric diagrams

10090943EN
 1

1. Conventions in this Manual

Read these instructions carefully before installation, commissioning or

maintenance of the burner. The given instructions must be followed.

Throughout this manual, the following three symbols are used to point out very
important information:

WARNING! A warning alerts you to possible danger to person, if the instructions are
not followed.

CAUTION! A caution alerts you to something, that has the potential to cause damage
to component, burner, process or surroundings, if the instructions are not followed.

Note! A note points out information of special interest.

KEEP THESE OPERATING AND MAINTENANCE INSTRUCTIONS

AS WELL AS THE ELECTRICAL SCHEMES AVAILABLE NEAR
THE BURNER!

10090943EN
 2

2. General
Oilon Junior Pro burners are fully automatic light oil burners.
The burners can be used on most heating appliances such as hot water boilers, steam boilers
and air heaters.
A fan attached to the burner and dimensioned to provide a sufficiently high and even air
pressure for efficient combustion in modern combustion chambers supplies the required air.
The burners are suitable for use on fuel oil (light fuel oil), with a viscosity of 4 - 6 mm²/s (cSt) at
a temperature of +20 °C.
The oil supplied to the burner must be filtered before the burner oil pump. Filtration degree is
from 20 - 40 μm. We recommend mounting of an Oilon Plus filter and deaerator unit.
Oil atomizing pressure 800 - 1400 kPa (8 - 14 bar). Factory setting approx. 10 bar.
”LJ” burners are equipped with a preheater.
Required combustion air quantity: 15 m³ combustion air for each burnt kg of oil.
Burner operation is controlled and monitored by the burner automation.
Boiler thermostats or pressurestats control the burner capacity.
Burner protection: IP20
Supply voltage 230 V (-15 %...+10 %) 50 Hz 1-phase
Consumption: approx. 135 W, 0,71 A, 230 VAC, 50 Hz, 1-phase (J10, J18, J20, J45, J50)
approx. 220 W, 1,0 A, 230 VAC, 50 Hz, 1-phase (LJ10, LJ18)
approx. 330 W, 1,7 A, 230 VAC, 50 Hz, 1-phase (LJ20, LJ45, LJ50)
The ambient temperature during burner operation must be +8...+40 °C.
The following should be checked before first start-up:
• connections are correct
• settings of boiler regulating and control devices are correct
• boiler and its equipment are in working condition
• boiler room is adequately ventilated
• valves in supply lines are open
• there is oil in the tank
• oil temperature is adequate so that the viscosity is 4 - 6 mm²/s (max. +60 °C).

10090943EN
 3

CAUTION! The burner must be installed firmly. Vibrations may damage burner or its
components.

CAUTION! Disconnect the plug connector before burner maintenance or removal from
the boiler. See chapter ”Connecting the Burner to the Mains”.

WARNING! In case of fire or other danger:

- switch off the main switch
- close the main fuel shut-off valve outside the plant
- take appropriate actions.

WARNING! Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.

WARNING! Keep the boiler door closed while starting the burner and during burner
operation.

Correct installation and adjustment together with regular servicing are the most reliable
guarantees of trouble-free burner operation.

Note! Local regulations and requirements must be adhered to when installing or servicing
the burner.

When ordering spare parts please give the burner type and serial number indicated on the
burner nameplate.

10090943EN
 4

3. Burner Technical Data

3.1. Exploded View (Junior Pro 1 LJ10)

10090943EN
 5
3.2. Parts List
PCs
1 Burner housing 1
2 Name plate 1
3 Gasket 1
4 Hinge pin 2
5 Fixing screw for combustion head 3
6 Combustion head 1
J10
J18
J20
J45
J50 with adjustment ring
7 Fixing screw for mounting flange
M10 x 25 2 and/or
M8 x 25 4
8 Mounting flange 1
9 Flange gasket 1
10 Air adjustment ring 1
Pro 1: 1/2-opening
Pro 2: 1/1-opening
11 Fixing nut for adjustment ring 1
12 Air cone 1
13 Fixing screw for air cone 3
14 Fixing screw for fan wheel 1
15 Fan wheel 1
Pro 1: Ø 120 x 52
Pro 2: Ø 133 x 52
16 Motor 1
17 Fixing screw for oil pump 3
18 Plug connector for motor 1
19 Fixing screw for motor 4
20 Oil pump coupling 1
21 Plug connector for oil pump 1
22 Nipple for pressure pipe 1
23 Oil pump 1
24 Cover plate for motorbox 1
25 Motorbox 1
26 Fixing screw for motorbox 2
27 Grommet for preheater cable 1
28 Flame detector (photo resistor) 1
29 Holder for flame detector 1
30 Plug connector, socket 1
31 Fixing screw for socket 2
32 Plug connector, plug-in part 1
33 Limit switch 1
34 Fixing screw for limit switch 2
35 Limit switch cable 2
36 Air setting scale 1
37 Fixing screw for air setting 1
38 Fixing screw for air setting scale 1
39 Cable sleeve for ignition cable 2
40 Ignition transformer 1
41 Plug connector for ignition transformer 1
42 Fixing screw for ignition transformer 2
43 Self-closing air flap 1
44 Front plate 1
45 Insulation for air intake 1

10090943EN
 6

PCs
46 Air intake 1
47 Fixing screw for air intake 4
48 Clamp for run hour counter, optional extra 1
49 Locking nut for grommet 1
50 Grommet 3
51 Fixing screw for control unit bracket 1
52 Control unit bracket 1
53 Signal lamp indicating readiness for operation 1
54 Baseplate for control unit 1
55 Fixing and earth screws for control unit 3
56 Control unit 1
57 Run hour counter, optional extra 1
58 Fixing screw for ignition electrode holder 1
59 Ignition electrode holder 1
60 Nozzle 1
61 Preheater + nozzle conduit 1
Pro 1: FPHB5
Pro 2: FPHB10
/ Nozzle holder + nozzle conduit, without preheating
62 Fixing screw for nozzle conduit holder 1
63 Nozzle conduit holder: 1
J10, J18, J20, J45, J50, LJ10, LJ18: Ø 10
LJ20, LJ45, LJ50: Ø 18,5
64 Cover plate 1
65 Eccentric piece 1
66 Locking screw for eccentric piece 1
67 Ignition electrodes 1
68 Ignition electrode holder 1
69 Locking screw for ignition electrode holder 1
70 Sight glass 1
71 Plug connector for preheater 1
72 Protective sleeve for ignition cable nipple 2
73 Ignition cable 2
74 Fixing screw for cover plate 2
75 Pressure pipe 1
76 Gasket ring for oil hose nipple 2
77 Nipple for oil hose 2
78 Oil hose 2
79 Nipple for oil hose 2
80 Filter cover 1
81 Bracket for filter 1
82 Filter 1

10090943EN
 7
3.3. General
• burner types:
• without preheating • with preheating
Junior Pro 1 Junior Pro 1
J10 LJ10
J18 LJ18
Junior Pro 2 Junior Pro 2
J20 LJ20
J45 LJ45
J50 LJ50
• the burner can be hinged to both sides
• the standard burner must be installed in such a position, that the motor shaft lies
horizontally; but the burner must not, however, be installed upside down. In the case the
burner must be installed upside down, a separate installation set with instructions must be
ordered from the manufacturer.
• burner control unit internally connected
• safety switch (limit switch) on the hinged burner housing
• stepless adjustable air regulation
• oil pump atomizing pressure 800 - 1400 kPa (8 - 14 bar), factory setting approx. 10 bar
• electrical connection with a plug connector
• standard equipment for two pipe system
• recommended nozzle types:
- solid 45° - 60° (Junior Pro 1 J10, J18, LJ10, LJ18)
- solid 60° (Junior Pro 2 J20, J45, J50, LJ20, LJ45, LJ50)
• NOx-class 2

Optional extra
• boiler dual thermostat
- regulating thermostat max. 95 °C
- limit thermostat 100 °C
• pocket for thermostat
• run hour counter
• deaerator Tigerloop
• oil flow meter
• Oilon Plus filter and deaerator unit:
- filter
- deaerator
- pressure gauge
- protective cover
- multi-function meter, optional extra

10090943EN
 8
3.4. Capacity Table

Burner Burner capacity range

kg/h kW
Junior Pro 1
J10 1,4 - 2,3 17 - 27
J18 1,7 - 2,8 20 - 33
Junior Pro 2
J20 2,3 - 4,1 27 - 48
J45 3,0 - 4,8 36 - 57
J50 2,3 - 6,5 27 - 77
Junior Pro 1
LJ10 1,4 - 2,3 17 - 27
LJ18 1,7 - 2,8 20 - 33
Junior Pro 2
LJ20 2,3 - 4,1 27 - 48
LJ45 3,0 - 4,8 36 - 57
LJ50 2,3 - 6,5 27 - 77

Burner capacities are achieved according to standard EN267.

3.5. Name Plate

Burner type is marked with a X. Example Junior Pro 1 LJ10.

Use only original spare parts. When ordering spare parts please give burner type and serial number
indicated on the burner nameplate.

10090943EN
 9

4. Burner Installation

4.1. Burner Mounting

The furnace, which has a flame-shaped design, does not require refractory. Boilers without
bottom cooling require refractory to prevent heat from reaching boiler foundations.
The flame must at no point come into contact with the furnace walls. If this cannot be avoided,
such points must be covered with refractory. This applies especially to the refractory at the back
wall of short furnaces.

1 Mounting plate 5 - 7 mm
2 Gasket 3 - 5 mm
3 Thermal insulation
approx. 50 mm

The mounting plate must have either two M10 threaded holes or four M8 threaded holes for the
mounting of the burner according to the drawing.

10090943EN
 10
4.2. Hinged Burner Housing
As standard the burner can be hinged to both sides.

4.3. Electric Connections

The burner must be connected according to the electrical diagrams delivered together with the
burner. General and local standards and regulations as well as requirements of electrical
equipment on electrical connections must be adhered to.

4.4. Connecting the Burner to the Mains

Electrical connection on burner is with a plug connector. Connect the cable of the plug supplied
with the burner to the boiler thermostat or pressurestat. The socket has been firmly attached to
the burner housing. Disconnect the burner from the mains (burner switch in position 0) by
pressing the locking button and pulling out the plug from the socket at the same time.

1 Socket (fixed on the burner

housing)
2 Locking button
3 Plug (pull-out part)

CAUTION! Disconnect the plug connector before burner maintenance or removal from
the boiler.

10090943EN
 11
4.5. Connecting the Burner to Oil Supply Line
The burner is equipped for two-pipe system.
Two-pipe system
The piping must be done for two-pipe system according to the drawing, if no Oilon Plus -filter
and deaerator unit is used. Two-pipe system has both suction and return lines for fuel oil to the
tank.

1 Shut-off valve
2 Oil filter lock
3 Oil filter
4 Suction hose
5 Oil pump
6 Return hose
7 Shut-off valve/non-return valve
A-A Delivery limit

Oilon Plus filter and deaerator unit

We recommend use of an Oilon Plus filter and deaerator unit, where the oil flows from the tank
in one pipe to the unit. The oil pump is connected as in two-pipe system. The by-pass plug must
be fixed in the oil pump. The pressure gauge of the unit indicates if the filter possibly clogs.

1 Oilon Plus filter and deaerator

unit
2 Suction hose
3 Oil pump
4 Return hose
5 Siphonage stop valve,
optional extra

A siphonage stop valve is

necessary, if the oil level in the
tank lies higher than the filter and
deaerator unit

Filter
The filter should be changed in a two-pipe system at intervals of 1 - 1,5 years. If an Oilon Plus
filter and deaerator unit is used, the time of use is longer.

10090943EN
 12

5. Fuel System

5.1. Oil Pipes

The oil tank and the oil pipes must be installed to avoid the risk of the oil cooling below cloud
point. The cloud point of heating oil depends on the oil quality. If the oil is allowed to cool to the
cloud point, valves and filters will block. The most suitable oil temperature is +15...+25°C.
Note! The viscosity of oil coming to the burner must be 4 - 6 mm ²/s (cSt).
The maximum lengths for other viscosities can be calculated by the simple ratio of viscosities
i.e. if the table shows lengths for 5 or 6 mm²/s (cSt) viscosity, multiply the length shown in the
table by 5 or 6 and divide by the value of the new viscosity mm²/s (cSt).
Keep in mind that absolute tightness is the fundamental pre-requisite for secure operation. A
leaking suction line may cause, among other things, afterspraying of oil into the boiler. It is
advisable to use ball valves instead of needle valves.

The tables give the maximum lengths (in meters) of return and suction lines.
Overlying oil tank Underlying oil tank
Hm DANFOSS BFP/MS (ø d mm) Hm DANFOSS BFP/MS (ø d mm)
ø 6 mm ø 8 mm ø 10 mm ø 6 mm ø 8 mm ø 10 mm
0 17 53 100 0 17 53 100
0,5 19 60 100 0,5 15 47 100
1,0 21 66 100 1,0 13 41 99
1,5 23 72 100 1,5 11 34 84
2,0 25 79 100 2,0 9 28 68
2,5 27 85 100 2,5 7 22 53
3,0 29 91 100 3,0 5 15 37
3,5 31 98 100 3,5 - 9 22
4,0 33 100 100 4,0 6
2800 rpm, 6 mm²/s (cSt) 2800 rpm, 6 mm²/s (cSt)

Hm SUNTEC 45/47 (ø d mm) Hm SUNTEC 45/47 (ø d mm)

ø6 ø8 ø 10 ø 12 ø6 ø8 ø 10 ø 12
mm mm mm mm mm mm mm mm
0 14 49 123 150 0 14 49 123 150
0,5 16 55 136 150 0,5 12 43 109 150
1,0 18 61 150 150 1,0 10 37 94 150
2,0 22 73 150 150 2,0 7 26 65 138
3,0 25 85 150 150 3,0 - 14 37 78
4,0 29 96 150 150 4,0 - - 8 18
2850 rpm, 5 mm²/s (cSt) 2850 rpm, 5 mm²/s (cSt)
Dmax = 20 m Hmax = 4,5 m
(D-H)max. = 4,5 m
See the oil piping dimensions from the Oilon Plus manual, if an Oilon Plus filter and deaerator
unit is used.

10090943EN
 13
5.2. Oil Pumps

Danfoss Suntec

1. Suction line connection 6. Pressure regulation

2. Return line connection 8. By-pass plug
3. Nozzle connection 9. Filter
4. Pressure gauge connection 10 Solenoid valve coil
5. Vacuum meter connection

Oil pump venting

Two-pipe system needs no venting as the air comes away when starting the burner. In order to
speed up the air removal, nipple (4) in the pressure gauge connection can be loosened.

Removal of oil pump and pump coupling

Remove the oil pump (1) from the motor (4) by loosening three fixing screws (3) and withdraw
the oil pump. Check the condition of the oil pump coupling (2) and replace, if necessary.

1 Oil pump
2 Oil pump coupling
3 Fixing screws, 3 pcs
4 Motor
5 Fan wheel

10090943EN
 14

6. Burner Operation

6.1. Operating Scheme, Oil Pump BFP 21 L3

1 Oil filter 9 Ignition electrodes

2 Return hose 10 Solenoid valve, normally closed, NC
3 Suction hose 11 Nozzle
4 Oil pump 12 Control unit
5 Pressure pipe 13 Control device (thermostat/pressurestat)
6 Burner fan 14 Preheater, LJ-burners only
7 Burner motor 15 Flame detector
8 Ignition transformer

6.2. Operating Scheme, Oil Pump AS 47C

1 Oil filter 9 Ignition electrodes

2 Return hose 10 Solenoid valve, normally open, NO
3 Suction hose 11 Nozzle
4 Oil pump 12 Control unit
5 Pressure pipe 13 Control device (thermostat/pressurestat)
6 Burner fan 14 Preheater, LJ-burners only
7 Burner motor 15 Flame detector
8 Ignition transformer

10090943EN
 15
6.3. Burner Operation Principle

Required input signals to control unit

Control signals from control unit

TZ Limit thermostat M1 Burner motor (fan/oil pump)

TS Regulating thermostat T1 Ignition transformer
E1 Preheater EV1 Solenoid valve
TSW Preheater thermostat B1 Flame detector/flame signal

Prerequisites for start-up

• burner is getting fuel
• failures and interlocks are reset
• contacts of switches of control voltage supply on control unit and contacts of
thermostats are closed, whereby the control voltage is applied to terminal 1 in control
unit.

A´ Start on burner with preheating

• control signal from control unit terminal 8
• preheater begins to heat up the fuel
• contact of lower limit thermostat (TSW) in preheater closes after time ”tw” (approx.
1 min), when the oil temperature has reached approx. 70 °C, whereby the control
signal is applied to terminal 3 in control unit.

A Start on burner without preheating

• control signal is applied from terminal 8 to terminal 3 in control unit
• burner motor (fan/oil pump) starts
• pre-ignition begins
• pre-purge begins.

B´ Solenoid valve receives control signal

• safety time begins (max. 10 s)
• solenoid valve opens (Danfoss) or closes (Suntec)
• atomizing of oil begins
• flame has to be ignited during safety time, otherwise control unit goes to lock-out

10090943EN
 16

B Flame is established
• flame relay (FR) is energised, whereupon terminals 8 and 3 are linked. Opening of
preheater thermostat contact does not shut down the burner during flame.
• burner has started
• post-ignition 2 s (control from terminal 7).

C Control unit/burner in normal operating condition

• control program of control unit ends
• burner remains operating supervised by control unit (flame) and controlled by
regulating thermostat.

D Controlled shut-down with regulating thermostat

• burner motor stops
• solenoid valve closes
• flame extinguishes.

See chapter ”Control Functions in the Event of Faults”.

10090943EN
 17

7. Burner Adjustment

7.1. Capacity Regulation

Adjust the burner thermal output by changing the size of the nozzle or the oil pump pressure.
Combustion air quantity (and position of the adjustment ring on burner types J50 and LJ50)
must be checked after having changed the nozzle. See chapter ”Change of Nozzle”.

7.1.1. Nozzle Selection

Select the nozzle size according to the boiler capacity.

Nozzle selection according to CEN-standard

The marking according to CEN standard. Kg/h is valid at an atomizing pressure of 10 bar,
viscosity of 3,4 mm²/s (cSt) and density of 840 kg/m³. In this case the nozzle is marked
with EN.

P P = boiler capacity in kW
kg/h = Ha = lower calorific value for fuel oil in kWh/kg
Ha × η × kp
η = 0,80 - 0,95 (efficiency 80 - 95 %)
Also the following formula gives the kp = pressure factor (see table)
pressure factor: P1 = 10 bar (according to CEN standard)
P2 P2 = pressure to be used
kp =
P1

Calculation example:
Nozzle for a boiler of 25 kW with an efficiency of 0,90 and pressure to be used is 10 bar.

25
nozzle kg/h = = 2,34 kg/h ⇒ select nozzle 2,37 kg/h
11,86 × 0,90 × 1,00

Nozzle selection according to USgal/h

The marking according to USgal/h. US gallon is valid at an atomizing pressure of 7 bar,
viscosity of 3,4 mm²/s (cSt) and density of 820 kg/m³.
P 1 USgal = approx. 3,2 kg of oil
USgal/h = P1 = 7 bar (according to USgal/h)
Ha × η × 3,2 × kp

Calculation example:
Nozzle for a boiler of 25 kW with an efficiency of 0,90 and pressure to be used is 10 bar.

25
nozzle USgal/h = = 0,61 USgal/h ⇒ select nozzle 0,60 USgal/h
11,86 × 0,90 × 3,2 × 1,20
Pressure factor table
Oil pressure bar 7 8 9 10 11 12 13 14 15 16
P2 kPa 700 800 900 1000 1100 1200 1300 1400 1500 1600
Pressure CEN 0,84 0,89 0,95 1 1,05 1,10 1,14 1,18 1,22 1,26
factor P1=10 bar
kp USgal/h 1 1,07 1,13 1,20 1,25 1,31 1,36 1,41 1,46 1,51
P1=7 bar

To convert kg/h into l/h, divide kg/h by the density of fuel oil (0,833 g/cm³).
On burners with preheating the nozzle capacities are approx. 10 - 15 % lower than on burners
without preheating.

10090943EN
 18
7.1.2. Oil Pump Pressure Regulation
Fit a pressure gauge in the connection (see chapter ”Oil Pumps”). Adjust the oil pressure by
turning the pressure regulating screw. The pressure increases by turning the screw clockwise
and decreases counter-clockwise. Oil pump pressure is set at the factory during testing at
approx. 1000 kPa (approx. 10 bar). Pressure setting range is from 700 to 1400 kPa (7 - 14
bar).
When the pressure is changed the oil flow and pressure follow the following formula:

V1 = capacity marked on the nozzle

V1 P1 V2 = nozzle capacity at a pressure of P2
= P1 = 10 bar gives kg/h according to CEN standard
V2 P2
7 bar gives USgal/h
P2 = pressure to be used

Calculation example
Calculate the nozzle capacity when the nozzle size is 2,37 kg/h (0,6 USgal/h) and pressure is set
at 13 bar.
According to CEN standard

V1 P1 P2 13 bar
= ⇒ V2 = V1 × = 2,37 kg/h × = 2,37 kg/h × 1,14 = 2,7 kg/h
V2 P2 P1 10 bar

According to USgal/h

P2 13 bar
V2 = V1 × = 0,6 USgal/h × = 0,6 USgal/h × 1,36 = 0,82 USgal/h ⇒ approx. 2,7 kg/h
P1 7 bar

7.1.3. Calculation of Burner Capacity

If the nozzle size is known, the burner capacity can be calculated as follows:
Example:
Nozzle size 1,87 kg/h (0,5 USgal/h) and pressure to be used 10 bar.
According to CEN standard
Burners without preheating
P = kg/h × Ha × kp
P = 1,87 × 11,86 × 1 = 22 kW

On burners with preheating the capacity decreases by 10 - 15 %

⎛ 22 kW × 15 ⎞ = 19 kW
P = 22 kW - ⎜ ⎟
⎝ 100 ⎠

According to USgal/h
Burners without preheating
P = USgal/h × Ha × 3,2 × kp
P = 0,5 × 11,86 × 3,2 × 1,2 = 22 kW
On burners with preheating the capacity decreases by 10 - 15 %

⎛ 22 kW × 15 ⎞
P = 22 kW - ⎜ ⎟ = 19 kW
⎝ 100 ⎠

10090943EN
 19
7.2. Nozzle Table
Nozzle capacities at different nozzle pressures.
Calorific value 11,86 kWh/kg
Density 0,833 kg/m³
Efficiency 0,9 (90 %)

CEN Capacity kW
kg/h USgal/h Atomizing pressure
8 bar 10 bar 12 bar 14 bar
1,46 0,40 14 16 17 19
1,66 0,45 16 18 20 21
1,87 0,50 18 20 22 24
2,11 0,55 20 22 24 26
2,37 0,60 21 24 26 28
2,67 0,65 23 26 29 31
2,94 0,75 27 30 33 36
3,31 0,85 31 34 37 40
3,72 1,00 36 40 43 48
4,24 1,10 40 45 50 53
4,45 1,20 43 48 52 57
4,71 1,25 45 51 56 60
5,17 1,35 49 55 60 65
5,84 1,50 54 61 67 72
6,08 1,65 60 66 72 77
6,55 1,75 64 71 77 -
- 2,00 73 77 - -

10090943EN
 20
7.3. Nozzle and Ignition Electrode Settings
The measures shown are for guidance. They may vary according to the nozzle type being used.
The oil spray must not come into contact with the electrodes and the diffuser disc. The electric
arc should be created at that point in the oil where the spray begins. The ignition electrodes
must not come into contact with diffuser disc.

1 Mounting flange
2 Fixing screw of combustion
head
3 Combustion head
4 Nozzle
5 Ignition electrodes
6 Locking screw

Burner L-measure
J10 7
J18 7
J20 7
J45 7
J50 7
LJ10 5
LJ18 5
LJ20 5
LJ45 5
LJ50 5

7.4. Change of nozzle

Loosen the screw (6) and withdraw the ignition electrodes (5) with holder and ignition cables
forward. When removing nozzle, two set spanners of 16 mm are needed. After having changed
the nozzle adjust the ignition electrodes according to the drawing.

CAUTION! When removing nozzle, two set spanners of 16 mm are needed; one to
support the preheater/nozzle holder and the other for turning on the nozzle.

10090943EN
 21
7.5. Adjusting the Air Velocity in the Combustion Head J50, LJ50
Adjust the air velocity in the combustion head by turning the setting screw (5), to change the
distance between the adjustment ring and the edge of the diffuser disc (4). There is a scale with
four grooves in the combustion head, which is directed to the back edge of the adjustment ring
according to the capacity. At low capacity the adjustment ring is advanced and at high capacity
retracted. If the adjustment ring is too far forward with respect to the capacity, the air velocity in
the combustion head is too high. Hence it follows, that the ignition is more difficult and/or there
is not enough air to support combustion at full load. If the adjustment ring is too far back, the air
velocity in the combustion head is too low. Hence it follows, that the combustion values become
worse. Check burner combustion characteristics by means of flue gas analysis.

1 Mounting flange
2 Flame tube
3 Adjustment ring
4 Diffuser disc
5 Setting screw

Normative positions of the adjustment ring, when the nozzle pressure is 10 bar (factory setting).
Capacity Position of Nozzle Usgal/h
kg/h adjustment ring LJ50 J50
2,5 - 3,0 1 0,75 - 1,00 0,65 / 0,75
4,0 2 1,25 1,00
5,0 3 1,50 1,25
6,0 / 6,5 4 1,75 / 2,00 1,50 / 1,75

Note! If the position of the adjustment ring has to be altered in relation to the diffuser disc,
the air velocity and quantity in the combustion head will change. Check the
combustion values by flue gas analysis and, if necessary, adjust the combustion air
quantity to be adequate.

10090943EN
 22
7.6. Adjusting the Distance and Centrality of the Nozzle
Distance
Loosen the locking screws (2) but not more than that the cover plate keeps contact with the
burner housing. Move the cover plate in the direction of slots (see for L-measure the chapter
”Nozzle and Ignition Electrode Settings”) and tighten locking screws (2).
Centrality
Loosen the screw (4) in the eccentric piece. Adjust the vertical centrality of the nozzle by
turning the eccentric piece by key. Adjust the horizontal centrality of the nozzle by moving the
nozzle conduit (5) in the hole of the eccentric piece. Check the centrality of the nozzle in
comparison with the hole of the diffuser disc. Screw the screw (4) of the eccentric piece and
tighten. Screw the cover plate's screws (2) and tighten.

1 Cover plate
2 Locking screw for
adjusting the distance
3 Eccentric piece
4 Locking screw for
adjusting the centrality
5 Nozzle conduit
6 Hexagonal socket key

10090943EN
 23
7.7. Combustion Air Adjustment
Make sure that air, required by the burner, enters the boiler room through the fresh air
ventilator. The ventilator must not be closed. The fresh air inlet must be led to the top of the
room. Eventual outlet valve has to be closed in wintertime.
Check, that the self-closing air flap (5) moves easy and that it is positioned according to the
drawing.
Loosen the locking screw (2) and turn the setting scale (1). Tighten the locking screw after
having found the right combustion air quantity.

1 Air setting scale

2 Locking screw of air
adjustment
3 Indicator
4 Air intake
5 Self-closing air flap

Coarse combustion air setting, as example burner LJ 10

Oil pump pressure 10 bar (factory setting).
Nozzle Position of air setting
USgal/h scale
0,50 approx. 3,5
0,55 approx. 5,0
0,60 approx. 10,0

Note! Only coarse adjustment can be made by observation. Fine setting usually needs flue
gas analysis. The burner has to reach in modern oil heating appliances as far as
combustion is concerned, the following performance characteristics:
Residual oxygen content (O2) 3-5%
Carbon dioxide content (CO2) 12 - 13,5 %
Carbon monoxide content (CO) < 100 ppm
Smoke number < 1 BH

10090943EN
 24
7.8. Flame Inspection
The ignition process may be observed through the sight glass by turning aside the cover in the
shape of a drop. It must be replaced in the normal operating position after inspection.

Inspection position Operation position

1 Sight glass
2 Cover
3 Fixing screw for sight glass

Removal of sight glass

Unscrew the fixing screw (3) approx. 4 turns. Move the sight glass to the right and withdraw.
The sight glass is now loose. Mounting of the sight glass in reverse order. Check, that the sight
glass is tight.

10090943EN
 25

8. Control Unit BHO 64.A/LOA 24.173A27

8.1. Time Sequence Diagram (Control Program)

Required input signals to control unit

Control signals from control unit

Legend
TZ Limit thermostat
TS Regulating thermostat
E1 Preheater
TSW Preheater thermostat
M1 Burner motor (fan/oil pump)
T1 Ignition transformer
EV1 Solenoid valve 1
EV2 Solenoid valve 2
B1 Flame detector/flame signal
FR Flame relay
BHO 64.A LOA 24.173A27
tw Heating up time of oil preheater (from cold
condition) up to connecting of contact ”TSW” approx. 1 min approx. 1 min
t1 Pre-purge time approx. 13 s approx. 13 s
t3 Pre-ignition time approx. 13 s approx. 13 s
t3n Post-ignition time (control from terminal 6) approx. 15 s approx. 20 s
t3n′ Post-ignition time (control from terminal 7) approx. 2 s approx. 2 s
t2 Safety time max. 10 s max. 10 s
t4 Interval between detection of flame and
release of terminal 5 approx. 15 s approx. 20 s
--- Reaction time on loss of flame <1s <1s

A' Commencement of start-up with burners with oil preheater.

A Commencement of start-up with burners without preheater.
B Time, when flame is detected (burner started).
C Control unit (burner) in normal operating position (control program has ended).
D Controlled shut-down by control thermostat TS

10090943EN
 26
8.2. Control Functions in the Event of Faults
Extraneous light / premature flame signal
During pre-purge and/or pre-ignition period there must never be a flame signal. If there is a
signal during this period, caused possibly by premature ignition due to a leaking oil valve,
extraneous light, a short-circuit in the flame detector (photo resistor) or its wiring, a fault in the
flame signal amplifier, etc., the control unit locks out on expire of the pre-purging and safety
period. Under these circumstances the oil valve does not open during the safety time.

Non-appearance of the flame signal

If no flame signal has appeared by the end of the safety period, the control unit immediately
locks out.

Flame failure during operation

On flame failure during operation the control unit immediately shuts down the fuel supply and
automatically attempts to restart. On completion of ”t4” the control unit performs the full starting
sequence.
With every lock-out control outputs 3 to 8 and terminal 11 are de-energized in less than 1
second, while terminal 10 for the remote signalling of lock-outs receives voltage. Resetting the
control is possible only when, after lock-out, at least 50 seconds have elapsed.

Protection against under-voltages

The electronic protection against under-voltages ensures that in the event of mains
disturbances with dangerous under-voltages (< 165 V) the control unit shuts down the burner
and prevents a new start-up.

8.3. Technical Data of Control Unit

Supply voltage 220 VAC -15 %...240 VAC +10 %
Protection against under < 165 V
Frequency 50 - 60 Hz, ±6 %
External fuse max. 10A
Permissible ambient temperature -20...+60 °C

8.4. Current through Flame Detector

220 VAC 230 VAC
Photo resistor (flame detector) QRB
Min. required detector current with flame 35 μA DC 40 μA DC
Max. permissible detector current without flame 5 μA DC 6 μA DC
Max. possible detector current with flame 40 μA DC 45 μA DC
Internal resistance of the d.c. measuring instrument max. 5 kOhm (+pole to terminal 12)

10090943EN
 27
8.5. Measurement of Flame Signal

WARNING! This control unit is a safety unit! Do not open it. Any unauthorized
tampering can result in unforeseen detrimental consequences.

10090943EN
 28

9. Maintenance

WARNING! Always switch off the electric power from your burner and close the
manual shut-off valves in the fuel supply line before servicing your burner. When
inspecting your burner you only have to switch off the electric power from your burner.
The manual shut-off valves in the fuel supply line can then be open.

Burner maintenance
In order to ensure reliable operation clean the ignition electrodes and check their setting.
Flame detector has to be kept clean.
Replace the filter, if necessary.
Clean or replace, if necessary, the filter of the oil pump.
Change the nozzle if it is worn, damaged or blocked.
Clean your burner from damp and other airborne impurities and keep the burner clean.
Clean the air flap during the annual maintenance or when needed. Use for ex. normal washing-
up liquid as cleaning agent.
Clean oil and grease spots from burner housing and plastic cover surfaces with a clean wet
cloth. Use as cleaning agent a slightly alkaline washing agent or normal hand washing-up
liquid.
Check regularly the combustion characteristics by flue gas measurements.
An authorized person should inspect the burner at least once a year.

Heating appliance control

Keep the boiler room always clean and the door closed.
Make sure, that there is always sufficient water (pressure) in the heating system.
Have the furnace and the chimney swept regularly.
Check regularly, that the smoke damper is correctly adjusted.
Protect your burner against splash water.
The oil tank must be cleaned when needed, at least every 4 - 5. years.
The boiler room fresh air ventilator must be open.
Check safety devices of heating appliance and burner according to the local requirements.
Check that the boiler and its equipment are on working condition.

10090943EN
 29

10. Fault Conditions and Procedures

In the event of fault conditions the basic requirements for correct operation must be first
examined:
1. Is the signal lamp indicating the readiness for running going on (burner switch in position
”operation”)?
2. Check, that fuse is not blown or loose.
3. Check the electric supply.
4. Check that all regulating and control devices are correctly set.
5. Are the safety devices in normal operating condition?
6. Is the burner getting fuel, are the valves in fuel line open, is there oil in the tank?

When it is established, that the fault is not due to above mentioned, the individual burner
functions must be checked. Reset the burner control unit if it is in lock out position (the signal
lamp is lit). Burner starts. Observe the burner functions. Measuring instruments can be used
while finding the fault.

CONDITION POSSIBLE CAUSE REMEDY

1. Motor
Burner motor does not Faulty motor Replace
start
Faulty control unit Replace

Faulty preheater on LJ-burners Replace

2. Ignition failure
Burner motor starts, Dirty or worn ignition electrodes. Clean or replace
control voltage from control Insulator cracked
unit to ignition transformer
is switched on, no ignition Ignition electrodes wrong Adjust according to instructions
and after a short time positioned
burner goes to lock out.
Incorrect setting of nozzle Adjust according to instructions
distance

Damaged or loosened ignition Replace or fix

cable

Faulty ignition transformer Replace

3. No flame establishment
Burner motor starts, Solenoid valve does not Replace faulty part
ignition is in order, after a function:
short time burner goes to - faulty solenoid valve or coil or
lock out. cable damaged
- faulty control unit

Nozzle does not supply oil Atomizing pressure of oil is too See chapter ”4 Oil pump”
low

Blocked or worn nozzle Replace

Blocked preheater Replace

(”LJ” burners)

10090943EN
 30

CONDITION POSSIBLE CAUSE REMEDY

4. Oil pump
Supplies no oil or atomizing Dirty filter in pump Clean or replace
pressure is too low
Leaking suction line Seal

Filter in piping is dirty Replace

Pump capacity decreases:

- faulty or worn pump Replace
- damaged pump coupling Replace

Severe mechanical noise Pump sucks air Tighten joints

Vacuum in oil line too high Replace filter

Check the size of the suction
line
Nozzle supplies no oil Solenoid valve in pump does not
function Replace coil or pump

5. Premature flame formation

Burner motor starts, flame Leaking solenoid valve Clean or replace pump
forms under pre-purge (Danfoss) / leaking shut-off valve
period, then lock-out (Suntec)
occurs.

6. Flame monitoring fault

Burner motor starts, flame Flame detector wrong positioned Adjust
forms, then lock-out occurs.
Dirty flame detector Clean

(Flame) illumination too weak Check burner settings

Faulty flame detector Replace

Faulty control unit Replace

Lock-out during pre-purge Faulty flame detector Replace

period
Faulty control unit Replace

10090943EN
 31

CONDITION POSSIBLE CAUSE REMEDY

7. Combustion head
Inside oily or has heavy Distance between diffuser disc Adjust
carbon deposits and nozzle incorrect

Incorrect combustion air Adjust

adjustment

Nozzle wrong sized or of wrong Replace as appropriate

type
Replace
Nozzle worn
8. Other possible causes
Control unit goes to lock-out Boiler smoke damper is closed Adjust

Boiler or chimney is blocked Clean

Boiler room not adequately Add supply of air

ventilated

No smoke comes out of Excessive air supply Adjust

chimney, only bluish smoke
and heat noticeable as a
rippling effect at the
chimney mouth. An oily
smell in the yard.

Dark, oil-bearing smoke is Not enough air to support Adjust

coming out of chimney combustion

10090943EN