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LIGHT OIL BURNERS
MAIOR P 500.1 PRE
MAIOR P 600.1 PRE
Technical data
Operating instructions
Electric diagrams
Spare parts list www.ecoflamburners.com
EN
MAIOR P 500 PRE.1 TC
MAIOR P 500 PRE.1 TL S
10-01-2017
3144806
EN
INDEX
MAIOR P 500.1
MAIOR P 600.1
0
General warnings - Conformity declaration
Burner designation - Modular delivery system
Burner description
Electrical control panel
Technical data
Working diagrams
Test boiler - Flame dimension
Overall dimensions
Oil operating mode - General safety functions
1000
Installation
Fitting the burner to the boiler
Oil connection
Feeding and suction line for light oil
Electrical connections
Start-up: checking procedure
Exhaust gas test
Start-up oil side
Fuel selection - Start-up
Adjusting the max air flow rate
Firing head setting
Adjusting the max oil flow rate
Servomotor Lamtec - Air damper motor pre-setting
Adjusting the pump pressure
Adjusting the intermediate burner capacity
Maintenance program
Troubleshooting instructions
Operating troubles
Appendix
Control box - Display
Fluidics nozzle chart
Bergonzo nozzle tables
Pump and pressure regulators
Electrical diagrams
Spare parts list
2000 3000 4000 5000 6000
10
10
11
12
13
14
15
16
16
16
16
17
17
17
18
7000 kW
3
4
5
5
6
7
7
8
9
19
20
21
22
23
24
25
27
28
29
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GENERAL WARNINGS - CONFORMITY DECLARATION
MAIOR burners are designed for the combustion of light oil.
The design and function of the burners meet the standard EN267. They are suitable for use with all heat generators complying with standard within their respective performance range.
Any other type of application requires the approval of ECOFLAM.
Installation, start-up and maintenance must only be carried out by authorised specialists and all applicable guidelines and regulations must be complied with.
BURNER DESCRIPTION
MAIOR burners are progressive mechanical fully automatic monoblock devices.
Emissions values may differ, depending on combustion chamber dimensions, combustion chamber load and the firing system (three-pass boilers, boilers with reverse firing).
EN 267
Automatic forced draught burners for liquid fuels.
EN 60335-1, -2-102
Specification for safety of household and similar electrical appliances, particular requirements for gas burning appliances
INSTALLATION LOCATION
The burner must not be operated in rooms containing aggressive vapours (e.g. spray, perchloroethylene, hydrocarbon tetrachloride, solvent, etc.) or tending to heavy dust formation or high air humidity.
Adequate ventilation must be provided at the place of installation of the furnace system to ensure a reliable supply with combustion air.
PACKAGING
The burner, and all the additional components are supplied in a modular system of packages according to the configuration ordered that based on the country of installation shall follow the applicable standards and the local rules and code of practise.
The following standards should be observed in order to ensure safe, environmentally sound and energy-efficient operation:
Declaration of conformity for oil burners
We ,
Ecoflam Bruciatori S.p.A.
declare under our sole responsibility that the oil burners named
MAIOR conform to the following standards:
EN 267
EN 55014-1
EN 60335-1
EN 61000-6-2
EN 50156-1
EN 55014-2
EN 60335-2-102
EN 61000-6-3
These products bear the CE mark in accordance with the stipulations of the following directives:
2014/35/UE Low Voltage Directive
2014/30/UE EMC Directive
2006/42/EC Machine directive
2011/65/EU RoHS2 directive
!
BURNER SELECTION: Type of operation and configuration must be done by professional personnel in order to grant correct working of the burner. Installation, start-up and maintenance must be carried out by authorised specialists and all applicable guidelines and regulations
(including local safety regulations and codes of practise) must be observed.
We accept no responsibility for damage arising from:
- inappropriate use;
- incorrect installation and/or repair on the part of the buyer or any third party, including the fitting of non-original parts;
- non authorised modifications made on the burner.
Final delivery and instructions for use
The firing system installer must supply the operator of the system with operating and maintenance instructions on or before final delivery. These instructions should be displayed in a prominent location at the point of installation of the heat generator,
They should include the address and telephone number of the nearest customer service centre.
Notes for the operator
The system should be inspected by a specialist at least once a year.
Depending on the type of installation, shorter maintenance intervals may be necessary.
It is advisable to take out a maintenance contract to guarantee regular servicing.
EN
Ecoflam burners have been designed and built in compliance with all current regulations and directives.
All burners comply to the safety and energy saving operation regulations within the standard of their respective performance range. The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2008.
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3
EN
BURNER DESIGNATION
MAIOR P 300.1 PR TC 230-400-50
RANGE NAME BY FUEL TYPE
MAIOR Light oil
MODEL SIZE (Gas: kW; Oil: kg/h)
MAIOR P 300.1
253 kg/h - 3000 kW
-
EMISSIONS
Standard Class 1 - OIL EN267 (<250 mg/kWh)
OPERATION TYPE
PR
MD
PRE
2 stages progressive mechanical gas / oil
2 stages modulating mechanical with PID
2 stages modulating electronic
HEAD TYPE
TC
TL
Short head
Long head
FUEL
BIODIESEL
KEROSENE
Light oil
Biodiesel
Kerosene
ELECTRICAL POWER SUPPLY
230-400-50 230-400 Volt, 50 Hz
MODULAR DELIVERY SYSTEM
Light oil burners
All light oil burners are delivered complete in one single packaging including filter and flexible hoses up to 6 MW.
Additional accessories and options shall be installed by the installer in accordance to the instruction and local safety regulations and codes of practise.
KITS - Accessories
Kits and accessories are managed and delivered separately.
Component type
CB
KIT
ACS
Complete burner
Kits
Accessories
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BURNER DESCRIPTION
EN
Control panel
HLF
V
HLBT
R 0: OFF
1: ON
SAL main switch I/0
HLF working lamp
HLBT thermal lock-out lamp
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EN
TECHNICAL DATA
MODEL
Thermal power max.
kW kcal/h
Thermal power min.
kg/h kW kcal/h kg/h
Operation mode
Regulation ratio nominal
Fuel
Emission class
Control unit
Air regulation
Type
Type
Type std
Air flap control with servomotor
Flame monitoring
Ignitier
Motor
Rpm
Voltage
Total power consumption operation
Weight body BBCH
Electrical panel protection level
Sound pressure level without silencer
Sound pressure level with silencer
Ambient temperature storage
Ambient temperature use
Oil pump
Nozzles
Type
Type
Model
Type
Model kW
N°
V/Hz
W
Kg
IP dB(A)
Lab tests
Min/Max
Model
Type
MAIOR P 500.1 PRE
5.000
4.300.000
422
1.200
1.032.000
101
1.290.000
126
Progressive mechanical oil - Modulating with PID
1÷3 OIL
Light oil (L.C.V. 10.200 kcal/kg max. visc 1,6÷6 mm 2 /s at 20°C) (EL) Hu = 11,86 kWh/kg
Standard Class 1 OIL EN267 (<250 mg/kWh)
LAMTEC ETAMATIC BT3xx
Air flap Air flap
LAMTEC
UV CELL
BRAHMA
MAIOR P 600.1 PRE
5.800
4.988.000
489
1.500
11
2.800
15
2.800
230/400 V - 50 Hz
12.000
16.500
IP55
91,1
85,7
TA3
-20°…+70° C
-10°…+60° C according to the output requested
IP55
92,8
86,7
TA4
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WORKING DIAGRAMS mbar 25
20
15
10
5
MAIOR P 500.1
MAIOR P 600.1
7000 kW
6000 kcal/h*1000 kg/h
Calculation of burner output
QF = Burner output (kW)
QN = Rated boiler output(kW)
η = Boiler efficiency (%)
QF =
QN x 100
η
Working diagrams
The working diagram shows burner output as a function of combustion chamber pressure.
It corresponds to the maximum values specified by EN 276 measured at the test fire tube.
Boiler efficiency should be taken into consideration when selecting the burner.
0
1000
1000
100
2000
2000
200
3000
3000
300
4000
4000
400
5000 6000
5000
500
TEST BOILER - FLAME DIMENSIONS
FLAME LENGHT LIGHT OIL BURNERS
L (m) 11
10
9
8
7
6
5
4
3
2
0
1000 2000 3000 4000
1000
100
2000
200
3000
300
4000 5000
400
5000
6000
500
6000
7000
600
7000
8000
700
8000 9000 10000 11000
9000
800
10000
900
11000 12000
1000
13000
1100
12000
14000
1200
13000
15000
1300
14000
16000
1400
15000 kcal/h x 1000
17000 kW kg/h
FLAME DIAMETER LIGHT OIL BURNERS
Ø (m) 2
1,8
1,2
1
0,8
1,6
1,4
0,6
0,4
0,2
0
1000
1000
2000
2000 3000
3000
4000
4000
5000
5000
6000
100 200 300 400 500
6000
7000
600
7000
8000
700
8000 9000 10000 11000
9000
800
10000 11000
900
12000
1000
13000
1100
12000
14000
1200
13000
15000
1300
14000
16000
15000 kcal/h x 1000
17000 kW
1400 kg/h
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The burner/boiler matching does not pose any problem if the boiler is CE typeapproved.
If the burner must be combined with a boiler that has not been CE type-approved and/or its combustion chamber dimensions are clearly smaller than those indicated in diagram, consult the manufacturer.
The firing rates were set in relation to special test boilers, according to EN 267 regulations.
The sizes are indicative and dipend on the configuration, to the combustion chamber pressure and to the draught.
The values have been taken out from tests executed with flame tubes.
The dimensions of the flame are made in test boiler in laboratory without resistence therefore exists max and min lenght that take into account the difference in lenght that comes from the boiler backpressure.
Example:
Burner thermal output = 8000 kW;
L flame (m) = 5 m (medium value)
D flame (m) = 1 m (medium value)
WARNING: Some flame modifications can be done in our FLEXSHOP in the factory in order to shape the flame and adapt it to some special boiler or application.
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EN
EN
OVERALL DIMENSIONS
E D - D1 B
A
0
1
2
0
1
2
C
SUNTEC
M
I
D = Short head
D1= Long head
Dimensions (mm)
Model
MAIOR P 500.1 PRE
MAIOR P 500.1 PRE S
MAIOR P 600.1 PRE
A
1240
1240
1240
B
635
635
635
C
605
605
605
D
355
-
355
D1
555
835
555
E
1100
1100
1100
F
320
320
320
G
570
570
570
H1
965
965
965
I
330
330
330
L
330
330
330
M
M16
M16
M16
Burner-boiler mounting flange
Fixing hole dimensions are “I” and “L” as per dimension table.
Boiler hole shall be done according to the blast tube dimension “F” plus
15-25 mm in order to be able to extract it during maintenance.
WARNING: Please follow the suggested dimension for the hole on the boiler flange in order to fit the burner. Make sure that between the boiler and the blast tube proper insulation is fitted.
Packaging (only burner)
Model X Y Z
MAIOR P 500.1 PRE S 1750 2380 1460
MAIOR P 600.1 PRE S 1750 2380 1460 kg
330
420
X
Y
Z
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OIL OPERATING MODE - GENERAL SAFETY FUNCTIONS
START-UP MODE
As soon as the furnace system is required to supply heat the burner control circuit will close and the program be started. After the program has run down the burner will start.
The air damper is closed when the burner iis out of operation.
The automatic furnace controller controls and monitors the starting function.
The electric actuator opens the closed air damper to its full-load position so that the burner will sweep the furnace compartment and exhaust ports at the required air flow rates. At the end of the specified pre-ventilation time the air damper will be moved into its partial load position. This operation will be followed by the pre-ignition procedure and the oil feed start.
The solenoid valves will open and thus allow the pressurized oil to flow to the nozzle and to the return line.
The oil will be atomized, mixed with the combustion air and ignited.
A safety period is provided to allow the flame to develop a proper and steady pattern.
On the termination of the safety period, a flame signal must have been received by the automatic furnace controller via the flame monitor and remain on until the regular shut-off.
The startup program of the burner has now been completed.
OIL OPERATING MODE
After the flame has developed the load regulator will be enabled which brings the burner into its operating position.
The load regulator will now control the burner automatically between its partialload and full-load stages.
Depending on the heat demand, the electric actuator of the mechanical compound control system will be fed with the OPEN or CLOSE signal via the regulator and thus increase or decrease the oil and air flow rates.
This compound control system will vary the positions of the oil control valve and air damper and thus regulate the oil flow rate in conjunction with the air flow rate. The burner can either be controlled in twostage sliding mode or, if a respective controller is provided, in stepless control mode.
The stepless control will allow the burner to be operated at any desired stage between its partial-load and full-load positions. The burner will be turned off from its partial-load position. The air damper will be closed when the burner is out of operation and will thus prevent cold air flowing through the burner chamber, heat exchanger and chimney.
The interior cooling losses will be greatly minimized.
EN
GENERAL SAFETY FUNCTIONS
In case a flame does not develop when starting the burner (fuel release) the burner will shut off at the end of the safety period (safety lock-out).
A safety lock-out will also occur in the case of flame failure during operation, air flow failure during the pre-ventilation phase and pressure failure during the whole period of burner operation.
Any failure of the flame signal at the end of the safety period and a flame signal during the pre-ventilation phase (external light control) will result in a safety lock-out with the control box being locked.
The trouble is indicated by the trouble signal lamp lighting up.
The control box can be unlocked immediately after a safety lock-out by pressing the unlocking key. The program unit will return to its starting position and proceed with the restart of the burner.
A voltage failure will result in a regular shut-off of the burner. Upon voltage recovery there may be an automatic restart unless another interlock is provided, e.g. by the safety system. In any case of trouble the fuel oil supply will be shut off right away. The program unit will stop at the same time causing also the trouble location indicator to stop.
The symbols will indicate the kind of trouble.
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EN
INSTALLATION
Fitting the burner to the boiler
!
WARNING: handling and moving operations must be carried out by specialised personnel.
Use the eyebolts to lift the burner in order that it will not overturn and fall down.
To perform the installation of the burner into the boiler drill the boiler plate according to the dimension given on this manual and place the burner towards it by lifting and moving the burner by means of eyebolts.
Place the gasket on the burner flange and install the burner into the boiler by fixing nuts into the bolts.
The space between the blast tube and the boiler lining must be sealed with appropriate insulating material.
Burner blast tube insertion depth and brickwork
Unless otherwise specified by the boiler manufacturer, heat generators without a cooled front wall require brickwork or insulation 5 as shown in the illustration.
The brickwork must not protrude beyond the leading edge of the blast tube, and should have a minimum conical angle of
60°. Gap 6 must be filled with an elastic, non-combustible insulation material. For boilers with reverse firing, the minimum burner tube insertion depth A as speci fied in the boiler manufacturer’s instructions must be observed.
On boilers the blast tube insertion depth should be observed as per the boiler manufacturer's instructions.
Reverse flame boiler :
A = 50-100 mm.
Three pass boilers :
A1 = 50-100 mm.
Exhaust system
To avoid unfavourable noise emissions, right-angled connectors should not be used on the flue gas side of the boiler.
A1
A
Position of the electrodes - nozzle installation
3
÷
4 mm
Ignition Electrode
BURNER LINING
Check before burner installation:
1. Depending on the type of boiler (reverse flame or three pass) check the burner blast tube installation depth according to the data specified by the boiler manufacturer or consult the burner producer.
2. From the factory the nozzle for progressive version must be specified from the customer according to boiler output and combustion chamber geometry, otherwise we will select the nozzle for the 80% capacity of the burner.
3. Check the ignition electrodes and the nozzle on the burner head as per factory setting (see figures).
The setting of the mixing and ignition unit according to the boiler output will be performed during commissioning procedure.
4. Check that the head is preset at 50%.
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5
÷
6 mm
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INSTALLATION
Oil connection
!
WARNING: make sure that the feeding line is properly dimensioned and is in compliance with the local safety rules and code of practise in the country of installation
HYDRAULIC CIRCUIT
LIGHT OIL FEEDING
176: oil pump
178: solenoid valve
184: output control valve
311: return oil pressure switch
CV: check valve
RL: return line
VL: suction line
VLO: working oil valve
V L
RL
176
CV
178
311
V LO
184
EN
OIL PRESSURE CONTROL (FEED)
The feed pressure is controlled by means of the pressure regulator installed in the pump and should be set at 25 bar. The pressure regulator is operated by turning its screw. Make sure to fill the pump with oil prior to taking into operation.
PUMP BLEEDING
Open the feed and return stop valves and ensure the ring line (if any) is in operation.
Reduce the oil pressure at the pressure regulating valve. Turn on the pump by pressing the contactor.
Check the pump for proper direction of rotation. Check for proper oil delivery and absence of leaks in the hydraulic oil system. For bleeding the pump open the pressure gauge connection, for example.
When taking the burner into operation pro ceed by gradually increasing the pressure to operating level (25 bar).
CHECKING THE PRESSURE
(OIL SUCTION PRESSURE)
The maximum permissible vacuum is 0,4 bar. At higher vacuum levels the fuel oil will tend to separate air from oil which may lead to operating trouble. In the ring line mode of operation the recommended oil pressure is 2 bar.
close to the burners as possible and to arrange them in a way that the boiler door and the burner can be swing out without any obstruction.
Refer to the technical documentation for the line dimensions for the feed and return lines from the stop valves to the tank.
OIL FILTER
A filter must be installed upstream of the pump to protect the oil pressure pump and the hydraulic system.
OIL CONNECTION
Hoses are used for connection to the oil lines and stop valves. The hoses must be installed according to the applicable standards (relieved of tensile load, free of distortion) to avoid kinking and exclude the danger of breakage. Take care when mounting the oil lines to bring their ends as
INSTALLATION OPTIONS
• Two-line installation (separate feed and return lines without delivery pump).
• Ring line system (with delivery pump and gas-air separator).
10
9
LEGENDA
1. Inlet
2. Return
3. Bleed and pressure gauge port
4. Vacuum gauge port
5. Pressure adjustment
6. Nozzle outlet
7. Heater
8. Hose
9. Oil filter
10. Oil ball valve
8
8
!
WARNING: Check that the pump rotation is correct and before start up it has been pre-filled
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EN
INSTALLATION
Feeding and suction line for light oil
SUCTION LINE LENGTHS FOR PIPE SYSTEMS
• Two-pipe siphon feed system
• Two-pipe lift system
H
H
H
(m)
3
2,5
2
1,5
1
0,5
0
-0,5
-1
-1,5
-2
-2,5
-3
-3,5
-4
The burner is equipped with a self-priming pump which is capable of feeding itself within the limits listed in the table at the side.
PIPE LENGTH (m)
TA3 TA4
ø 14 mm ø 16 mm ø 20 mm ø 20 mm ø 30 mm
10 32 115 65 150
8
7
28
25
110
100
60
55
150
150
6
5
--
--
--
--
--
22
20
17
15
10
5
--
95
85
75
65
55
45
37
50
45
40
35
28
22
12
150
150
150
150
150
150
150
--
--
--
--
--
--
--
--
--
--
30
22
9
--
--
7
--
--
--
--
150
150
123
78
38
WARNING: To calculate the length of the pipework all the straight parts, curves, up and down pipes must be taken into consideration.
The static suction height is the distance between the standing valve and the axis of the burner pump.
Negative pressure must not exceed 0,45 bar; if negative pressure is greater pump operation may become faulty, leading to an increase in mechanical noise and perhaps even breakage.
All oil ring installations must comply with the local safety rules existing in the country of installation
The pumps that are used can be installed both into single-pipe and double-pipe systems:
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet that deliver the pressurized oil to the nozzle and part of the oil not used goes back to the pump. With this single pipe the by-pass plug must be removed and the return port must be sealed with steel plug and washer.
Double-pipe system: this is the default solution from the factory.
The return pipe send the excess oil from the pump to the tank. Depending on the type of pump used to change from a 1-pipe system to a 2-pipesystem, insert the by-pass plug (as for ccw-rotation referring to the pump shaft).
Note for commissioning: during commissioning, the filter, pipelines and pumps must be pre-filled with fuel oil and vented.
The direction of rotation of the motor should be checked. When commissioning it must be ensured that pump never run dry.
NOZZLE SELECTION
Please refer to diagram to select Ecoflam recommended nozzle for the output that is required given the output necessary in the installation.
Regular maintenance is highly recommended.
Nozzle has to be cleaned in petrol or paraffin and if filter or other parts are defective or damaged the nozzle must be replaced.
NOZZLE CHART IS AVAILABLE ON APPENDIX PAGE
SUNTEC TA
Oil under suction
Oil under pressure
Vacuum or inlet pressure gauge port
B y passed oil returned to tank, or to suction
Pressure gauge port
Intake from T ank
B y pass plug inserted
Pressure adjustment
Intake from T ank
B y pass plug removed
T o nozzle
Return
TWO PIPE
INSTALLATION
ONE PIPE
INSTALLATION
Return plugged
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INSTALLATION
Electrical connections
!
WARNING: Electrical wiring must be carried out with electrical supply disconnected and with burner switch in position OFF.
Electrical supply must correspond to the one shown on the burner label.
APPLICABLE STANDARD
The electrical connection work comprising all the installation materials, terminals and earth connections must be carried out in accordance with the applicable regulations. For the electrical installation of the burner care must be taken to observe the circuit diagram made out for the furnace system.
The electrical connection of the burner and instruments shall be entrusted to authorized specialists only.
NOTE: For the installation of the connection cables care must be taken to provide cable loops of sufficient length to allow for the swing-out of the boiler door and burner.
Make sure after the completion of the electrical connection work to check the wiring of the electrical system of the burner. This should include a check of the direction of rotation of the burner motor
(fan).
GENERAL WARNINGS:
All applicable electrical safety regulations must be followed. Failure to correctly dimension the suitable input power and earth the equipment may cause damages to person and compromise the correct function of the burner therefore the electrical system shall be checked by qualifed personnel.
The manufacturer declines all responsibility for modifcations or connections different from those shown in the electrical scheme.
Adapters, multiple plugs and extension cables may not be used for the equipment’s power supply.
An omnipolar switch in accordance with current safety regulations is required for the mains supply connection.
ATTENTION: Wiring is not supplied.
The burners are produced with connections suitable for power supply
380-400 V three-phase.
The burners with electric motors of an output lower or equal to 3 kW can be adapted to 220-230 V (please follow the instructions on the backside); motors with higher output can only work 380-400 V three-phase. In case of request of burners different from the above mentioned standard, it is recommended to make specific mention in the order.
Instructions: how to adapt electric motors of an output lower or equal to 3 kW to 220-230 V power supply
It is possible to change the voltage of the burner by operating as follows:
1. change the connection inside the electric box of the motor, from star to delta
(see picture 1);
2. change the setting of the thermal relay, referring to the absorption values indicated in the motor nameplate. If necessary, replace the thermal relay with another one of suitable scale.This operation is not possible on motors above 3 kW.
For more information, please contact the
Ecoflam staff.
PROBES CONNECTION
ACTIVE PROBE CONNECTION
(FOR MODULATING VERSION) fig.1
400V
230V
9 10 11 12 13
SA
G L M U1
Q BE ....
PASSIVE PROBE CONNECTION
(FOR MODULATING VERSION)
9 10 11 12 13
S P
M
Q AE ...
B
LEGENDA
HLB: lock-out lamp
STAB: two stages thermostat
HLF: burner on flame lamp
STC: boiler thermostat
STS: safety thermostat
SA: active probe
SP: passive probe
ELECTRICAL CONNECTION
1) of the burner
- Built-in electrical cabinet
Use cable gland in order to secure the required level of protection. All the links, power and control, are connected to the terminal block of the cabinet. Provide cables in sufficient length to secure the rotation of the burner body according to the assembly.
Check and adjust the size of the contactors and thermal relays and the wires section according to the motor and supply voltage specs.
PE
R
S
T
N
50 Hz 400V
R S T N 1 2 3 4 5 6 7 8 9 10 11 12 13
Q
HLB
STAB
T
P
HLF
STC
T
P
STS
T
P
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EN
EN
START-UP: CHECKING PROCEDURE
CHECKS BEFORE COMMISSIONING:
• That the burner is assembled in accordance with the instructions given here.
• Setting the combustion components.
• All electrical connections must be correct.
• Check the burner motor for correct direction of rotation.
• The heat generator must be ready for operation, and the operating regulations for the heat generator must be observed.
• The heat generator and heating system must be filled with water and the circulating pumps must be in operation.
• The temperature regulator, pressure regulator, low water detectors and any other safety or limiting devices that might be fitted must be connected and operational.
• The exhaust gas duct must be unobstructed and the secondary air system, if available, must be operational.
• An adequate supply of fresh air must be guaranteed.
• Check tank, lines and oil pump are filled with oil and correct oil nozzle is fitted.
• With burner in starting position check that air damper is in “CLOSED” position.
• Check that control box is unlocked and in its original position.
• A standard-compliant measuring point must be available, the exhaust gas duct up to the measuring point must be free of leaks to prevent anomalies in the measurement results.
OIL START-UP
Open all shut-off valves of oil supply system.
• Set fuel selector switch to its “Oil” position.
• Fill pump with oil.
• Mount pressure gauge in the feed line and return line.
• Mount the pressure gauge for checking the pump suction pressure.
• Make sure that the nozzle is size and mounted correctly.
Bleeding of oil system
Shortly start the burner and check for proper direction of rotation. Bleed the oil line and oil pump.
CAUTION: The hydraulic system has been filled with oil by the manufacturer.
This may cause ignition trouble when initially operating the system.
When starting the burner take care to increase the oil pressure slowly to the operating level.
Prior to the initial fuel feed start make a functional test of the burner program flow:
Oil system:
• Open all shut-off valves of the oil supply system.
• The oil solenoid valve in the feed line disconnect on the terminal strip (see
Circuit Diagram).
• Start burner and check program flow for correct start-up sequence:
1. Fan starts.
2. Pre-ventilating damper.
3. Air pressure check.
4. Partial-load air damper.
5. Ignition.
6. Valves open (disconnected valve remains closed).
7. Safety lock-out after expiry of safety period (see control box).
• Reconnect the valve.
• Unlock the control box.
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EXHAUST GAS TEST
To ensure an economically efficient and trouble-free operation of the system it will be necessary to adjust the burner specifically in accordance with the furnace system. This is achieved by means of a fuel-combustion air compound control unit which adjusts the burner to ensure a proper combustion. Exhaust gas tests are required for this purpose.
The percentage CO2 and O2 and the exhaust gas temperature will have to be measured to determine the efficiency and combustion quality.
Prior to any measurement make sure to check the boiler and exhaust gas system for absence of leaks.
Secondary air will falsify the measured results
Check that the exhaust gases have a residual oxygen (O2) content as low as possible and a carbon dioxide (CO2) content as high as possible.
The carbon monoxide content of the exhaust gases must be below the currently applicable specifications in all load stages.
In the fuel oil combustion mode the permissible soot number in the exhaust gas is not allowed to be exceeded
Recommended combustion parameters
Fuel
Natural gas
Light oil
Heavy oil
Recommended
(%) CO2
10 ÷ 9
13 ÷ 11,5
12,5 ÷ 11
Recommended
(%) O2
3,1 ÷ 4,8
3,3 ÷ 5,3
4,2 ÷ 6,2
Ratio between O
2
- and CO
2
- for natural gas H (CO
2 max = 11,7%)
Ratio between O
2 for light oil EL (CO
- and CO
2
2
- max = 15,40%)
Ratio between O
2
- and CO
2
- for heavy oil S (CO
2 max = 15,60%)
O
2
= 21 CO 2 max - CO
2 gem = %
CO
2 max
CO
2 gem = % CO
2 measured on dry flue gases
WARNING: if the installation is above sea level the output of the burner vary base on the diagram.
The regulation of the burner in this case shall take into account the reduced power of the burner due to the missing air.
M
e
a
n
a
ir pressure vs
.
a
ltitude
a
bove se
a
-level
5000
4500
4000
3500
3000
2500
2000
1500
1000
5 00
0
0 5 10 15 20 25 30 35
F
a
n
ca
p
ac
ity redu
c
ed by [%]
40 45 50
EN
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EN
START-UP OIL SIDE
Fuel selection - Start-up
Select the oil operation in order to proceed with start up on the oil side.
0
SAL
1
MAIN SWITCH
0 - OFF
1 - ON
KMV
!
KMV contactor: check the air fan motor rotation.
If the rotation if not correct invert the two phases on the power supply.
START UP THE BURNER
The control box starts the pre-purge cycle, the fan motor and the oil motor and opens the air flaps in full open positon.
At the end of pre-purging, the control box drives the servomotors into the igniton positon and starts the igniton transformer.
After a few seconds the control box opens the oil valve and starts the flame. After the flame stabilisaton the control box drives the servomotor in the low flame.
In case of faulty igniton, the control box switches the burner into safety condition, in such a case you must rearm the burner.
Gradually increase burner output from the low flame to the high flame and set oil servomotor curve in order to have a stable flame. Refer to LAMTEC manual attacched.
Adjusting the maximum air flow rate
Air and Oil adjustment are accomplished through LAMTEC parameters setting. Refer to LAMTEC manual attacched.
Firing head setting
The firing head is pre-adjusted at the 50% from the factory. The setting fully open enables to reach the full power of the burner and full close to reach the minimum power of the burner.
The optimal position depends on the output that we need to reach but the default setting shall be modified only when you are not able to reach the suggested combustion value by adjusting the air flow in the maximum flame.
+
– B
-+
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START-UP OIL SIDE
Adjusting the maximum oil flow rate
Put the selector on the maximum operation. Adjust the oil pressure reading the value on the return manometer / pressure gauge according to the nozzle tables provided in the appendix.
NOTE: the pump pressure is set from the factory at the pressure required nozzle pressure required as per table of nozzle selection in appendix. If the output required is different from the one set from the factory the pressure can be adjusted according to the instruction below.
Servomotor LAMTEC - Air damper motor pre-setting
Air adjustment is accomplished through LAMTEC parameters setting. Refer to LAMTEC manual attacched.
EN
Adjusting the pump pressure
1 - INLET
2 - RETURN
3 - BLEED AND PRESSURE GAUGE PORT
4 - VACUUM GAUGE PORT
5 - PRESSURE ADJUSTMENT
6 - TO NOZZLE
4
SUNTEC TA....
3
1
5
2
The pump pressure is set at a value of 22-25 bar during the testing of burners.
Before starting the burner, bleed the air in the pump through the gauge port.
Fill the piping with light oil to facilitate the pump priming. Start the burner and check the pump feeding pressure.
In case the pump priming does not take place during the first pre-purging, with a consequent, subsequent lock-out of the burner, rearm the burner’s lock-out to restart, by pushing the button on the control box.
If, after a successful pump priming, the burner locks-out after the prepurging, due to a fuel pressure drop in the pump, rearm the burner’s lock-out to restart the burner.
Do never allow the pump working without oil for more than three minutes.
!
NOTE: before starting the burner, check that the return pipe is open. An eventual obstruction could damage the pump sealing device.
6
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EN
START-UP OIL SIDE
Adjusting the intermediate burner capacity
Oil adjustment is accomplished through LAMTEC parameters setting. Refer to LAMTEC manual attacched.
WARNING: the variable profile of the cam shall have a normal proportional curvature in order to have good combustion values and reduce its mechanical stress breakdown.
1
VS VL
A
R
3
6
I
I 7
5 ma x
4
!
WARNING: Once the setting on the oil has been completed make sure that you close the manometer
– pressure switch tap.
PR
A
R
1
VS
3 m in
VL
4
6
I
I
7
5
PR
LEGENDA
1.
Oil pump
VS. Oil safety valve
3.
Adjusting cam
4.
Check valve
VL. Working valve
PR. Pressostat (optional)
5.
Nozzle
6.
Pressure regulator
7.
Manometer – pressure gauge
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MAINTENANCE PROGRAM
!
Burner and boiler servicing must only be carried out by authorised qualied personnel at least once a year.
Depending on the type of installation, shorter maintenance intervals may be necessary.
The system operator is advised to take out a maintenance contract to guarantee regular servicing.
WARNING: Use original spare parts.
SAFETY WARNINGS:
1. Turn off the power supply and protect the system from accidental start-up
2. Cut oil
3. Make sure there is no residual power in the system and that the actions in points 1 and 2 have been completed
4. Before opening the burner casing, ensure that the fan motor has stopped completely
Failure to observe any of these instructions will result in the risk of death or injury!
0
SAL
1
WORKS RECOMMENDED AS PART OF ANNUAL BURNER MAINTENANCE:
• Emergency stop button function check
• Check burner start characteristics
• Run burner test and input measurement in the boiler room
• Clean the combustion components and replace defective parts if necessary
• Check the combustion head components and make sure that all components are in good condition otherwise replace them
• Replace ignition electrodes and nozzle if necessary and check their correct position after any intervention
• Flame monitor and automatic combustion control unit function check
• Clean the fan wheel and the housing and grease rotating parts if necessary
• Clean the oil filter cartridge with gasoline periodically and check the tightening of the O rings, replace them if necessary
• Make visual inspection of the burner’s electrical components and eliminate malfunctions if necessary
• Burner safety devices function check (air pressure/switches if any)
• Commissioning the burner and correct the adjustment values if necessary
NOTES ON REASSEMBLING: Perform the described step in reverse order and make sure to refit components as they were originally assembled and the system is free from leaks. Use only original spare parts.
DRAW UP A MEASUREMENT REPORT ACCORDING TO THE LOCAL REGULATION AND CODES OF PRACTISE OF THE
COUNTRY
EN
EXHAUST GAS LOSS
Exhaust gas loss by way of free heat will occur as a result of the temperature difference between the fuel-air mixture entering the furnace chamber and the gases discharged. Any increase in the excess of air and the resultant higher exhaust gas volume will cause the exhaust gas loss to rise. The exhaust gas loss can be calculated as follows: q
A
= (t
A
- t
L
)
A
1
CO
2
+ B
A1
B
Light oil
EL
0,50
0,007
Heavy oil
S
0,490
0,007
Example
Data measured in natural gas mode:
CO
2 content of exhaust gases: 10,8%
Exhaust gas temperature: 195°C
Air intake temperature: 22°C q
A t
A t
L
CO
2
= exhaust gas loss [%]
= exhaust gas temperature [°C]
= combustion air temperature [°C]
= volumetric content of carbon dioxide [%]
The exhaust gas loss can be calculated as follows: q
Af
= (195-22)(
0,37
10,8
+ 0,009) = 7,48%
Natural gas Town gas
0,370 0,350
0,009 0,011
Data measured in fuel oil mode:
CO
2
LPG
0,420
0,008 content of exhaust gases: 12,8%
Exhaust gas temperature: 195°C
Air intake temperature: 22°C
The exhaust gas loss can be calculated as follows: q
Af
= (195-22)(
0,49
12,8
+ 0,007) = 7,83%
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19
EN
MAINTENANCE PROGRAM
REMOVING
THE BLAST TUBE
REMOVING
THE FIRING HEAD
3
4
+
-
1
2
POSITION OF ELECTRODES
ATTENTION: to remove the nozzle use the suitable box wrench taking care to not damage the electrodes .
Check the position of the electrodes after any intervention as wrong position could cause ignition troubles.
3
÷
4 mm
Ignition Electrode
5
÷
6 mm
OIL FILTER CLEANING
ATTENTION: Periodically clean oil cartridge with gasoline and replace them if it is necessary!
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TROUBLESHOOTING INSTRUCTIONS
For Setting and Error Lists refer to LAMTEC manual attacched.
OPERATING TROUBLE
In case of operating trouble it should be checked whether the system is in proper working order.
Make a check for the following:
1. Availability of fuel.
Availability of gas in the line at sufficiently high pressure.
Availability of fuel oil in the tank (for dual fuel burner).
Correct position of fuel selector switch.
2. Availability of electric power in the burner system.
3. Proper functional order and setting of all control and safety instruments such as temperature controller, safety limiter, water failure cut-out, electrical limit switches, etc.
If the trouble is not found to be due to any of the above-mentioned points it will be necessary to test the burner functions very carefully.
Prevailing conditions:
The burner will be found to be out of operation and in faulty and interlocked position.
Proceed with searching for the cause of the trouble and eliminate it. Unlock the control box by pressing the fault eliminate key and start the burner.
Do not press the fault eliminate key longer than 10 seconds.
The start-up program will be initiated and should be carefully monitored.
The possible cause of the fault may be quickly found by reference to the fault indicator of the control box and watching the start-up and operating program.
APPENDIX
Function - Lamtec BT3xx control and safety unit
The control and safety unit BT 3xx controls and monitors the forced draught burner.
The microprocessor-controlled program sequence ensures the maximum consistency of the cycle times involved, regardless of fluctuations in the mains voltage or ambient temperature. The control and safety unit is designed to detect power failures. Depending on the parameter assignment, the unit either switches to malfunction mode or goes into the standby position if the power supply falls below the mains voltage. In the standby position, there is an automatic restart as soon as the set threshold value is exceeded by 105%.
Manual locking and unlocking
Using the reset button , the control and safety unit can be locked manually
(interlocked) or unlocked, provided the unit is connected to the mains power supply.
This function must not be confused with automatic locking and fault acknowledgement in case of an error.
Pressing the unlocking button on the unit for
... 1 second ...
... 2 seconds ...
.... causes ....
the control unit to unlock.
the control unit to lock.
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Reduces the marked value.
!
Always switch off the power supply before installing or removing the control unit. Do not attempt to open or carry out repairs on the control unit.
Modifies/Confirms the value shown.
Unlocks the control unit.
Red LED (flashes if a fault is present).
Refer to LAMTEC manual attacched.
EN
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21
EN
APPENDIX
Fluidics nozzle chart
25
RETURN NOZZLE
The nozzle type Fluidics W is a by-pass nozzle with integrated spring-loaded cut-off needle.
The throughput rate is controlled by varying the return pressure while keeping the supply pressure at a constant level.
Prior to burner start, check the nozzle size against the required output.
It might be necessary to replace the nozzle (see nozzle selection diagram).
Return pressure
20
15
≤ 60 kg/h
> 60 kg/h
10
50° 70° 90° Spray angle
Supply
25 Bar
Bar 5
20 40 60 80 100 % Output
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APPENDIX
Bergonzo nozzle tables
EN
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23
EN
APPENDIX
Bergonzo nozzle tables
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420010813300
APPENDIX
Bergonzo nozzle tables
EN
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25
EN
APPENDIX
Pumps and pressure regulators
PUMP SUNTEC TA TECHNICAL DATA
Note: All TA models are delivered for two-pipe system (by-pass plug fitted in vacuum gauge port).
For one-pipe system, the by-pass plug must be removed and the return port sealed by steel plug and washer.
P UM P
I D EN T I F I C A T ION
( Not a ll mode l combinations are a v ai l ab l e
Consu l t y our Suntec representati v e )
T A : t y pe
Oil under suction
Oil under pressure
Vacuum or inlet pressure gauge port
B y passed oil returned to tank, or to suction
Pressure gauge port
Gear set capacit y
( see pump capacit y cur v es )
S h a f t rotation
( seen f rom s h a f t end )
A : c l oc kw ise rotation
C : anti c l oc kw ise rotation
Intake from T ank
B y pass plug inserted
Pressure adjustment
T o nozzle
T A 2 A 4 0 10 5 Return
TWO PIPE
INSTALLATION
P ressure ran g e :
30 : 7 30 bars
40 : 7 40 bars
P re h eater f aci l it y
Intake from T ank
B y pass plug removed
R e v ision number
ONE PIPE
INSTALLATION
Return plugged
General
M o u ntin g
C onn ec tion t h reads
Inl e t e n d re t ur n
T o nozzl e
P ressure g au g e p o r t
V acuum g au g e p o r t
S h a ft
B y -pass p l ug
W e i gh t
Hydraulic data
F l a n g e m o u ntin g
C ylin dr i ca l acc o rd in g to I S O 22 8/ 1
G 1 / 2 "
G 1 / 2 "
G 1 / 4 "
G 1 / 4 "
Ø 12 mm
In ser t ed in v acuum gauge p o r t fo r 2 p i pe s y s t em ; to b e rem ov ed wit h a 3/ 1 6" All e n k e y fo r 1 p i pe s y s t em
5, 4 k g ( T A 2)
6 k g ( T A 4)
-
-
5,7 k
6, 4 k g g
(
(
T
T
A3
A5
)
)
N ozzl e pressure ra n ges 3 0 : 7 3 0 b ars
40 : 7 40 b ars
De liv er y pressure se ttin g 3 0 b ars
O pera tin g vi sc o s ity 4 4 5 0 cS t
Oil t empera t ure
Inl e t pressure
Re
Ra
S t t t ar ur ed n tin pressure speed g to r q ue
0 140°C ma x. in t he pump li gh t oil : 0 , 4 5 b ars ma x. v acuum to pre v e nt a i r separa tion f r o m oil hea vy oil : 5 b ars ma x.
li gh t oil : 5 b ars ma x.
hea vy oil : 5 b ars ma x.
36 00 rpm ma x.
0 ,3 N .
m
P ump capacity
Capac ity (L/ h)
1 5 00
1400
1 3 00
1200
1100
1000
9 00
T
T
A5
A4
2 85 0 rpm
8 00
7 00
6 00
5 00
400
T
T
A 3
A2
3 00
200
100
0
0 5
Vi sc o s ity =
10 1 5 20 2 5 3 0 35 40 P ressure
(b ars)
200 cS t
20 cS t
5 cS t Ra t ed speed = 2 85 0 rpm
Da t a sh own are fo r n e w pumps , wit h no a llow a n ce fo r w ear .
C hoice of heater
Car t r i dge
F ittin g
Ra tin g
Ø 12 mm acc o rd in g to D I N 404 3 0 , NFC 68 1 9 0 ( N° 9 e l ec .
)
8 0-100 W
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APPENDIX
Electrical diagrams
X30
1
X31
1
X32 X33 X34
1
420010813300
WITH PROHIBITION OF USE AND REPRODUCTION GRAM THIS WIRING DIA TY OF VED THE PROPER WS WE RESER BY TERM LA
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27
EN
EN
APPENDIX
Electrical diagrams
UV CELL CELL
TION
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420010813300
APPENDIX
Spare parts
EN
420010813300
BT3xx
L
C
M
1
00
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29
EN
APPENDIX
Spare parts list
N°
1
2
3
4
8
9
10
11
12
13
14
15
DESCRIPTION
OIL PUMP
COIL
OIL VALVE
NIPPLE
5 HOSES
6 FILTER
7 COVER
GLASS
PEEP WINDOW FRAME
MOTOR
DISPLAY
CONTROL BOX
UV CELL
BOX
MOTOR THERMAL RELAY
16 REMOTE CONTROL SWITCH
17
18
19
20
26
27
28
29
30
31
32
33
34
35
36
37
ANTIJAMMING FILTER
MANOMETER
CABLE
ELECTRODES
21 IGNITION TRANSFORMER
22 SELECTOR
23 MAIN SELECTOR
24 FUSE SUPPORT
25 LAMP
RELAY BASE
RELAY
FAN
AIR CONVEYOR
COVER AIR INLET
AIR DAMPER MOTOR
ROD
NOZZLE HOLDER
DIFFUSER SUPPORT
DIFFUSER
BLAST TUBE
INNER ASSEMBLY
38 GASKET
39 AIR PRESSURE SWITCH
40 COUPLING
41 MOTOR PUMP
42 MOTOR THERMAL RELAY
43 REMOTE CONTROL SWITCH
44 SILENCER
45 ADJUSTMENT PRESSURE
46 CHECK VALVE
47 MODULE FOR PROBE
SUNTEC TA4C40106
LUCIFER 1/2 E321H25
LUCIFER 1/2 E321H25
TN 18X1200
TN 18X1500
70501/03
11 kW
15 kW
BCU LAMTEC
BT 330 667R13
FFS08-UV1 659D31
AEG 21-26A
AEG 24-32A
AEG LS18K.00
BF3800A230
CEWAL R1/4 D50-40 BA R
TC
TLX
Brahma T8 13000/35
ART.ECX1040
HK 520 04-1 10A
LYVIA 10x28 BA9S 240V
RED LED
360 x 135
380 x 135
STE4,5 Q3.51/6 3NM R W. PIN
TC
TLX
TC
TLX
TC
TL
65323137
-
65323170
65324105
65320944
740170016500
65325903
65323222
-
65325032
65324279
65324100
65325033
-
-
65321801
-
65324264
65324265
65311650
65325013
620190023000
65320716
65325053
65320784
65324815
840050301100
MAIOR P 500.1 PRE code
65322994
65323810
65323633
65323183
65323182
65324103
0FC09252-038
65320487
65320488
65326333
-
65326869
65325776
65312274
65325889
65324066
-
LGW10A2P
1,1 kW
AEG 3-4,7A
AEG LS05.10
ART. FZVR1
LCM100 LSB-M 667R0500-1
65321128
65323047
65325386
14100728
65323116
65323132
65074538
65324304
65325066
65311790
65325903
65323222
-
65325032
65324279
65324100
65325033
-
-
-
65321802
65324264
65324265
65311650
65325013
65320716
65325053
65320784
65324815
MAIOR P 600.1 PRE code
65322994
65323810
65323633
65323183
65323182
65324103
0FC09252-038
65320487
65320488
-
65325246
65326869
65325776
65312274
65325889
-
65323104
-
65323127
65323170
65324105
65320946
65321128
65323047
65325386
14100728
65323116
65323132
65074538
65324304
65325066
65311790
TC = SHORT HEAD TL = LONG HEAD
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31
EN
Ecoflam Bruciatori S.p.A.
Via Roma, 64 - 31023 Resana (TV) - Italy
Tel. +39 0423 719500
Fax +39 0423 719580 http://www.ecoflam-burners.com
e-mail: [email protected]
Società soggetta alla direzione e al coordinamento di Ariston Thermo S.p.A.
Via A. Merloni, 45 - 60044 Fabriano (AN) - CF 01026940427
Ecoflam Bruciatori S.p.A. reserves the right to make any adjustments, without prior notice, which is considered necessary or useful to its products, without affecting their main features
Ecoflam Bruciatori S.p.A. si riserva il diritto di apportare ai prodotti le modifiche che riterrà necessarie o utili, senza pregiudicarne le caratteristiche principali.
La maison Ecoflam Bruciatori S.p.A. se réserve le droit d’apporter les modifications qu’elle jugera nécessaires ou utiles
à ses produits sans pour autant nuire à leurs caractéristiques principales
Ecoflam Bruciatori S.p.A. se reserva el derecho a introducir en sus productos todas las modificaciones que considere necesarias o utiles, sin prejudicar sus caracteristicas
“Ecoflam Bruciatori S.p.A.” оставляет за собой право вносить в конструкцию оборудования любые необходимые изменения без особого предупреждения
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