Ecoflam MAIOR P 150.1 AB User manual

420010619500
15.01.2015
MAIOR P 150.1 AB
MAIOR P 200.1 AB
SISTEMA IDRAULICO
HYDRAULIC SYSTEM
SYSTEME HYDRAULIQUE
SISTEMA HIDRAULICO
BRUCIATORI DI GASOLIO
OIL BURNERS
BRULEURS A MAZOUT
QUEMADOR DE GASOLEO
IT
EN
FR
ES

pag.8
420010619500 Maior P 150.1/200.1 AB
EN TECHNICAL DATA
WORKING FIELDS
OVERALL DIMENSIONS
MODELS MAIOR P 150.1 AB MAIOR P 200 .1 AB
Thermal power max kcal/h 1.530.000 2.040.000
kW 1.780 2.372
Thermal power min. kcal/h 510.000 612.000
kW 592 710
Max. flow rate light oil kg/h 150 200
Min. flow rate light oil kg/h 50 60
Feeding power 50 Hz V 230/400 230/400
Motor kW 3 4
Rpm Nº 2.800 2.800
Ignition transformer kV/mA 10/30 13/35
Control box SIEMENS LMO 44 LMO 44
Fuel : light oil kcal/kg 10.200 max. visc 1,5°E a 20°C
M
L
I
SUNTEC
SUNTEC
SUNTEC
G
F
D - D1E
CB
A
H
MODELS ABCDD1E FGH I LM
P 150.1 AB 775 385 390 285 485 660 250 398 283 240 240 M14
P 200.1 AB 795 405 390 375 535 660 270 398 283 240 240 M14
D = short head D1 = long head
400 600 800 1000 1200 1400 1600 1800
0
2
4
6
8
40
mbar
kcal/h
x 1000
kg/h
kW
60 80 100 120 140 160 180
10
12
14
16
18
20
800 1400 1800
1600 2200200012001000
600
22002000
2400
200 220
2600
MAIOR P 200.1
MAIOR P 150.1
PRESSURE IN THE COMBUSTION CHAMBER
OUTPUT

pag.9
420010619500 Maior P 150.1/200.1 AB
EN
2
1345
6
7
BURNER INSTALLATION
HYDRAULIC CIRCUIT
VS
V2
V1
4
5
1 - HOSE
2 - OIL FILTER
3 - OIL COCK
4 - SUCTION
5 - RETURN
1 - BURNER
2-NUT
3 - WASHER
4 - GASKET
5-BOLT
6 - BOILER
7 - GASKET
To correct length of pipes is calculated by summing up the length of all vertical and horizontal right sections and bends. The static
suction head will be the distance between the non-return valve and the
burner’s pump axle. The depression must not be greater than 0.45 bar; should it be higher, some damages could occur to the
pump, with consequent increase in mechanical noises and ,eventually, a failure.
H
H
H (m)
ø 14 mm ø 16 mm
0
0,5
1
2
3
3,5
22
25
30
35
38
40
38
45
50
60
70
80
ø 14 mm ø 16 mm
16
18
20
25
29
31
29
33
37
44
52
55
J 7
(m)
H (m)
ø 14 mm ø 16 mm
0
0,5
1
2
3
3,5
25
20
18
10
5
2
45
38
33
20
10
4
ø 14 mm ø 16 mm
16
14
12
7
3
1
29
26
22
14
7
4
AJ 6
(m)
J 7
(m)
AJ 6
(m)
MAXIMUM LENGTH OF SUCTION LINES FOR TWO-PIPE SYSTEM
Two-pipe lift system
Two-pipe siphon feed system
Pipe length
Pipe length
1
1
23

pag.10
420010619500 Maior P 150.1/200.1 AB
EN
NOZZLE PUMP PRESSURE (bar)
GPH 10 11 12 13 14 15 16
2,50 9,50 9,97 10,41 10,83 11,24 11,64 12,02
3,00 11,40 11,96 12,49 13,00 13,49 13,96 14,42
3,50 13,30 13,95 14,57 15,17 15,74 16,29 16,83
4,00 15,20 15,94 16,65 17,33 17,99 18,62 19,23
4,50 17,10 17,94 18,73 19,50 20,24 20,95 21,63
5,00 19,00 19,93 20,82 21,67 22,48 23,27 24,04
5,50 20,90 21,92 22,90 23,83 24,73 25,60 26,44
6,00 22,80 23,92 24,98 26,00 26,98 27,93 28,84
6,50 23,70 25,91 27,06 28,17 29,23 30,26 31,25
7,00 26,60 27,90 29,14 30,33 31,48 32,58 33,65
7,50 28,50 29,90 31,22 32,50 33,73 34,91 36,05
8,30 31,54 33,08 34,55 35,97 37,32 38,63 39,90
9,50 36,10 37,87 39,55 41,17 42,72 44,22 45,67
10,50 40,06 41,73 43,74 45,41 47,20 48,90 50,50
12,00 45,60 47,80 50,00 52,00 54,00 55,90 57,70
13,80 52,40 55,00 57,50 59,80 62,10 64,20 66,30
15,30 58,10 61,00 63,70 66,30 68,80 71,10 73,60
17,50 66,50 69,80 72,90 75,80 78,70 81,50 84,10
19,50 74,10 77,70 81,20 84,50 87,70 90,80 93,70
21,50 81,70 85,70 89,50 93,20 96,70 100,10 103,40
24,00 91,20 95,70 99,90 104,00 107,90 111,70 115,40
28,00 106,40 111,60 116,60 121,30 125,90 130,30 134,60
30,00 114,00 119,60 124,90 130,00 134,90 139,60 144,20
GPH OUTPUT kg/h
NOZZLE FLOW RATE
DELAVAN B - MONARCH PLP - DANFOSS S
Use only the suitable box wrench provided for this operation to remove the nozzle, taking care to not damage the elec-
trodes. Fit the new nozzle with the same care. Note: Always check the position of electrodes after having replaced the
nozzle (see illustration). A wrong position could cause ignition troubles.
NOZZLE CLEANING AND REPLACEMENT
SUNTEC J 7 C 1000
6
53
2
SUNTEC
SUNTEC
14
6
5
4
3
21
SUNTEC
SUNTEC
SUNTEC AJ 6 C-C
PRIMING AND ADJUSTMENT OF OIL PUMP
3,5 mm
6 mm

pag.11
420010619500 Maior P 150.1/200.1 AB
EN
1 - INLET
2 - RETURN
3 - BLEED AND PRESSURE GAUGE PORT
4 - VACUUM GAUGE PORT
VERIFY:
- That piping system is perfectly sealed;
- That the use of hoses is avoided whenever is possible (use copper pipes preferably);
- That depression is not greater than 0,45 bar, to avoid pump’s cavitation;
- That check valve is suitably designed for the duty;
The pump pressure is set at a value of 12 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
prepurging, 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 even-
tual obstruction could damage the pump sealing device.
5 - PRESSURE ADJUSTMENT
6 - TO NOZZLE
BURNER START-UP AND ADJUSTMENT
Once having installed the burner, check the following items:
- The burner power feeding and the main line protection fuses
- The correct length of pipes and that the same are sealed.
- The type of fuel, which must be suitable for burner.
- The connection of boiler’s thermostats and all the safeties.
- The motor rotation direction.
- The correct calibration of the motor’s thermal protection.
When all the above mentioned conditions are checked and accomplished, it is possible to go on with burner’s tests.
Power the burner. The control box feeds the ignition transformer and the burner’s motor at the same time, which will
run a prepurging of the combustion chamber for about 26 sec.
At the end of prepurging, the control box opens the fuel pump and the 1st stage (Low flame) solenoid valves, the igni-
tion transformer produces a spark and the burner ignites. After a safety interval of 5 seconds and a correct ignition, the
control box turns off the ignition transformer and, 5 seconds later, sets the motorised air damper to its maximum ope-
ning and opens the 2nd stage solenoid valve (High flame). In case of faulty ignition, the control box switches the bur-
ner into safety condition. In order to obtain an optimal combustion, it is necessary adjust the LOW - HIGH flame air
flow, according to the instruction given further on. During such a phase, it will be possible to manually switch between
HIGH ( II ) and LOW ( I ) flame and viceversa, through the High/Low flame switch. At the end of the adjusting
phase, leave the switch in position II (HIGH flame).
The fuel pump feeding pressure, must remain around 12 bar.
I
II
I - 1st Stage.
II - 2nd Stage (with an eventual Low/High automatic switching through a further
thermostat connected to the terminal board, as shown by the scheme).

Air flow rate adjustment in Low flame running:
1) - Start the burner (checking that the air damper is partially open).
2) - Loosen clamping screw D.
3) - Turn air damper C until obtaining a correct combustion (checked
with a combustion gas analysis set).
4) - Tighten clamping screw D.
Air flow rate adjustment in High flame running:
WARNING: due to the presence of oil under pressure in the hydraulic
jack when the burner is working in High flame condition, the air flow
rate adjustment is to be made with the use of an adjusting ring nut 1
with the burner running in Low flame condition. The combustion
checks are to be done once the burner is turned to High flame condition
again.
1) - Loosen clamping ring nut 2
2) - Increase or decrease the air flow rate through the adjusting ring nut
1 (Clockwise to increase, counterclockwise to decrease).
3) - Tighten clamping ring nut 2.
4) - Switch manually from Low flame to High flame and check the combustion values.
pag.12
420010619500 Maior P 150.1/200.1 AB
EN
-
+
1234567
FIRING HEAD SETTING
COMBUSTION AIR FLOW ADJUSTMENT (HIGH-LOW FLAME)
C
2+ –
D
1
SIEMENS LMO 44 CONTROL INFORMATION SYSTEM
In case of burner lockout, it is possible to read which cause originated it. Proceed as follows: with the burner in lockout mode (red
LED switched on) keep pressed the lockout button for more than 3 sec. then release it. The red LED will blink according to the
following error code list:
Error Code Possible cause
2 blinks No establishment of flame at the end of «TSA»
- Faulty or soiled fuel valves - Faulty or soiled flame detector - Poor adjustment of burner,
no fuel - Faulty ignition
3 blinks Free
4 blinks Extraneous light on burner start-up
5 blinks Free
6 blinks Free
7 blinks Too many losses of flame during operation (limitation of the number of repetitions)
- Faulty or soiled fuel valves - Faulty or soiled flame detector - Poor adjustment of burner
8 blinks Time supervision oil pre-heater
9 blinks Free
10 blinks Wiring error or internal error, output contacts

pag.13
420010619500 Maior P 150.1/200.1 AB
EN
ELECTRICAL CONNECTIONS
All burners are factory tested at 400V - 50Hz 3-phase for motors, and 230V - 50Hz single phase with neutral for auxi-
liary equipments. Should it be necessary to power the burner with 230V - 50Hz, modify the connections on motor and
the terminal board as shown in the picture. Protect the burner supply line with suitable fuses and/or other safety devices
as required by the local regulations on the matter.
TROUBLESHOOTING
The burner does not start.
- Main switch in “0”.
- Fuses are blown.
- Boiler thermostats are in open position.
- Control box is defective.
The burner runs the prepurging but does not ignite and then switches into safety condition.
- Control box is defective.
- Ignition transformer is defective.
- Electrodes are dirty.
- Electrodes are defective.
- Electrodes are in wrong position.
- Nozzles are clogged.
- Nozzles are too worn.
- Filters are clogged.
- Oil pressure too low.
- Combustion air flow rate excessively high related to nozzle’s flow rate.
The burner ignites but then switches into safety condition.
- Control box is defective.
- Nozzles are clogged.
- Nozzles are too worn.
- The photocell does not detect the flame.
- Filters are clogged.
- Oil pressure too low.
- Combustion air flow rate excessively high related to nozzle’s flow rate.
The burner does not switch to High flame.
- 1st(Low flame) and 2nd (High flame) stage manual switch on control board is in wrong position.
- Control box is defective.
- 2nd stage solenoid valve coil is defective.
- Oil pressure too low.
- Filters are clogged.
- 2nd stage nozzle is too worn.
- 2nd stage nozzle is clogged.
- Air damper’s hydraulic jack not properly adjusted or defective.

pag.26
IT
EN
FR
ES
420010619500 Maior P 150.1/200.1 AB
TOT. SHEET
SHEET
DESIGNER
DESCRIPTION
DATE FIST CREATION
CODE
SIGNATURE
R&D DEPARTMENT
CONTROLLER
Ecoam Bruciatori
SERVOMOTOR FLAME SENSOR
S.p.A
ECN FIRST CREATION
BY TERM LAWS WE RESERVED THE PROPERTY OF THIS WIRING DIAGRAM WITH PROHIBITION OF USE AND REPRODUCTION
LEAKAGE CONTROL
CONTROL BOX
DATE ECN MODICATIONMODIFICATION DESCRIPTIONECN MODIFICATION
MAIOR P 150.1 AB HS
A.POZZOBON
02-12-2014
2
420110151800
1
A.RIGONI
B
RB14PC125
SIEMENS LOA 44-LMO44
F
1
E
D
2 3 4
C
B
A
12 3 4
5 6 7 8
F
E
D
5 6 7
C
B
8
A
FMV
FMV
97 98
KA1 KA2
KA3 KA4 KA5
7
SIEMENS LOA 44 - LMO 44
31 254 6 1198 10 12 31 32
P
T
STC
Q
HLB
S N T
P
T
STS
50 Hz 400V
PE
R
10NR TS 75 6 981 2 3 4 11 12
HLF
242120 2322 25 26 27
+
230 Vac
12 Vdc
-
3M
MV
UVW
KMV
R S T NO
LINE LOAD
Z
FU
P
T
STAB
BYVg2
TV
YVg1
230V
400V
FMV
HL1 YVgS HL2SAB
I II
SAL
HLBT
12V DC 12V DC
USCITA SEGNALAZIONE PRESENZA FIAMMA
USCITA SEGNALZIONE BLOCCO BRUCIATORE
INGRESSO CONSENSO RICHIESTA CALORE
INGRESSO CONSENSO MOTORE VENTILATORE ACCESO
OUTPUT SIGNAL FLAME ON
OUTPUT SIGNAL LOCKOUT BURNER
INPUT SIGNAL HEAT DEMAND
INPUT SIGNAL FAN MOTOR ON

pag.27
IT
EN
FR
ES
420010619500 Maior P 150.1/200.1 AB
TOT. SHEET
SHEET
DESIGNER
DESCRIPTION
DATE FIST CREATION
CODE
SIGNATURE
R&D DEPARTMENT
CONTROLLER
Ecoam Bruciatori
SERVOMOTOR FLAME SENSOR
S.p.A
ECN FIRST CREATION
BY TERM LAWS WE RESERVED THE PROPERTY OF THIS WIRING DIAGRAM WITH PROHIBITION OF USE AND REPRODUCTION
LEAKAGE CONTROL
CONTROL BOX
DATE ECN MODICATIONMODIFICATION DESCRIPTIONECN MODIFICATION
MAIOR P 150.1 AB HS A.POZZOBON
02-12-2014
2
420110151800
2
A.RIGONI
B
RB14PC125
SIEMENS LOA 44-LMO44
F
1
E
D
2 3 4
C
B
A
12 3 4
5 6 7 8
F
E
D
5 6 7
C
B
8
A
ESPIA DE BLOQUEO RELE TERMICO LAMPE DE THERMAL DE SECURITE THERMAL LOCK-OUT LAMP
HLBT LAMPADA DI BLOCCO TERMICO
YVg1
ELECTROVANNE MAZOUT PETITE ALLURE FIRST STAGE OIL SOLENOID VALVE ELETTROVALVOLA GASOLIO DI PRIMA FIAMMA
YVg2 YVgS
EXTRA SAFETY OIL SOLENOID VALVE ELECTROVALVULA DE GASOLEO DE SEGURIDAD ELECTROVANNE MAZOUT DE SECURITE ELECTROVALVULA DE GASOLEO 2^ LLAMA ELECTROVANNE MAZOUT GRANDE ALLURE SECOND STAGE OIL SOLENOID VALVE ELETTROVALVOLA GASOLIO DI SECONDA FIAMMA ELETTROVALVOLA GASOLIO DI SICUREZZA ELECTROVALVULA DE GASOLEO 1^ LLAMA
TERMOSTATO DE ALTA-BAJA LLAMA THERMOSTAT GRANDE-PETIRE ALLURE HIGH-LOW FLAME THERMOSTAT INTERRUPTOR DE ALTA-BAJA LLAMA INTERRUPTEUR GRANDE-PETIRE ALLURE HIGH-LOW SWITCH FOTORESISTENCIA PHOTORESISTANCE PHOTO-RESISTOR FILTRO DE PROTECION ANTIDISTURBIO FILTRE ANTIPARASITES ANTJAMMING FILTER FUSIBLE FUSIBLE FUSE MOTOR VENTILADOR MUTEUR VENTILATEUR MOTOR FAN TRANSFORMADOR TRANSFORMATEUR D'ALLUMAGE IGNITION TRANSFORMER INTERRUPTOR GENERAL CON FUSIBLE INTERRUPTEUR GENERAL AVEC FUSIBLE MAIN SWITCH WITH FUSE ESPIA DE BLOQUEO LAMPE DE SECURITE LOCK-OUT LAMP RELE' TERMICO MOTOR VENTILADOR RELAIS THERMIQUE MOTEUR VENTILATEUR MOTOR THERMAL RELAY (FAN MOTOR) ESPIA DE 1^ LLAMA LAMPE DE 1^ ALLURE 1.ST FLAME LAMP ESPIA DE 2^ LLAMA LAMPE DE 2^ ALLURE 2.ST FLAME LAMP TELERRUPTOR MOTOR VENTILATOR CONTACTEUR MOTEUR VENTILATEUR REMOTE CONTROL SWITCH (FAN MOTOR) TERMOSTATO CALDERA THERMOSTAT CHAUDIERE BOILER THERMOSTAT INTERRUPTOR DE LINEA INTERRUPTEUR DE LIGNE WORKING SWITCH TERMOSTATO DE SEGURIDAD THERMOSTAT DE SECURITE SAFETY THERMOSTAT TERMOSTATO DI ALTA-BASSA FIAMMASTAB TERMOSTATO DI SICUREZZASTS TERMOSTATO CALDAIASTC INTERRUTTORE DI LINEASAL INTERRUTTORE ALTA-BASSA FIAMMASAB CONTATTORE MOTORE VENTILATOREKMV LAMPADA DI BLOCCOHLB LAMPADA DI SECONDA FIAMMAHL2 LAMPADA DI PRIMA FIAMMAHL1 RELE' TERMICO MOTORE VENTILATOREFMV TRASFORMATORETV MOTORE VENTILATOREMV FUSIBILEFU FILTRO ANTIDISTURBOZ INTERRUTTORE GENERALE CON FUSIBILEQ FOTORESISTENZAB
KA1 RELE' KA2 RELE' KA3 RELE' 12 V DC KA4 RELE' KA5
RELAY RELAIS RELE' RELAY RELAIS RELE' RELAY 12 V DC RELAIS 12 V DC RELE' 12 V DC RELAY RELAIS RELE' RELE' 12 V DC RELAY 12 V DC RELAIS 12 V DC RELE' 12 V DC

pag.28
IT
EN
FR
ES
420010619500 Maior P 150.1/200.1 AB
MAIOR P 150.1 - 200.1 AB H.S.
3
10
26
27
46
2
37
41
42
43
45
44
1
6 5
40
28
4
39
38
47
29
21
7
8
9
13
MAIOR P 200.1 AB
14
15
12
11
18
16
34
¬
36
33
32
30
20
31
48
FINDER
0
I
25
24
22
23
49
50
FINDER
51
52

pag.30
420010619500 Maior P 150.1/200.1 AB
EN
TC = SHORT HEAD TL = LONG HEAD
MAIOR P 150.1 AB MAIOR P 200.1 AB
N° DESCRIPTION code code
1 OIL PUMP SUNTEC AJ 6CC 1000 65322950 -
SUNTEC J 7CC 1000 - 65322951
2 COIL PARKER 65323782 65323782
3 OIL VALVE PARKER 65323623 65323623
4NIPPLE TN 6X1500 65074466 65074466
5HOSES TN 14X1200 65323184 65323184
6FILTER 3/4 70104-03 65324806 65324806
7COVER 65320676 65320676
8GLASS 65320487 65320487
9 VIEWING WINDOW 65320488 65320488
10 MOTOR 3000 W 65322831 -
4000 W - 65322820
11 CONTROL BOX BASE SIEMENS 65320092 65320092
12 CONTROL BOX SIEMENS LMO44.255A2 65320024 65320024
13 PHOTORESISTOR SIEMENS 65320076 65320076
14 MOTOR THERMAL RELAY AEG 5,5-8,5A 65323113 -
AEG 8-12,5A - 65323119
15 REMOTE CONTROL SWITCH AEG LS7K.10 65324097 -
AEG LS11K.00 - 65323135
16 ANTIJAMMING FILTER 65323170 65323170
17 BOX SUPPORT 65320476 65320476
18 BOX 65320473 65320473
19 CABLE TC 65320942 65320942
TL 65320946 65320946
20 ELECTRODES 65325056 65325056
21 IGNITION TRANSFORMER 10/30 65323235 -
13/35 - 65323222
22 HIGH-LOW FLAME SWITCH cod.360000001 65323065 65323065
23 MAIN SWITCH cod.40100I1509 65323064 65323064
24 FUSE SUPPORT FUSIT FH-B 528 65322181 65322181
25 LAMP EL/N-SC4 65322053 65322053
26 FAN 280 x 140 65321798 65321798
27 AIR CONVEYOR 65320643 65320643
28 COVER AIR INLET 65320555 65320555
29 HYDRAULIC SYSTEM 65322333 65322333
30 ROD TC 65324824 65324824
TL 65324825 65324825
31 NOZZLE HOLDER 65320712 65320712
32 SUPPORT NOZZLE DIFFUSER 65324515 65324515
33 DIFFUSER 65320786 65320786
34 BLAST TUBE TC 65320451 65320453
TL 65320452 65320454
35 BLAST TUBE END - -
36 INNER ASSEMBLY TC 65322422 65322423
TL 65322421 65322424
37 GASKET 65321124 65321124
38 COIL SUN SL1V2805G1/8
39 OIL VALVE SUN SL1V2805G1/8 65325784 65325784
40 ROD 65321460 65321460
41 COUPLING (FAN) 65321788 65321788
42 UNION 65321791 65321791
43 COUPLING (ROD) 65321790 65321790
44 COUPLING 65321782 65321782
45 UNION 65321786 65321786
46 COUPLING (PUMP) 65324165 65324165
47 SILENCER 3142077 3142077
48 FAN SCOOP - 65320626
49 RELAY BASE FINDER MINI 40.52 65323152 65323152
50 RELAY FINDER MINI 40.52 65323142 65323142
51 RELAY FINDER MINI 44.52 12V DC 0R712-4 0R712-4
52 POWER PACK 240VAC 12VDC 2,5A 740090015000 740090015000