Ecoflam MAIOR P 500-1 PRE User manual

EN
MAIOR P 500 PRE.1 TC
MAIOR P 500 PRE.1 TL S 3144806
Technical data
Operating instructions
Electric diagrams
Spare parts list
MAIOR P 500.1 PRE
MAIOR P 600.1 PRE
www.ecoflamburners.com
LIGHT OIL BURNERS
10-01-2017

INDEX
MAIOR P 500.1
MAIOR P 600.1
420010813300
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2
General warnings - Conformity declaration 3
Burner designation - Modular delivery system 4
Burner description 5
Electrical control panel 5
Technical data 6
Working diagrams 7
Test boiler - Flame dimension 7
Overall dimensions 8
Oil operating mode - General safety functions 9
Installation 10
Fitting the burner to the boiler 10
Oil connection 11
Feeding and suction line for light oil 12
Electrical connections 13
Start-up: checking procedure 14
Exhaust gas test 15
Start-up oil side 16
Fuel selection - Start-up 16
Adjusting the max air flow rate 16
Firing head setting 16
Adjusting the max oil flow rate 17
Servomotor Lamtec - Air damper motor pre-setting 17
Adjusting the pump pressure 17
Adjusting the intermediate burner capacity 18
Maintenance program 19
Troubleshooting instructions 20
Operating troubles 21
Appendix 22
Control box - Display 23
Fluidics nozzle chart 24
Bergonzo nozzle tables 25
Pump and pressure regulators 27
Electrical diagrams 28
Spare parts list 29
0 1000 2000 3000 4000 7000 kW
5000 6000

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).
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:
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.
!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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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 50156-1
EN 55014-1 EN 55014-2
EN 60335-1 EN 60335-2-102
EN 61000-6-2 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 DESIGNATION
MAIOR P 300.1 PR TC 230-400-50
MAIOR Light oil
RANGE NAME BY FUEL TYPE
MAIOR P 300.1 253 kg/h - 3000 kW
MODEL SIZE (Gas: kW; Oil: kg/h)
-Standard Class 1 - OIL EN267 (<250 mg/kWh)
EMISSIONS
PR 2 stages progressive mechanical gas / oil
MD 2 stages modulating mechanical with PID
PRE 2 stages modulating electronic
OPERATION TYPE
TC Short head
TL Long head
HEAD TYPE
Light oil
BIODIESEL Biodiesel
KEROSENE Kerosene
FUEL
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230-400-50 230-400 Volt, 50 Hz
ELECTRICAL POWER SUPPLY
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 Complete burner
KIT Kits
ACS Accessories

BURNER DESCRIPTION
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Control panel
SAL main switch I/0
HLF working lamp
HLBT thermal lock-out lamp
V
R
HLF
HLBT
1: ON
0: OFF
0 I
SAL

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TECHNICAL DATA
MODEL MAIOR P 500.1 PRE MAIOR P 600.1 PRE
Thermal power max.
kW 5.000 5.800
kcal/h 4.300.000 4.988.000
kg/h 422 489
Thermal power min.
kW 1.200 1.500
kcal/h 1.032.000 1.290.000
kg/h 101 126
Operation mode Type Progressive mechanical oil - Modulating with PID
Regulation ratio nominal Type 1÷3 OIL
Fuel Type
Light oil (L.C.V. 10.200 kcal/kg max. visc 1,6÷6 mm2/s at 20°C) (EL) Hu = 11,86 kWh/kg
Emission class std Standard Class 1 OIL EN267 (<250 mg/kWh)
Control unit Type LAMTEC ETAMATIC BT3xx
Air regulation Type Air flap Air flap
Air flap control with servomotor Model LAMTEC
Flame monitoring Type UV CELL
Ignitier Model BRAHMA
Motor kW 11 15
Rpm N° 2.800 2.800
Voltage V/Hz 230/400 V - 50 Hz
Total power consumption operation W12.000 16.500
Weight body BBCH Kg
Electrical panel protection level IP IP55 IP55
Sound pressure level
without silencer dB(A)
Lab
tests
91,1 92,8
Sound pressure level
with silencer 85,7 86,7
Ambient temperature storage Min/Max -20°…+70° C
Ambient temperature use -10°…+60° C
Oil pump Model TA3 TA4
Nozzles Type according to the output requested

0
5
10
15
20
25
1000 2000 3000 4000 5000 6000 7000
1000 2000 3000 4000 5000 6000
100 200 300 400 500
mbar
kW
kg/h
kcal/h*1000
MAIOR P 500.1
MAIOR P 600.1
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WORKING DIAGRAMS
TEST BOILER - FLAME DIMENSIONS
The burner/boiler matching does not pose
any problem 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 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.
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
kg/h
100 200 300 400 500 600 700 800 900 1000 1100
kcal/h
x 1000
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
14000 15000 16000 17000
1200 1300 1400
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
kg/h
100 200 300 400 500 600 700 800 900 1000 1100
kcal/h
x 1000
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
14000 15000 16000 17000
1200 1300 1400
FLAME LENGHT LIGHT OIL BURNERS
FLAME DIAMETER LIGHT OIL BURNERS
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.
Calculation of
burner output
QF= Burner output (kW)
QN= Rated boiler output(kW)
η = Boiler efficiency (%)
QF= QNx 100
η

I
M
L
ED - D1
F
C
B
A
G
SUNTEC
1
0
2
1
0
2
H1
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OVERALL DIMENSIONS
Dimensions (mm)
D = Short head
D1= Long head
Model A B C D D1 E F G H1 I L M
MAIOR P 500.1 PRE 1240 635 605 355 555 1100 320 570 965 330 330 M16
MAIOR P 500.1 PRE S 1240 635 605 - 835 1100 320 570 965 330 330 M16
MAIOR P 600.1 PRE 1240 635 605 355 555 1100 320 570 965 330 330 M16
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.
Model X Y Z kg
MAIOR P 500.1 PRE S 1750 2380 1460
MAIOR P 600.1 PRE S 1750 2380 1460
X
Y
Z
330 420
330
420

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OIL OPERATING MODE - GENERAL SAFETY FUNCTIONS
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.
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 partial-
load 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 two-
stage 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.

5÷6 mm
3÷4 mm
!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
Position of the electrodes - nozzle installation
Ignition Electrode
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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 specified
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.
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%.
A
A1

!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
INSTALLATION
Oil connection
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
VLO
311
178
176
CV
184
VL
RL
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.
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 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.
INSTALLATION OPTIONS
• Two-line installation (separate feed and
return lines without delivery pump).
• Ring line system (with delivery pump and
gas-air separator).
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
!WARNING: Check that the pump rotation is correct and before start up it has been pre-filled
8
8
9
10
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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-pipe-
system, 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.
SUNTEC TA
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
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
Intake from Tank
ONE PIPE
INSTALLATION
Return
plugged
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Feeding and suction line for light oil
SUCTION LINE LENGTHS FOR PIPE SYSTEMS
• Two-pipe siphon feed system
H
H
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.
• Two-pipe lift system
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
H
(m)
PIPE LENGTH (m)
TA3 TA4
ø 14 mm ø 16 mm ø 20 mm ø 20 mm ø 30 mm
3 10 32 115 65 150
2,5 8 28 110 60 150
2 7 25 100 55 150
1,5 6 22 95 50 150
1 5 20 85 45 150
0,5 -- 17 75 40 150
0 -- 15 65 35 150
-0,5 -- 10 55 28 150
-1 -- 5 45 22 150
-1,5 -- -- 37 12 150
-2 -- -- 30 7 150
-2,5 -- -- 22 -- 150
-3 -- -- 9 -- 123
-3,5 -- -- -- -- 78
-4 -- -- -- -- 38

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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.
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.
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.
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
TP
P
T
P
T
STAB
9
Q
NRST 7658
S
N
T
R
PE
50 Hz 400V
13121110412 3
STC
HLB STS
HLF
PROBES CONNECTION
913121110
SA
QBE....
GLMU1
ACTIVE PROBE CONNECTION
(FOR MODULATING VERSION)
12 1311910
SP
QAE...
MB
PASSIVE PROBE CONNECTION
(FOR MODULATING VERSION)
230V
400V
fig.1

START-UP: CHECKING PROCEDURE
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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.

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.
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
5 1015 202530 35 4045 50
Mean air pressure vs.altitude above sea-level
Fan capacity reduced by [%]
Altitude of installation site [m]
CO2gem = % CO2measured on dry flue gases
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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

START-UP OIL SIDE
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16
Select the oil operation in order to proceed with start up on the oil side.
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.
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
+
--
Fuel selection - Start-up
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.
Adjusting the maximum air flow rate
Air and Oil adjustment are accomplished through LAMTEC pa-
rameters setting. Refer to LAMTEC manual attacched.
SAL
01

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.
Adjusting the pump pressure
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.
SUNTEC TA....
1 - INLET
2 - RETURN
3 - BLEED AND PRESSURE GAUGE PORT
4 - VACUUM GAUGE PORT
5 - PRESSURE ADJUSTMENT
6 - TO NOZZLE
1
2
5
6
34
!NOTE: before starting the burner, check that the return pipe is open. An eventual obstruction could damage the pump sealing device.
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Servomotor LAMTEC - Air damper motor pre-setting
Air adjustment is accomplished through LAMTEC parameters setting. Refer to LAMTEC
manual attacched.

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START-UP OIL SIDE
!WARNING: Once the setting on the oil has been
completed make sure that you close the manometer
– pressure switch tap.
VL
A
R
PR
max
min
1
5
I
I
I
I
7
7
6
6
3
3
4
VS
VL
A
R
PR
1
5
4
VS
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
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.

19
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420010813300
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!
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
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:
qA= (tA- tL) A1+ B
CO2
qA= exhaust gas loss [%]
tA= exhaust gas temperature [°C]
tL= combustion air temperature [°C]
CO2= volumetric content of carbon
dioxide [%]
Example
Data measured in natural gas mode:
CO2content of exhaust gases: 10,8%
Exhaust gas temperature: 195°C
Air intake temperature: 22°C
The exhaust gas loss can be calculated
as follows:
qAf = (195-22)( 0,37 + 0,009) = 7,48%
10,8
Data measured in fuel oil mode:
CO2content of exhaust gases: 12,8%
Exhaust gas temperature: 195°C
Air intake temperature: 22°C
The exhaust gas loss can be calculated
as follows:
qAf = (195-22)( 0,49 + 0,007) = 7,83%
12,8
Light oil
EL
Heavy oil
SNatural gas Town gas LPG
A1 0,50 0,490 0,370 0,350 0,420
B 0,007 0,007 0,009 0,011 0,008
SAL
01

3
4
+-
1
2
MAINTENANCE PROGRAM
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.
REMOVING
THE BLAST TUBE
REMOVING
THE FIRING HEAD
POSITION OF ELECTRODES
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20
5÷6 mm
3÷4 mm
Ignition Electrode
OIL FILTER CLEANING
ATTENTION: Periodically clean oil cartridge with
gasoline and replace them if it is necessary!