Ecoflam 3142132, Operating Instructions Manual

Page 1: ...00 1 PR TC SGT 400 50 NS 3143292 MULTICALOR 500 1 PR TL SGT 230 400 50 NS 3142132 MULTICALOR 500 1 PR TL SGT 230 400 50 NS 3143770 MULTICALOR 500 1 PR TL S 3148241 MULTICALOR 600 1 PR TC SGT 230 400 50 NS 3143771 MULTICALOR 600 1 PR TL SGT 230 400 50 NS 3143772 MULTICALOR 600 1 PR TL S 3145773 Technical data Operating instructions Electric diagrams Spare parts list MULTICALOR 500 1 PR MULTICALOR 6...

Page 2: ...3 Fuel selection Start up 23 Adjusting the max air flow rate 23 Firing head setting 23 Adjusting the max oil flow rate 24 Servomotor SQM50 Air damper motor pre setting 24 Adjusting the pump pressure 24 Adjusting the intermediate burner capacity 25 Servomotor SQM50 Oil side final setting 25 Start up gas side 26 Fuel selection Start up 26 Adjusting the max air flow rate 26 Firing head setting 26 Ser...

Page 3: ...3 www ecoflam burners com EN 420010463703 CONFORMITY DECLARATION ...

Page 4: ...g ask another operator for help or use a forklift harness the burner using belts if no eyebolts are available Use the accessories provided flange gasket pins and nuts to install the burner onto the boiler taking care not to damage the isolating gasket We can accept no warranty liability whatsoever for loss damage or injury caused by any of the following Inappropriate use Incorrect assembly or repa...

Page 5: ... comply to the local safety regulations For burners over 1700 kW gas train connection pipe must be ordered Kits and accessories are managed and delivered separately Component type BBCH Burner Body with Combustion Head without gas train GTCP Gas Train Connection pipe GT Gas Train delivered separately MULTICALOR 300 1 PR TC SGT 230 400 50 MULTICALOR Dual fuel Gas Light oil RANGE NAME BY FUEL TYPE MU...

Page 6: ... optional E A C D SAL SA s r HLBT HLoil HLgas SAMA R V R 0 STOP 1 UP 2 LOW 3 AUTO 0 1 RWF 40 0 OFF 1 ON SAgG G B F 2 AUTO 3 GAS 1 OIL 0 STOP GTCP 20 23 24 19 LEGEND 1 Housing 2 Electrical control panel 3 Blower motor 4 Pump and pump motor 6 Blast tube 8 Burner fixing flange 9 Air flap regulation 11 Silencer 12 Lifting eyebolts 13 Mechanical cam gas 14 Mechanical cam oil 15 Servomotor for gas and a...

Page 7: ...ightness control KITTC Model Compulsory 1200 kW Modulation Kit KITMD RWF 50 Probe Max Pressure switch KITPRES50 KITPRES150 Other accessories Ecoflam gas trains are delivered separately for all gas and dual fuel burners and are available in different configurations Double gas valves with actuators and regulator VGD Siemens and min pressure switch ACS gas filter 1 2 3 9 11 8 10 5 6 7 WARNING EN676 com...

Page 8: ...dard Class 1 OIL EN267 250 mg kWh Control unit Type LFL LGK Gas train GT VGD separate gas train Filter KIT Tightness control Other KIT ACS Gas connection GTCP Gas connection range RP 50 to DN 125 depending on the gas train selected NATURAL GAS pressure mbar 35 500 50 500 LPG pressure mbar 65 500 90 500 Air regulation Type Air flap Air flap Air flap control with servomotor Model SQM50 Air pressure ...

Page 9: ... 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 L m 2000 3000 4000 5000 6000 7000 8000 9000 10000 4 5 1000 2000 3000 1000 6 11000 0 2 3 7 8 12000 kW 13000 9 10 11 Nm3 h 100 200 300 400 500 kcal h x 1000 4000 5000 6000 7000 8000 9000 10000...

Page 10: ... 195 250 MULTICALOR 600 1 1200 590 610 355 555 1000 320 570 965 330 330 M16 195 250 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 Burner boiler mounting flange Packaging only burner WARNING Please follow the suggested dimension for the hole on the boiler ...

Page 11: ...oller 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 inter...

Page 12: ...te the ignition gas The UV cell gives flame signal to control box so that the safety shut off valves will be opened The gas will be fed to the gas nozzles via the gas damper while combustion air is supplied by the fan Gas and air will be intensively mixed in the mixing unit and ignited by the pilot flame with a specified safety period minimum furnace heat generating rate After the safety period ha...

Page 13: ...rm 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...

Page 14: ...uble In the ring line mode of operation the recommended oil pressure is 2 bar 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 close to the burners ...

Page 15: ...etrol or paraffin and if filter or other parts are defective or damaged the nozzle must be replaced NOZZLE CHART IS AVAILABLE ON APPENDIX PAGE Oil under suction Oil under pressure Pressure gauge port To nozzle Pressure adjustment By pass plug inserted By pass plug removed Return Intake from Tank TWO PIPE INSTALLATION Vacuum or inlet pressure gauge port By passed oil returned to tank or to suction ...

Page 16: ...al bore DN of the gas valves and instruments group care should be taken to observe the flue resistance of the boiler and the gas pressure loss of the burner and valves and instruments group GAS VALVESAND INSTRUMENTS GROUP The gas valves and instruments group can be connected directly to the gas feed line Take care to observe the correct order of installation and direction of flow arrow on housing ...

Page 17: ...he head loss diagram is only indicative and does vary depending on the setting of the head PILOT GAS TRAIN CONNECTION The pilot gas train is already installed to the burner and shall be connected to the main gas supply line preferebly with flexible pipe The pilot gas train is composed of n 2 safety valves and n 1 gas governor and filter Max inlet pressure 1 bar WARNING Pilot gas train must be conn...

Page 18: ...220 230 240 250 260 270 280 290 300 200 250 300 350 400 450 500 550 600 perdite di carico rampa gas testa di combustione pressure drop gas train firing head mbar VGD 40 080 F DN 80 VGD 40 065 F DN 65 VGD 20 503 F 2 natural gas VGD 40 080 VGD 40 065 VGD 20 503 VGD 40 100 F DN100 VGD 40 100 VGD 40 125 F DN125 VGD 40 125 INSTALLATION Gas pressure loss diagrams PRESSURE DROP includes COMBUSTION HEAD G...

Page 19: ...ICALOR 600 1 MULTIFLAM 600 1 VGD 40 125 no yellow 45 500 4C FILTER DN 125 50 500 VGD 40 100 no yellow 55 500 FILTER DN 100 60 500 VGD 40 080 no yellow 80 500 FILTER DN 80 100 500 VGD 40 065 no yellow 150 500 FILTER DN 65 180 500 VGD 20 503 no yellow 275 500 FILTER 2 340 500 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 ...

Page 20: ...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 ATTENTION Wiring is not supplied 2 of the gas train Connect the plugs pending to...

Page 21: ...ng level GAS START UP NOTE Adjust the gas unit according to the fuel oil unit Set the fuel selector switch to its Gas position Connect the measuring instruments for the gas head pressure on the test connection downstream of the gas damper and the air pressure on the burner test connection Open the gas shut off valve before the gas armatures and test the gas pressure on the pressure gauge Set the M...

Page 22: ...d to be exceeded DETERMINING THE VOLUMETRIC GAS FLOW RATE The thermal furnace output of a boiler QF is the amount of heat supplied with the gas in a unit of time When taking the burner into operation the volumetric fuel flow rate should be selected according to the nominal thermal capacity of the boiler Example Nom thermal output QN 1000 kW Boiler efficiency nK 0 88 Calorific value of gas Hu 9 1 k...

Page 23: ...y required Check the combustion values and adjust the oil pressure Firing head setting In order to adjust the maximum air flow rate see figure with selector in maximum operation Loosen the nut holding the air damper transmission rod and correct air flow till you reach the combustion values suggested by reading the value on the combustion analyser If you do not reach acceptable air flow rate you shall ...

Page 24: ...ut 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 SUNTEC TA 1 INLET 2 RETURN 3 BLEED AND PRESSURE GAUGE PORT 4 VAC...

Page 25: ...int oil cam configuration WARNING Once the setting on the oil has been completed make sure that you close the manometer pressure switch tap LEGEND 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 Once the point to point oil cam setting has been completed we need to set the final minimum out...

Page 26: ...2 3 0 operating elements locked in an intermediate position 1 operation on maximum capacity 2 operation on minimum capacity 3 automatic operation Adjusting the maximum air flow rate Firing head setting In order to adjust the maximum air flow rate see figure with selector in maximum operation Loosen the nut holding the air damper transmission rod and correct air flow till you reach the combustion valu...

Page 27: ... the air and gas setting you have to calibrate the air switch with the burner working on the low flame by slowly turning the relative knob clockwise until the burner locks out Read the value and then decrease it by 15 Set the pressure switch to the minimum by turning knob D to position 1 Start the burner and keep in low flame running while checking that combustion is correct Through a small cardbo...

Page 28: ...nd check the gas flow Clean the gas filter cartridge with air periodically replace it if necessary After the cleaning of the components of the gas train perform the leakage test Make visual inspection of the burner s electrical components and eliminate malfunctions if necessary Burner safety devices function check air pressure gas pressure switches Commissioning the burner and correct the adjustme...

Page 29: ...s valve REMOVING THE BLAST TUBE REMOVING THE FIRING HEAD 3 4 mm 5 6 mm Ignition Electrode POSITION OF ELECTRODES 22 23 SIEMENS min 70 ȝA UV CELL Microamperometer full scale 1000 μA LFL 1 333 The detector current is checked by inserting a micro ammeter scale 1000 μA d c in series with the UV cell The flame detector current has to been 70 μA GAS FILTER CLEANING GAS PILOT FILTER CLEANING ATTENTION Pe...

Page 30: ...ion Clean valves or replace if necessary X YES YES LACK OF AIR Air pressure switch fail to connect to Terminal 14 Check contacts X YES NO Fan contaminated dirty Clean fan X X X YES NO Fan motor rotation direction not correct Check direction and contactor X X X YES NO IGNITION FLAME STABLISATION PERIOD Flame supervision circuit internal test failed Replace control unit X YES NO Pilot flame failure ...

Page 31: ...failure VPS VDK Clean valves or replace leakage controller if necessary X YES Leakage Test failure LDU kit Check contacts clean valves or replace leakage controller if necessary X YES SEQUENCE START Servomotor OPEN position switch not reach Check servomotor settings X YES Servomotor MIN position switch not reach Check servomotor settings X YES Extraneous light Eliminate light source X YES LACK OF ...

Page 32: ...ignal from the Air Damper CLOSED limit switch is missing or a contact is not closed between terminals 12 and 4 or 4 and 5 or the contacts of all control and safety units in the controlled system are not closed e g gas pressure or air pressure switches temperature or pressure switches temperature or pressure regulators Operating stop because the OPEN signal from the Air Damper OPEN limit switch is ...

Page 33: ...or modulating oil gas or dual fuel burners The reversible actuator is fitted with a synchronous motor which drives a shaft via a gearbox The shaft end carries a coupling to drive the fuel and combustion air controlling element The SQM actuator has been designed for dual wire control by controller or switching units with change over contacts Potentiometers can be installed for a range of applicatio...

Page 34: ...34 www ecoflam burners com EN 420010463703 APPENDIX Fluidics nozzle chart ...

Page 35: ...35 www ecoflam burners com EN 420010463703 APPENDIX Fluidics nozzle chart ...

Page 36: ...36 www ecoflam burners com EN 420010463703 APPENDIX Fluidics nozzle chart ...

Page 37: ...50 175 B 20 285 280 275 270 270 265 265 260 255 250 245 240 230 200 185 170 150 175 A 25 60 61 62 63 64 65 66 68 70 72 78 80 82 85 92 98 105 110 120 140 160 175 B 25 330 330 330 330 325 325 325 320 315 310 300 295 280 270 260 252 245 235 225 200 180 175 A 30 67 68 69 70 71 72 73 74 75 76 77 79 80 82 85 90 92 95 100 105 110 118 125 140 160 180 175 B 30 360 360 360 355 355 350 350 345 345 340 340 33...

Page 38: ...45 155 170 190 215 240 275 350 B 20 590 580 570 560 550 540 530 500 480 465 450 440 400 375 360 340 350 A 25 120 122 124 126 128 132 134 136 138 140 145 150 155 165 175 185 200 225 255 275 350 350 B 25 620 620 620 615 614 612 610 605 600 595 575 565 550 530 510 490 470 450 410 380 360 350 A 30 125 125 127 129 131 133 135 138 141 143 145 150 155 160 168 174 184 195 210 225 245 265 280 325 370 350 B...

Page 39: ...0 210 230 250 275 300 340 410 475 B 20 740 735 730 720 710 700 680 660 640 620 490 560 530 500 475 450 475 A 25 140 162 164 166 168 170 175 180 188 195 205 215 225 245 265 280 305 340 380 480 475 B 25 850 845 840 835 830 820 810 800 790 780 760 740 720 700 675 650 620 580 540 510 475 A 30 170 171 172 173 174 176 177 178 180 186 194 200 210 225 235 245 255 275 285 305 330 365 400 460 540 475 B 30 9...

Page 40: ...LLATION Return plugged Inlet end return G 1 2 To nozzle G 1 2 Pressure gauge port G 1 4 Vacuum gauge port G 1 4 40 20 30 35 10 15 25 5 1000 1200 1400 200 400 0 600 800 TA5 TA4 TA3 TA2 0 900 1500 1100 1300 100 300 500 700 General Mounting Flangemounting Connection threads Cylindrical according to ISO 228 1 Shaft Ø 12 mm By pass plug Inserted in vacuum gauge port for 2 pipe system to be removed with...

Page 41: ...ALTA LLAMA pos 0 ARRESTO STOP SAMA 1 2 3 0 YVGS YVG T P SPGmin KA1 T P STAB YVGPS T P SPA TV UV KA HLg HLG YVgA YVgR LINE LOAD Z FU SAL HLBT SAMA 1 2 3 0 SAgG 1 2 3 0 FMP FMV 3 M MV U V W 3 M MP U V W KMV R S T NO KMP R S T NO YVGP KA_gas KA_oil 2 2 1 FMP 97 98 SA s r 7 8 9 6 5 4 2 3 1 11 12 10 12 10 11 3 1 2 6 5 4 7 8 9 FMV 97 98 FMV 95 96 FMP 95 96 TOT SHEET SHEET DESIGNER DESCRIPTION DATE FIST ...

Page 42: ...O GAS DE MINIMA POT PRESSOSTAT GAZ PRESSION MIN GAS PRESSURE SWITCH MIN PRESSOSTATO GAS DI MINIMA SPGmin YVGP YVGS YVgR YVgA THERMOSTAT CHAUDIERE TERMOSTATO CALDERA TERMOSTATO DI SICUREZZA COMMUTATORE GASOLIO GAS INTERRUPTEUR MAZOUT GAS CONMUTADOR GASOLEO GAS TERMOSTATO DE SEGURIDAD COMMUTATORE MANUALE AUTOMATICO SWITCH MANUAL AUTOMATIC INTERRUPTEUR MANUEL AUTOMATIQUE CONMUTADOR MANUAL AUTOMATICO ...

Page 43: ... APPENDIX Spare parts list 1 8 9 10 14 Multicalor 500 1 PR Multicalor 600 1 PR 6 5 4 36 11 3 39 31 29 30 27 32 35 47 26 7 28 42 41 40 55 43 44 45 46 38 49 48 1 0 13 12 25 16 17 15 21 22 18 24 20 19 37 23 34 56 57 50 51 50 51 52 54 53 60 59 58 2 ...

Page 44: ...ION CABLE TC 65320947 65320947 65320947 TL 65320947 65320947 65320947 TL 950 65325345 28 IGNITION ELECTRODES SET 65325222 65325222 65325222 29 PIPE TC 65321675 65321675 65321675 TL 65324491 65324491 65324491 TL 950 65329212 30 ROD TC 65324492 65324492 65324492 TL 65324434 65324434 65324434 TL 950 65329210 31 FIRING HEAD 65321676 65321676 65321676 32 FRONT DISC 65324157 65324157 65324157 33 NOZZLE ...

Page 45: ...DIX Spare parts list 1 8 9 10 14 Multicalor 500 1 PR PR S Multicalor 600 1 PR PR S 6 5 4 36 11 3 39 47 26 7 42 41 40 55 43 44 45 46 38 49 48 1 0 13 12 25 16 17 15 21 22 18 24 20 19 37 23 56 57 50 51 50 51 52 54 53 60 59 31 29 30 27 32 33 35 28 34 58 ...

Page 46: ...65323139 26 UV CELL SIEMENS QRA 2 65320075 65320075 27 IGNITION CABLE TC 65320947 65320947 TL 65320947 65320947 28 IGNITION ELECTRODES SET 65325222 65325222 29 PIPE TC 65321675 65321675 TL 65324491 65324491 30 ROD TC 65324492 65324492 TL 65324434 65324434 31 FIRING HEAD 65321676 840050198500 32 FRONT DISC 65324157 65324157 33 DIFFUSER LPG 840030020501 GN 65325795 34 LIGHT OIL FIRING HEAD TC 653244...

Page 47: ...47 www ecoflam burners com EN 420010463703 ...

Page 48: ...oflam 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 d...