Ecoflam BLU 8000.1 PR User manual

Technical data
Operating instructions
Electric diagrams
Spare parts list
GAS BURNERS
EN
BLU 7000.1 PR
BLU 8000.1 PR
BLU 10000.1 PR
BLU 12000.1 PR
Gas train manual is separate
www.eacoon.com
KIT PER 3142589 3143029

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EN
420010511800
2
INDEX
BLU 7000.1 PR
BLU 8000.1 PR
BLU 10000.1 PR
BLU 12000.1 PR
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 14000 kW
10000 11000 12000 13000
General warnings - Conformity declaration 3
Burner designation - Modular delivery system 4
Burner description 5
Electrical control panel 5
Gas train - Kit - Accessories: assembly to the burner 6
Technical data 7
Gas category by country 7
Working fields 8
Test boiler - Flame dimension 8
Overall dimensions 9
Gas operating mode - General safety functions 10
Installation 11
Fitting the burner to the boiler 11
Gas line 12
Pilot gas train, kit and accessories connection - Head loss diagram 13
Pressure loss diagrams 14
Electrical connections 18
Start-up: checking procedure 19
Exhaust gas test 20
Start-up 21
Adjusting the max air flow rate 21
Firing head setting 21
Servomotor pre-setting 21
Adjusting the intermediate burner capacity 22
Pressure switch adjustment 22
Servomotor: final setting 22
Maintenance program 23
Troubleshooting instructions 25
Operating troubles 26
Appendix 27
Control box - Damper actuators 27
Electrical diagrams 28
Spare parts list 32

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EN
420010511800
GENERAL WARNINGS - CONFORMITY DECLARATION
Declaration of conformity
for gas burners
We,
Ecoflam Bruciatori S.p.A.
declare under our sole responsibility
that the products:
BLU 7000.1 PR
BLU 8000.1 PR
BLU 10000.1 PR
BLU 12000.1 PR
conform to the following standards:
EN 676: 2008
EN 60335-1: 2008
EN 60335-2-30: 2006
EN 60335-2-102: 2007
EN 55014-1: 2008 + A1: 2009
EN 55014-2: 1998 + A1: 2001 + A2: 2008
These products are built in accordance
with the following directives
2006/42/EC Machinery directive
2004/108/EC EMC directive
2006/95/EC Low voltage directive
2009/142/EC Gas appliances Directive
CE certification, when required, must be
done at installation site by the end user
Resana, 20th December 2010
M. PANIZZON
BLU burners are designed for the
combustion of natural gas or LPG with kit.
The design and function of the burners
meet the standard EN676. 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
BLU 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).
PACKAGING
The burner, the gas train 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:
EN 676
Forced-draught gas burners
EN 60335-1, -2-102
Specification for safety of household and
similar electrical appliances, particular
requirements for gas burning appliances
GAS LINES
When installing the gas lines and gas train,
the general EN676 directives and
guidelines must be observed.
EN676 compulsory kit and accessories in
order to comply to the safety regulations.
Additional accessories and kits shall be
installed by the installer in accordance to
the local safety regulations and codes of
practise.
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.
!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.
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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420010511800
BURNER DESIGNATION
MODULAR DELIVERY SYSTEM
Gas burners
All gas burners are delivered in separate set/box, i.e. burner body including combustion
head and separate gas train with separate additional kit and accessories that shall
complete the gas train or the burner according to the applicable standard.
Kit and accessories are delivered separately.
Gas train - GTCP - KITS - Accessories
All gas and dual fuel burners gas trains are delivered separately in different models and
configuration.
Export configuration gas train completion are available but it is mandatory for the local
installer in this case to 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)
BLU 8000.1 PR TC SGT 230-400-50
BLU Gas
RANGE NAME BY FUEL TYPE
BLU 8000.1 8000 kW
MODEL SIZE (Gas: kW; Oil: kg/h)
Standard Class 2 - GAS EN676 (<120 mg/kWh)
LN Low NOx Class 3 - GAS EN676 (<80 mg/kWh)
EMISSIONS
PAB 2 stages soft start
PR 2 stages progressive mechanical
E2 stages modulating electronic
OPERATION TYPE
230-400-50 230-400 Volt, 50 Hz
ELECTRICAL POWER SUPPLY
TC Short head
TL Long head
HEAD TYPE
Natural gas
LPG Liquid gas
BIOGAS Biogas
FUEL
SGT Separate gas train
EQUIPMENT

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420010511800
BURNER DESCRIPTION
GTCP
LEGENDA
1. Housing
2. Electrical control panel
3. Blower motor
5. Hinge flange
6. Blast tube
7. Burner head
8. Burner fixing flange
9. Air flap regulation
11. Silencer
12. Lifting eyebolts
13. Mechanical cam gas
15. Servomotor for gas and air
16. Gas train
19. Gas filter
20. Ball valve
23. Antivibration coupling
24. Tightness control
GTCP. Gas train connection pipe
Control panel
20
23
24
19
16
15
13
1
7
6
8
12
1
9
11
3
2
1 - Fuse
2 - Termal lock-out lamp
3 - Working lamp
4 - Selector
:
0 Loking of devoices for operating at intermediate outputs
Operation at max. output
Operation at min. output
AUTO Automatic operation
5 - Main switch I / O
6 - Lockout disable push button
7 - Lock-out lamp
PGM EXIT
5
0
I
GAS
RESET
0
AUTO
6
4
1
7
3
2

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420010511800
M
Air
Gas
313
160
170
144
142
141
120
150
314
349
151
155
100
143
To be supplied by the installer
To be supplied by the installer
107
143
Antivibration
coupling
144 Gas governor
150 Batterfly valve
151 Gas train Landis VGD....
155 Pilot gas train
160 Kit tightness control (optional)
170 Kit tightness control for pilot gas valve (optional)
313 Min.gas pressure switch
314 Max.gas pressure switch (optional)
349 Air/gas damper motor
BURNER DESCRIPTION
Gas train - Kit - Accessories: assembly to the burner
MATCHING GAS TRAIN WITH DIAGRAM OF PRESSURE DROPS
ARE IN THE DEDICATED SECTION OF THIS MANUAL
VGD 20.503 Rp 2” / VGD 40.065 - 40.080 - 40.100 - 40.125 1. Main gas pipe
2. Ball valve ACS
3. Antivibration coupling ACS
5. Min gas pressure switch
EXPORT
GAS TRAIN
EN676
6. Safety gas valve + 10. Actuator
7. Working gas valve + 11. Actuator
8. Gas leakage control KITTC *
9. Gas filter ACS
KIT - MAX Gas pressure switch KITPRES
ACS - Gas train connection pipe GTCP **
!GTCP-...* WARNING: in order to fit the gas train, the corresponding connection pipe must be ordered (GTCP size and fitting depend on the
burner and the gas train selected).
!WARNING: EN676 compulsory kit and accessories in order to comply to the safety regulations. Additional accessories and kits
shall be installed by the installer in accordance to the local safety regulations and codes of practise.
HOW TO INSTALL THE GAS TRAIN INTO THE BURNER AND CALCULATE THE OVERALL DIMENSIONS:
refer to the dimension page and the gas train manual for all detailed information
Gas governor / Filter
FGDR - FILTER
Compulsory EN676
Tightness control
KITTC- Model
Compulsory > 1200 kW
Modulation Kit
KITMD-RWF40
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
12 3 911810
5
67

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420010511800
TECHNICAL DATA
GAS CATEGORY BY COUNTRY
MODEL BLU 7000.1 BLU 8000.1 BLU 10000.1 BLU 12000.1
Thermal power max.
kW 7.500 8.500 10.500 13.000
kcal/h 6.450.000 7.310.000 9.030.000 11.180.000
Thermal power min.
kW 1.500 2.000 2.500 2.700
kcal/h 1.290.000 1.720.000 2.150.000 2.322.000
Operation mode Type Progressive mechanical gas - Modulating with PID
Regulation ratio nominal Type 1÷4 GAS
Fuel Type
G20 (L.C.V. 8.570 kcal/Nm3), G25 (L.C.V. 7.370 kcal/Nm3)
G31 (L.C.V. 22.260 kcal/Nm3), G30 (L.C.V. 29.320 kcal/Nm3)
Emission class std Standard Class 2 - GAS EN676 (<120 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 DN65 to DN125 depending on the gas train selected
NATURAL GAS pressure mbar 60÷700 85÷700 115÷700 175÷700
LPG pressure mbar 125÷700 185÷700 110÷700 160÷700
Air regulation Type Air flap Air flap Air flap Air flap
Air flap control with servomotor Model SQM50
Air pressure switch mbar 1…10 mbar
Flame monitoring Type Ionization
Ignitier Model COFI
Motor kW 15 18,5 22 37
Rpm N° 2.800 2.800 2.800 2.800
Voltage V/Hz 230/400 V - 50 Hz
Tot. power consumption operation
W16.500 20.000 23.500 38.500
Weight body BBCH Kg
Electrical panel protection level IP IP40 IP40 IP40 IP40
Sound pressure level
without silencer dB(A)
Lab tests
94,1 94,6 95,6 96,3
Sound pressure level
with silencer 86,9 87,8 88,1 88,9
Ambient temperature storage
Min/Max
-20°…+70° C
Ambient temperature use -10°…+60° C
Gas category Country
2,3 Family AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LT LU LV MT NL NO PL
PT RO SE SI SK AL HR MK TR - - - - - - - - - - - - - - - -

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WORKING FIELDS
TEST BOILER - FLAME DIMENSIONS
The burner/boiler matching does not pose
any problems if the boiler is CE type-
approved.
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 EN676 -
EN267 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.
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 11000 12000 13000 14000 15000
14000 15000 16000 17000
Ø (m)
2000 3000 4000 5000 6000 7000 8000 9000 10000
0,6
0,8
1000
2000 3000
1000
1
11000
0
0,2
0,4
1,2
1,4
12000 kW
13000
1,6
1,8
2
kcal/h
x 1000
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
14000 15000 16000 17000
FLAME LENGHTGAS BURNERS
FLAME DIAMETER GAS BURNERS
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
Nm3/h
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
0
5
10
15
20
25
30
35
40
0 2000 4000 6000 8000 10000 12000 14000
02000 4000
kW
kcal/h*1000
6000 8000 10000 12000
mbar
BLU 7000.1
BLU 12000.1
BLU 10000.1
BLU 8000.1
Working fields
The working field shows burner
output as a function of
combustion chamber pressure.
It corresponds to the maximum
values specified by EN 676
measured at the test fire tube.
Boiler efficiency should be
taken into consideration when
selecting the burner.
Calculation of
burner output
QF= Burner output (kW)
QN= Rated boiler output(kW)
η= Boiler efficiency (%)
QF= QNx 100
η

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420010511800
ED - D1
F
G
C
B
A
H1
M16
550
M
L
I
N
O
600
540
OVERALL DIMENSIONS
HOW TO INSTALL THE GAS TRAIN
INTO THE BURNER AND CALCULATE
THE OVERALL DIMENSIONS:
refer to the dimension page and the gas train
manual for all detailed information
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 flange in order to fit the burner. Make sure that between
the boiler and the blast tube proper insulation is fitted.
X Y Z kg
BLU 7000.1 1750 2380 1460
BLU 8000.1 1750 2380 1460
BLU 10000.1 1750 2380 1460
BLU 12000.1 1750 2380 1460
Dimensions (mm)
D = Short head
D1= Long head
X
Y
Z
A B C D D1 E F G H1 I L M N O
BLU 7000.1 1210 585 625 470 - 1212 420 775 1270 460 460 M20 195 232
BLU 8000.1 1280 655 625 470 - 1212 420 775 1270 460 460 M20 195 232
BLU 10000.1 1310 685 625 470 - 1212 420 775 1270 460 460 M20 195 232
BLU 12000.1 1420 795 625 470 - 1212 450 775 1270 460 460 M20 195 232
460 540
460
600
550
476
275
N°6M16

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GAS 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 flow started.
When the program has come to its end,
the burner will be turned on.
An automatic test is made for the tightness
of the gas valves prior to each burner start.
The air damper is in its closed position
when the burner is out of operation.
The electric actuator will open the closed
air damper to its full-load position so that
the burner will ventilate the furnace and
the exhaust hoods with the specified air
rate.
Shortly after the preventilation process has
been started the lack-of-air cut-out must
change over to operating position within a
certain time, i.e. the minimum air pressure
setting must be reached and maintained
until the burner is turned off. At the end of
the specified pre-ventilation time the air
damper will be moved into its partial-load
position in a linked control concept with the
gas damper.
The ignition transformer will be started.
At the end of the pre-ignition time the
ignition gas solenoid valves will be opened
to allow gas to flow into the pilot burner.
The ignition electrodes incorporated in the
pilot burner will ignite the ignition gas.
The ionization probe 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 has run down the
pilot burner will be turned off.
Attention:
If there are shut-off dampers in the flue
gas tract they must be completely open.
Otherwise there will be a high danger of
low-speed detonation or explosion!
GAS 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 partial-
load and full-load stages. Depending on
the heat demand, the electric actuator of
the compound control system will be fed
with the OPEN or CLOSE command via
the regulator and thus increase or
decrease the gas and air flow rates.
This compound control system will vary
the positions of the gas control valve and
air damper and thus regulate the gas flow
rate in a linked concept with the air flow
rate. The burner can either be controlled
by a 2-stage sliding or, if a respective
controller is provided, a stepless control
concept.
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 always be turned off out of
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 thus be
greatly minimized.
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 (shut-off on trouble).
A shut-off on trouble 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 shut-off on trouble
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 shut-off on trouble 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.
Leistungsregulierung
Zündung
Gasventile
EIN
Teillast
Freigabe
AUS
Betriebsstellung
Vollast
Leistungsregulierung
EIN
Gasventile
Zündung
Startlast
Teillast
Freigabe
AUS
Betriebsstellung
Vollast
2-stage sliding Stepless
Gas control:
ON OFF
Full load
Operating position
Load regulator
Release
Partial load
Ignition /gas valves
Full load
Operating position
Load regulator
Release
Start load
Partial load
Ignition /gas valves
ON OFF

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!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.
INSTALLATION
Fitting the burner to the boiler
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 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. Check the ignition electrodes 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.
3. Check that the head is preset at 50%.
Position of the electrodes
0
I
MAIN SWITCH
0 - OFF
1 - ON
5
10
Elettrodo
accensione
Elettrodo
rivelazione
Ignition Electrode
Ionization Probe
=
=
15

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420010511800
M
Air
Gas
313
160
170
144
142
141
120
150
314
349
151
155
100
143
To be supplied by the installer
To be supplied by the installer
107
100 Burner
107 Pilot gas filter/governor
120 Air damper
141 Ball valve
142 Gas filter
143 Antivibration coupling
144 Gas governor
150 Batterfly valve
151 Gas train Landis VGD....
155 Pilot gas train
160 Kit tightness control (optional)
170 Kit tightness control for pilot gas valve (optional)
313 Min.gas pressure switch
314 Max.gas pressure switch (optional)
349 Air/gas damper motor
INSTALLATION
Gas line
GAS VALVES AND INSTRUMENTS GROUP
The gas valves and instruments group used
with the furnace will be selected according to
the specific requirements to be met by a
burner system.
The following factors must be taken into
account:
• burner output
• furnace back pressure
• gas pressure loss of the burner head
• gas pressure losses of the gas valves and
instruments group
NOTE: Only gas trains assembled by the burner manufacturer and approved in
accordance with the burner test specifications.
EN676 compulsory kit and accessories in order to comply to the safety regulations.
Additional accessories and kits shall be installed by the installer in accordance to the
local safety regulations and codes of practise.
GAS CONNECTION PRESSURE
A minimum connection pressure must be
available upstream of the burner gas valve
to ensure the proper functioning of the
burner.
WARNING: the total gas pressure loss
must always be smaller than the available
gas flow pressure.
For the installation of the valves and
instruments group take care to observe the
mounting instructions supplied by their
manufacturers (these are packed with the
equipment).
The gas line installed to the burner must
be dimensioned in accordance with the
throughput rate and the available
pressure.
For selecting the nominal 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 VALVES AND 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).
Check the valves and instruments and
connection pieces for absence of dirt
particles and foreign matter before
installation and initial operation. To provide
effective conditions for start-up make sure
the distance between the burner and the
gas stop valve is as short as possible.
LEAK TEST
The gas line upstream of the burner gas
valves and instruments group must be
installed in accordance with the applicable
regulations, checked for absence of leaks,
vented and certified accordingly by the gas
installation company. The screwed unions
and flanged joints must be checked for
proper tightness (by making a pressure
test). The leak test must be made under
pressure using approved foaming agents
which do not cause corrosion. For steam
boiler furnaces the result of the leak test
must be duly certified.
VENTING
Prior to taking the burner into operation or
after any repair work make sure to vent the
complete gas feed line and the gas valves
and instruments group into the open
atmosphere (e.g. by means of a hose)
taking care to avoid any hazards.
In no case should the gas line be vented
into the heating or furnace chambers.
Make use of a test burner to check the
gas-carrying spaces are free from an
inflammable gas mixture.
SUPPORT
The valves and instruments group must be
supported with a telescopic jacking
member or similar during and after
installation (e.g. on filter and valve).
JOINT
It is recommended to provide an easy to
disconnect joint (with planar sealing faces)
to facilitate repair work on the boiler
(furnace) and allow the boiler door to be
swivelled out if required.
CONNECTION DIAGRAM FOR BURNERS WITH
SEPARATE PILOT (GAS TRAIN LANDIS VGD...)

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INSTALLATION
Pilot gas train, kit and accessories connection - head loss diagram
GAS PRESSURE LOSS DIAGRAM:
combustion head - platform 630
The diagram provides combustion head
pressure loss. To have pressure loss
combined with the different type of gas
train you must refer to the pressure loss
diagrams.
WARNING:
Note that the head loss diagram
is only indicative and does vary
depending on the setting of the head.
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
300 400 500 600 700 800 900 1000 1100 1200 1300 1400
pressure mbar
OUTPUT - Stm3/h
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 connected according to the drawing of the
gas line.
GAS VALVES ADJUSTMENT
Note : the pilot valves are pre-adjusted in the factory. To increase or reduce the
gas flow act on the gas governor.
GAS GOVERNOR ADJUSTMENT
The gas governor, with built-in filter, must be installed so as
to stabilise the outlet gas pressure and to avoid that
eventual impurities reach the gas valve. To increase gas
pressure, remove the cover of governor and turn screw C.
Unscrew screw C to reduce pressure, then fit the cover.
Note: the inlet gas pressure must not be higher than the
specified max. gas pressure.
KITTC- Tightness control
Tightness control is provided as a kit and shall be
assembled into the main gas train according to the
instructions of the gas train separate manual.
KITPRES... Maximum pressure switch assembly
Maximum pressure switch is provided as a kit and
shall be assembled into the main gas train
according to the instructions of the gas train
separate manual.
KITMD-RWF40 PID regulator
All progressive burner can be turned modulationg
with the installation of the PID that regulates the
output combined with a probe.
Tightness control
KITTC- Model
Compulsory > 1200 kW
Modulation Kit
KITMD-RWF40
Probe-...
Max Pressure switch
KITPRES50
KITPRES150
+
–
C

14 www.eacoon.com
EN
420010511800
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 7000.1 PR
MULTICALOR 700.1
MULTIFLAM 700.1
VGD 40.125 no yellow 55 700
5C
FILTER DN 125 60 700
VGD 40.100 no yellow 70 700
FILTER DN 100 75 700
VGD 40.080 no yellow 115 700
5C.2
FILTER DN 80 140 700
VGD 40.065 no yellow 225 700
FILTER DN 65 280 700
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
350 450 550 650 750 850 950
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train+ firing head) mbar
portata/flow m3/h 5C
VGD 40.080 + F-DN80
VGD 40.065 + F-DN65
natural gas
VGD 40.065
VGD 40.080
tabellaC
10
20
30
40
50
60
70
80
90
350 450 550 650 750 850 950
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train+ firing head) mbar
portata/flow m3/h 5C.2
VGD 40.100 + F-DN100
VGD 40.125+ F-DN150
natural gas
VGD 40.125
VGD 40.100
tabellaC
flow m3/h
pressure drop (gas train + firing head) mbar
flow m3/h
pressure drop (gas train + firing head) mbar

15
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EN
420010511800
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 8000.1 PR
MULTICALOR 800.1
MULTIFLAM 800.1
VGD 40.125 no yellow 80 700
6C
FILTER DN 125 85 700
VGD 40.100 no yellow 100 700
FILTER DN 100 110 700
VGD 40.080 no yellow 170 700
6C.2
FILTER DN 80 210 700
VGD 40.065 no yellow 320 700
FILTER DN 65 410 700
10
20
30
40
50
60
70
80
90
100
110
120
350 450 550 650 750 850 950 1050
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train+ firing head) mbar
portata/flow m3/h6C
VGD 40.100 + F- DN100
VGD 40.125 + F- DN150
natural gas
VGD 40.125
VGD 40.100
tabellaC
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
350 450 550 650 750 850 950 1050
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train+ firing head) mbar
portata/flow m3/h6C.2
VGD 40.080+F- DN 80
VGD 40.065 + F- DN 65
natural gas
VGD 40.065
VGD 40.080
tabellaC
flow m3/h
pressure drop (gas train + firing head) mbar
flow m3/h
pressure drop (gas train + firing head) mbar

16 www.eacoon.com
EN
420010511800
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 10000.1 PR
MULTICALOR 1000.1
MULTIFLAM 1000.1
VGD 40.125 no yellow 100 700
7C
FILTER DN 125 115 700
VGD 40.100 no yellow 130 700
FILTER DN 100 165 700
VGD 40.080 no yellow 230 700
7C.2
FILTER DN 80 290 700
VGD 40.065 no yellow 440 700
FILTER DN 65 550 700
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
500 600 700 800 900 1000 1100 1200 1300
perdite di carico (rampa gas +testa di combustione / pressure drop (gas train +firing head) mbar
portata/flow m3/h7C
VGD 40.100 +F- DN100
VGD 40.125 + F- DN150
natural gas
VGD 40.125
VGD 40.100
tabellaC
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
460
480
500
520
540
500 600 700 800 900 1000 1100 1200 1300
perdite di carico (rampa gas +testa di combustione / pressure drop (gas train +firing head) mbar
portata/flow m3/h7C.2
VGD 40.080+F- DN80
VGD- 40.065 + F- DN 65
natural gas
VGD 40.080
VGD- 40.065
tabellaC
flow m3/h
pressure drop (gas train + firing head) mbar
pressure drop (gas train + firing head) mbar
flow m3/h

17
www.eacoon.com
EN
420010511800
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 12000.1 PR
MULTICALOR 1200.1
MULTIFLAM 1200.1
VGD 40.150 no yellow 150 700
8C
FILTER DN 150 160 700
VGD 40.125 no yellow 160 700
FILTER DN 125 175 700
VGD 40.100 no yellow 200 700
FILTER DN 100 230 700
VGD 40.080 no yellow 340 700
FILTER DN 80 420 700
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
800 900 1000 1100 1200 1300 1400 1500
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train + firing head) mbar
portata/flow m3/h8C
VGD 40.080 + F-DN80
VGD 40.100 + F- DN100
VGD 40.125 + F- DN125
natural gas
VGD 40.125
VGD 40.100
VGD 40.080
tabellaC
VGD 40.150 + F- DN150
VGD 40.150
flow m3/h
pressure drop (gas train + firing head) mbar

18 www.eacoon.com
EN
420010511800
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
gas valves 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.
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.
ATTENTION: Wiring is not supplied.
2) of the gas train
- Connect the plugs pending to the valve:
either on the cabinet,
or on the coupling case on the body of the
burner.
PROBES CONNECTION
12 1311
9 10
9 13
12
11
10
SA
QBE....
GLMU1
SP
QAE...
MB
AC TIVE PROBE LINK
PASSIVE PROBE LINK
TP
12N
17
16 18
STAB
HLF
4
3 13
TP
STS
50 Hz 400V
R
PE
T
S
N
TP
STC
N9
T7
6
5 8 11
10
RS
HLB
Q
12
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
ACTIVE PROBE CONNECTION
(FOR MODULATING VERSION)
PASSIVE PROBE CONNECTION
(FOR MODULATING VERSION)

19
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EN
420010511800
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.
• Make a test of the all gas-carrying
elements for absence of leaks.
• 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.
GAS START-UP
• 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 “Manual-Automatic” selector
switch to “Manual”.
If the gas valves are tested for absence of
leaks, this should be continued until a
positive result is obtained. If a valve is
found to leak, the program will not step
forward to the control box.
The burner will start according to the
program flow of the control box.
Prior to the initial fuel feed start make
a functional test of the burner program
flow:
Gas system:
• Shortly open the gas shut-off valve
before the gas train until pressure is
available and close again.
• Start burner and check program flow for
correct start-up sequence:
1. Fan.
2. Pre-ventilation damper.
3. Check air pressure.
4. Partial-load damper.
5. Ignition.
6. Valves open.
7. Shut-off upon trouble after expiry of
safety period (see control box) or shut-off
because of gas supply failure.
7. The burner will either stop as the gas
valves open (due to gas pressure
decrease) or lock out at the end of the
safety time.
• Unlock the control box.

20 www.eacoon.com
EN
420010511800
EXHAUST GAS TEST
QF= QN= 1000 = 1136 kW
Volumetric gas flow rate at STP:
vBn = QN= 1000 = 125 m3/h
Volumetric gas flow rate in operating
condition:
vBB = vBn
T= pn=
= 125 273+15 1013,25 = 123,9 m3/h
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
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 QN1000 kW
Boiler efficiency nK0,88
Calorific value of gas Hu9,1 kWh/m3
Gas pressure pU100 mbar
Barometer reading pamb 980 mbar
Gas temperature
relative tgas 15°C
Gas temperature
absolute T (tgas+273)
Standard atmosferic
pressure pn1013 mbar
0,88
nK
Hu*nK9,1*0,88
273 pamb+ pu
273 980+100
Recommended combustion parameters
Ratio between O2- and CO2-
for natural gas H (CO2max = 11,7%)
Ratio between O2- and CO2-
for light oil EL (CO2max = 15,40%)
Ratio between O2- and CO2-
for heavy oil S (CO2max = 15,60%)
O2= 21 CO2max - CO2gem = %
CO2max
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.
Fuel Recommended
(%) CO2
Recommended
(%) O2
Natural gas 10 ÷ 9 3,1 ÷ 4,8
Light oil 13 ÷ 11,5 3,3 ÷ 5,3
Heavy oil 12,5 ÷ 11 4,2 ÷ 6,2
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
510 1520 2530354045 50
Mean air pressure vs. altitude above sea-level
Fan capacity reduced by [%]
Altitude of installation site [m]
CO2gem = % CO2measured on dry flue gases