Ecoflam MAX GAS 350 PR User manual

Technical data
Dati tecnici
Données techniques
Datos técnicos
Технические характеристики
Operating instructions
Istruzioni per l’uso
Notice d’emploi
Manual de uso
Руководство по эксплуатации
Electric diagrams
Schemi elettrico
Schémas électrique
Esquemas eléctrico
Электрические схемы
Spare parts list
Parti ricambi
Pièces de rechange
Piezas de recambio
Запчасти
GAS BURNERS
EN
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MAX GAS 350 PR
MAX GAS 500 PR
MAX GAS 350 PR-MD TC GN SGT TW 230-50 3140047
MAX GAS 350 PR-MD TL GN SGT TW 230-50 3140048
MAX GAS 500 PR-MD TC GN SGT TW 400-50 3140049
MAX GAS 500 PR-MD TL GN SGT TW 400-50 3140050
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Overview - Index of contents / Panoramica - Indice dei contenuti / Vue d'ensemble - Table des matières
Descripción - Sumario / Обзор - Содержание
Technical data
Dati tecnici
Données techniques
Datos técnicos
Технические характеристики
EN
IT
FR
ES
RU
3
Working fields
Campi di lavoro
Domaine de fonctionnement
Ámbito de funcionamiento
Рабочий диапазон
EN
IT
FR
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RU
4
Dimensions
Dimensioni
Dimensions
Dimensiones
Размеры
EN
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FR
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5
Operating instructions for authorised specialists EN 6 - 26
Istruzione per l’uso per il personale qualificato IT 27 - 47
Notice d’emploi pour l’installateur spécialiste FR 48 - 68
Instrucciones de montaje para el instalador especialista ES 69 - 89
Инструкция по эксплутации для
квалифицированных специалистов RU 90 - 110
Gas pressure diagrams
Diagrammi di pressione gas
Diagrammes de pression de gaz
Diagramas de presión de gas
Диаграммы давления газа
EN
IT
FR
ES
RU
111 - 112
Electric diagrams
Schemi elettrico
Schémas électrique
Esquemas eléctrico
Электрические схемы
EN
IT
FR
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RU
113 - 116
Spare parts list
Parti di ricambio
Pièces de rechange
Piezas de recambio
Запчасти
EN
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117 - 118
Conformity declaration
Dichiarazione di conformità
Déclaration de conformite
Declaración de conformidad
Сертификат соответствия
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119

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Technical data - Dati tecnici - Données techniques - Datos técnicos - Технические характеристики MAX GAS 350 PR MAX GAS 500 PR
Burner output max/min kW - kcal/h
Potenza bruciatore max/min kW - kcal/h
Puissance du brûleur max/min kW - kcal/h
Potencia del quemador máx/mín kW - kcal/h
Мощность горелки макс./мин., кВт - ккал/ч
350 100 500 120
301.000 86.000 430.000 103.200
Operation Funzionamento Fonctionnement Funcionamiento Moдифиkaция Progressive mechanical gas
Regulating ratio Rapporto di regolazione Rapport de régulation Relación de regulación Коэффициент
регулирования 1÷3 GAS
Fuel Combustibile Fuel Combustible Топливо
Natural Gas (L.C.V. 8.570 kcal/Nm3), LPG (L.C.V. 22.260 kcal/Nm3)
(G20) Hu = 10,35 kWh/m3- (G25) Hu = 8,83 kWh/m3
(G31) Hu = 25,89 kWh/m3
Emission class Classe di emissione Classe d’émission Tipo de emisión Класс выделения
загрязняющих веществ Standard Class 3 - GAS EN676 (<80mg/kWh)
Control box Apparecchiatura di
controllo Coffret de sécurité Cajetín de seguridad Блок управления и
безопасности THERMOWATT TCG 5xx
Gas train Rampa gas Rampe gaz Rampa de gas Газовая рампа GAS TRAIN TABLE - DIFFERENT MODELS / CONFIGUATIONS
Gas connection Allacciamento gas Raccordement gaz Conexión de gas Подсоединение газа Rp 20 3/4” - Rp 40 1”1/2 Rp 20 3/4” - Rp 40 1”1/2
Gas input pressure Pressione di ingresso gas Pression d’entrée du gaz Presión de entrada
del gas Давление газа на входе 17 (20 Max Gas 500) - 500 mbar
(SEE GAS TRAIN MATCHING TABLE)
LPG input pressure Pressione di ingresso
LPG
Pression d’entrée du gaz propane
Presión de entrada LPG Давление LPG на входе 29 (37 Max Gas 500) - 500 mbar
(SEE GAS TRAIN MATCHING TABLE)
Air regulation Air flap
Regolazione aria Serranda dell'aria
Réglage de l’air Volet d’air
Ajuste del aire Válvula de aire
Настройка подачи воздуха Воздушная заслонка
Schneider STE4,5Q3.51/6 3NM R Schneider STE4,5Q3.51/6 3NM R
Flame monitor Rivelatore di fiamma Surveillance de flamme Vigilancia de llama Контроль пламени ionization ionization
Ignition transformer Trasformatore
d'accensione Allumeur Encendedor Устройство розжига 1-Pole Electronic 1-Pole Electronic
Electric motor rpm - watt
Motore elettrico giri motore - watt
Moteur rpm - watt
Motor rpm - watt
Электродвигатель об/мин - watt
2800 rpm 2800 rpm
300 W 550 W
Voltage Tensione Tension Tensión Напряжение 230 V (230/400 V Max Gas 500) / 50 Hz
Power consumption (operation)
Potenza elettrica assorbita (Esercizio)
Puissance électrique absorbée (en service)
Potencia eléctrica absorbida (en funcionamiento)
Потребляемая электрическая мощность: (при работе)
600 W 940 W
Weight Peso Poids Peso Приблизительный вес 19,6 kg 23,5 kg
Protection level Classe di protezione Indice de protection Índice de protección Класс электрозащиты IP40
Sound pressure level dB(A)
Livello pressione sonora dB(A)
Niveau presion acoustique dB(A)
Nivel de presion acústico dB(A) Уровень шума, dB(A) 73 73
Ambient temp. for storage
Temperatura ambiente di stoccaggio
Température ambiante de stockage
Temperatura ambiente de almacenamiento Температура хранения -20°…+70° C
Temperature for use Temperatura
d’utilizzazione Température d’utilisation Temperatura ambiente
de utilización Рабочая температура -10°…+60° C
Overview / Panoramica / Vue d'ensemble / Descripción / Обзор

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Working field 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. The efficiency rating of the boiler should be taken into account when selecting a burner. Calculation of burner output: QF = QN
ηK
QF = Burner output (kW) QN = Rated boiler output (kW) ηK= Boiler efficiency (%)
Curva Il campo di attività indica la potenza del bruciatore in funzione della pressione della camera di combustione. Corrisponde ai valori massimi previsti dalla norma EN 676 misurati sul tubo della fiamma di controllo. In occasione della scelta del bruciatore si deve tenere conto del rendimento energetico della caldaia. Calcolo della potenza della caldaia: QF = QN
ηK
QF= potenza della caldaia (kW) QN= potenza nominale della caldaia (kW) ηK= rendimento energetico
della caldaia (%)
Domaine de fonctionnement Le domaine de fonctionnement correspond aux valeurs mesurées lors de l’homologation. Elle correspond aux valeurs max mesurées sur tunnel d’essai d’après l’EN 676. Pour le choix du brûleur, tenir compte du rendement de la chaudière. Calcul de la puissance calorifique: QF = QN
ηK
QF= Puissance calorifique (kW) QN= Puissance nominale chaudière (kW) ηK= Rendement chaudière (%)
Ámbito de funcionamiento El ámbito de funcionamiento corresponde a los valores registrados en el momento de la homologación. Corresponde a los valores máx medidos en el túnel de ensayo según la EN 676. Para la elección del quemador, se ha de tener en cuenta el rendimiento de la caldera. Cálculo de la potencia calorífica: QF = QN
ηK
QF = Potencia calorífica (kW) QN = Potencia nominal de la caldera (kW) ηK = Rendimiento de la
caldera (%)
Рабочий диапазон Рабочий диапазон показывает производительность горелки в зависимости от давления в топочной камере. Он соответствует максимальным значениям согласно EN 676, измеренным в контрольной топочной камере. При выборе горелки необходимо учитывать КПД котла. Расчет тепловой мощности: QF = QN
ηK
QF = Тепловая мощность, кВт QN= Номинальная мощность котла, кВт ηK= КПД котла, %
Overview - Working fields / Panoramica - Curve / Vue d'ensemble - Domaine de fonctionnement / Descripción - Ámbito de funcionamiento / Обзор - Рабочий диапазон
10050 200
200100 300 400
300 400 500 600
0 1 2 3 4 5 6 7 8 9
mbar
kW
kcal/h x 1000
MAX GAS 350 PR
MAX GAS 500 PR
500

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Overview - Dimensions / Panoramica - Dimensioni / Vue d'ensemble - Dimensions / Descripción - Dimensiones / Обзор - Размеры
X
Y
Z
Packaging
MAX GAS 350-500 PR
GAS TRAIN DIMENSIONS: refer to GT manual
Pr
Ø r
Sr
MAX GAS 350-500 PR
Model AB C D D1 E F G I L M N O
MAX GAS 350 PR 510 302 208 175 335 500 157 280 185/200 185/200 M8 62 101 MAX GAS 500 PR 510 302 208 175 335 500 157 280 185/200 185/200 M8 62 101
Model Ø a Ø b Ø c d°..
MAX GAS 350 PR 167 262 283 45° MAX GAS 500 PR 167 262 283 45°
d..°
Ø a Ø b
Ø c
M
Boiler plate drilling
Model XYZ kg
MAX GAS 350 PR 500 830 600 23,5 MAX GAS 500 PR 500 830 600 29
D = short head D1 = long head Dimensions (mm)

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Contents - Index - General warnings
Important notes
MAX GAS 350-500 PR burners are
designed for the low-pollutant combustion
of natural gas and Liquefied Petroleum
Gas. The design and function of the
burners comply with standard EN676.
Assembly and commissioning must be
carried out only by authorised specialists
and all applicable guidelines and directives
must be observed.
Burner description
MAX GAS 350-500 PR are two-stage
progressive, fully automatic, monoblock
type burners. The special design of the
burner head provides low-polluting
combustion with high efficiency. In line with
testing as defined by EN676, the values
comply with emissions class 3
(NOx<80mg/kWh) Emissions values may
differ, depending on combustion chamber
dimensions, combustion chamber load and
the firing system (three-pass boilers,
boilers with reverse firing).
They are suitable for use with all heat
generators complying with EN 303 or for
use with hot air generators complying with
DIN 4794, and DIN 30697 within their
respective performance range.
Use for any other application requires the
approval of Ecoflam.
The following standards should be
observed in order to ensure safe,
environmentally sound and
energy-efficient operation:
EN 676
Forced-draught gas burners
EN 226
Connection of fuel oil and forced-draught
gas burners to a heat generator.
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.
Variations may arise as a result of local
regulations.
We can accept no warranty liability
whatsoever for loss, damage or injury
caused by any of the following:
- Inappropriate use.
- Incorrect assembly or repair by the
customer or any third party, including the
fitting of non-original parts.
Provision of the system and the
operating instructions
The firing system manufacturer 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, and 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. 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.
Overview Technical data 3
Working fields 4
Dimensions 5
Contents Index 6
General warnings 6
Burner description 7
Function General safety functions 8
TCG5xx control box 9-10-11
Terminal allocation chart 230 Volt connection 12
Terminal allocation chart low voltage connections 13
Installation Burner assembly 14
Electrical connection - Checks before commissioning 15
Start up Pre-setting without flame 16
Adjusting burner output 17-18
Setting the flame 19-20
Operating mode 20
Air pressure switch adjustment - setting gas pressostat - Saving the adjustment values in the display 21
Service Maintenance 22-23
Troubleshooting 24
Troubleshooting - Fault diagnosis menu 25
Operating statistics menu 26
Overview Gas pressure diagrams 111-112
Electrical diagrams 113-116
Spare parts list 117-118
Contents Conformity declaration 119

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A1 TCG 5xx Gas control unit
A4 Display
F6 Air pressure switch
M1 Electric motor
T1 Ignition transformer
Y10 Air damper motor
3 Air regulation in the burner head
5 Housing
8 Blast tube
15 Burner flange
16 Reset key
113 Air intake
Scope of delivery
The burner is delivered in a modular system of
packagings i.e. separate set/box:
BBCH: Burner Body with Combustion Head
with flange.
- 1 bag including :- multilanguage technical manual.
- spanner.
- screws, nuts and washer.
GT: separate Gas Train
KIT & ACS are managed and delivered separately
Contents - Burner description
KIT & ACS delivered separately
15
MAX GAS 350 LN PR TC TW
MAX GAS
RANGE NAME BY FUEL TYPE
MAX GAS 350
MODEL SIZE
LN Low NOx Class 3 GAS EN676 (<80 mg/kWh)
- Standard Class 2-GAS EN676 (<120 mg/kWh)
EMISSION COMBUSTION TYPE
PAB 2 stages soft start
PR 2 stages progressive mechanical
OPERATION TYPE
TC Short head
TL Long head
HEAD TYPE
TW Thermowatt
CONTROL BOX
113
Y10
5
8
A1
A4
F6
3
M1
16

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Function - General safety functions
Description of functions
When the system is switched on for the
first time, after a power failure or safety
shutdown, after a lack of gas or after the
system has been out of operation for 24
hours, the pre-ventilation period of 24
seconds begins.
During pre-purge period:
- blower pressure is monitored
- the combustion chamber is monitored for
flame signals.
At the end of the pre-purge period:
- ignition is switched on.
- main and safety valve are opened.
- burner starts.
Monitoring
The flame is monitored by an ionisation
probe. The probe is insulated and
fitted to the gas head and is routed
through the flame disc into the flame
zone. The probe must not have any
electrical contact with earthed parts.
The burner switches to lock-out if a short
circuit occurs between the probe and
the burner earth.
During burner operation, an ionised
zone is produced in the gas flame
through which a rectified current flows
from the probe to the burner head.
Safety functions
- If no flame is produced when the burner
is started (gas release), the burner will be
switched off at the end of the safety
period, lasting no more than 3 seconds,
and the gas valve will close.
- If the flame goes out during operation,
the gas supply is interrupted within one
second and the control unit goes to block.
- If there is a lack of air during reventilation
or operation, a safety lock-out occours.
- If there is a lack of gas, the burner does
not begin operation or switches off.
A waiting time of 2 minutes follows. This is
followed by a further start attempt. If there
is still no gas pressure, a further waiting
time of 2 minutes follows. The waiting time
can only be reset by interrupting the
power supply to the burner.
Waiting times: 3 x 2 min, then 1 hour.
In the event of controller shutdown
- Controller thermostat interrupts heat
request.
- Gas solenoid valves close.
- Flame goes out.
- Burner motor switches off.
- Burner is ready for operation.
1108106Y12104 F4119 pBr Y13
119.2
F6
143
F4 Minimum gas pressure switch
F6 Air pressure switch
Y13 Solenoid valve
Y12 Solenoid valve
1 Thermally-triggered safety shut-off valve
(installation by installer)
104 Gas pressure regulator
106 Filter
108 Gas ball valve (installation by installer)
119pBr Measuring point for gas outlet pressure
143 Antivibration coupling (installation resident).

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Function - TCG 5xx control box
Pressing the
unlocking
button on the
unit for
.... causes ....
... 1 second ... the control unit to
unlock.
... 2 seconds ... he control unit to
unlock.
... 9 seconds ... the statistics to be
deleted
The TCG 5xx control and safety unit
controls and monitors the forced draught
burner. The microprocessor-controlled
program sequence ensures maximum
stability of time periods, regardless of
fluctuations in the power supply voltage or
the ambient temperature. The automatic
combustion control unit is designed to
cope with brownouts. Whenever the
supply voltage drops below its rated
minimum level (< 185V), the control unit
shuts down - even in the absence of a
malfunction signal. The control unit
switches itself back on again once the
voltage has returned to normal levels (>
195V).
Locking and unlocking
The control unit can be locked (switched to
malfunction mode) by pressing the
unlocking button and unlocked (fault
deleted), provided the unit is connected to
the mains power supply.
!
Always switch off the power supply
before installing or removing the
control unit. Do not attempt to open
or carry out repairs on the control
unit.
Screen Description Screen Description
Awaiting the heat request from the boiler Opening the gas valve and safety time
Air flap is forced open for pre-ventilation. Flame is present, awaiting authorisation of
regulation
Pre-ventilation
Burner in operation. The lower cell shows the
strength of the signal and the operating time of
the burner.
Closing the air flap to the ignition position,
pre-ignition
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Reduces the marked value.
Modifies/Confirms the value shown.
Unlocks the control unit.
Red LED (flashes if a fault is
present).

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Function - TCG 5xx control box
In parallel with its control and safety
functions, the TCG5xx control unit allows
the following to be set: (see illustration)
- the position of the air flap during ignition.
- the position of the air flap at minimum
output.
- the position of the air flap at maximum
output.
The parameters for the control unit are set
using the display and 5 keys. Operating
values are shown in real time on the
display.
Pressing the keys gives access to 7
menus:
• menu for setting the
servomotor.
• menu for storing the
servomotor setpoints in
the display.
• menu for consulting
faults.
• menu for statistical
data.
• menu for setting /
adjusting the standard
configurations.
• menu for setting
industrial applications.
• menu for manual
control.
In these menus, it is
possible to adjust the
control unit's standard
configurations. These
are pre-set in the factory.
No modifications may be
carried out on-site
without prior consultation
with ECOFLAM.
The access code and the
setting setpoints for this
menu are available on
request.

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Function - TCG 5xx control box
Operating cycle phases:
1: No voltage
2: Powering up, no heat request
3: Checking the air flap is closed
4: Opening an air flap, arrival in pre-
ventilation position.
5: Checking the rest status of the air
pressure switch.
6: Pre-ventilation: energizing of the
motor, checking the air pressure.
7: End of pre-ventilation.
8: Air flap closes to the ignition position
9: Switching on the igniter, unauthorised
flame monitoring.
10:Starting the burner: Opening of the
solenoid valve, flame formation,
safety time: max. 3 s.
11:Awaiting regulator release
12:Opening the air flap, until the
maximum output is reached.
13:Closing of the air flap until the
minimum regulation position is reached.
14:Operation at intermediate regulation
power.
15:Operation at minimum regulation
power.
16:Regulator shutdown, closure of the
air flap to 0°.
17:Awaiting a new heating request

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Function - Terminal allocation chart 230 Volt connection
Terminal Description Connector
1 Burner motor phase
4
2 Earth
3 Neutral
4 Solenoid valve live
2
5 Neutral
6 Earth
7 Solenoid valve live
8 Live
9 Live L1
6
10 Earth
11 Neutral
12 Earth
13 Earth
14 Igniter live
5
15 Earth
16 Neutral
17 Control thermostat live
T6/7/8
18 Signal T7
19 Signal T8
Terminal Description Connector
20 Minimum output thermostat live (T1) 19
21 Heating request signal (option T2)
22 Flame monitoring signal
11
23 Neutral
24 Live
25 Air pressure switch signal 10
26 Live
27 Live 20
28 Remote unlocking signal
29 Neutral 21
30 Signal fault live
31 Live 8
32 Gas pressure switch signal mini
33 Not used 34
34 Not used

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Terminal Description Connector
1 not used
30
2 not used
3 not used
4 not used
27
28
29
5 not used
6 not used
7 not used
8 not used
9 not used
10
Display or PC interface
16
/
17
11
12
13
14
15
16
17
Terminal Description Connector
18 not used
14
19 not used
20 not used
21 not used
22 not used
23 not used
24 not used 33
25 not used
26 not used 32
27 not used
28
Air servomotor 15
29
30
31
32
33
Function - Terminal allocation chart low voltage connections

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Installation - Burner assembly
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 Aas 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 assembly
The burner is fixed by mean of connecting
flange and therefore to the boiler.
Installation:
• fix the flange to the boiler with
the screws.
Removal:
• loosen screw.
• pull the burner out of the boiler.
General regulations applying to the
gas connection
• The gas train must only be connected
to the gas mains by a recognised
specialist.
• The cross-section of the gas line should
be of a size designed to guarantee that the
gas flow pressure does not drop below the
specified level.
• A manual shut-off valve (not supplied)
must be fitted upstream of the gas train.
Gas lines
When installing the gas lines and gas train,
the general EN676 directives and
guidelines must be observed.
Additional accessories and kits shall be
installed by the installer in accordance to
the local safety regulations and codes of
practise.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head
+ complete gas train)
Pin: Minimum inlet pressure
For operation with Liquefied Petroleum
Gas, it is necessary to order the kit and
follow the instructions given in the
specific manual.
LPG TRANSFORMATION
KITLPG-MAXGAS...
1
2
–
+
A
A1

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Installation - Electrical connection - Checks before commissioning
Electrical connection
The electrical installation and connection
work must only be carried out by an
authorised electrical specialist.
All applicable rules and regulations must
be observed.
The electrical installation should include a
type A circuit breaker.
The applicable guidelines and
directives must be observed, as well as
the electrical circuit diagram supplied
with the burner!
• Check to ensure that the power supply
voltage is as specified in the electric
diagram and in data plate.
• Burner fuse: 5 A.
Checks before commissioning
The following must be checked before
initial commissioning:
• That the burner is assembled in
accordance with the instructions given
here.
• That the burner is pre-set in accordance
with the values in the adjustment table.
• Setting the combustion components.
• The heat generator must be ready for
operation, and the operating regulations
for the heat generator must be observed.
• All electrical connections must be correct.
• The heat generator and heating system
must be filled with water and the
circulating pumps must be in operation.
• The thermostats, 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.
• The heat request must be available.
• Sufficient gas pressure must be
available.
• The fuel supply lines must be assembled
correctly, checked for leaks and bled.
• 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.
Position of electrodes
Setting the ionisation probe and
ignition electrode: see diagram
Always check the position of the
electrodes after service or substitution
or assembly of LPG kit as wrong position
might cause ignition problem.
Electrical connection (plug-in)
It must be possible to disconnect the
burner from the mains using an
omnipolar shutdown device complying
with the standards in force. The burner
and heat generator (boiler) are connected
to the terminal block of the cabinet (fig.1).
Connecting the gas train
Connect the gas train to the plugs on the
burner.
A
A
2,5
3
IONIZATION
PROBE
IGNITION
ELECTRODE
1
HLFHLB
TP
STAB
Q
3
TP
STC
TP
STS
4 85 6 7 109 11 12SR T 1
50 Hz 400V
R
PE
T
S
N
N
2 13

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Start up - Pre-setting without flame
Setting is carried out in 2 phases:
- pre-adjustment without flame.
- setting the flame, to fine tune the settings
based on the combustion results.
When the burner is switched on, the
control unit displays the screen below.
Important
At this point, no setting position for the
servomotor has been defined, therefore
the burner cannot be started under these
conditions.
!
N.B.:It is possible to set different positions within a large
range of values. However, for safety reasons, the control
unit enforces a minimum interval of 2° between the
different positions (except between the ignition position
and the 1st stage).
• For the next step, press any button.
• The overall view of the menus is
displayed, and the air flap positions settings
menu is selected.
• Open the settings menu by pressing the
button .
You must now enter the access code (see
the label on the back of the display)
• Increase or decrease the value in
increments by repeatedly pressing or .
• When the first figure has been set, move
the cursor to the right by pressing .
• Repeat the operation until you reach the
last figure.
• Confirm the access code by pressing .
The control unit then openshe settings
mode.
The screen displays the factory pre- settings
for the different positions of the air flap.
The following positions for the air flap are
presented:
• ignition position (when the menu is
opened, the curser goes to this position).
• the position of the air flap at minimum
pressure.
• the position of the air flap at maximum
pressure.
Modifying a settings value for the servomotor position:
- To modify the value of a position, move the cursor to the
corresponding location with the button or .
- Select the value to be modified using the button , the selected
value will flash.
- Increase or decrease the value in increments of 0.1° by
repeatedly pressing or . For large modifications, press and
hold the button or , the value will scroll quickly up or down.
- Confirm the new value using the button flashing.
When all the positions of the servomotor
have been determined according to the
required settings, it is then possible to move
on to the next section for commissioning -
"Setting the flame".
To do this, place the cursor in the lower part
of the screen on the symbol and confirm
by pressing the button .
if it is necessary to quit the menu without
saving the pre-settings, position the cursor
on the symbol and confirm with the
button .
End of settings menu without flame

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Start up - Adjusting burner output
!Risk of air blast!
Continuously check CO, CO2and soot emissions when adjusting the output of the burner. Optimise combustion values in the
event of CO formation. CO must not exceed 50 ppm.
Firing head setting (B).
To act on the screw in figure:
• turn Allen key till you reach the
requested value (index 1-5).
3
3LIATE
D
+
-
A
+
-
1
1LIATED
B
”PR” version gas burners gas train in-
stallation and setting instructions (A)
Fix the gas train to burner body by means
of the 4 screws of the flange, pay attention
to set correctly the gasket ( O-ring ). Con-
nect electrically the gas train with the 2
connectors of the valve (black) and gas
pressure switch(gray).
Switch on the burner (it has already been
tested in the factory, so it is pre set on ave-
rage values) and verify the tightness of
gas train connections made during installa-
tion. Act as follows to adapt the burner out-
put to the boiler.
Regulating the combustion of burner
Follow the sequence of operations:
Maximum power regulation:
1) position the air valve in the fully open
setting (90°, through the dispaly. For parti-
cularly low power only, if the reduction of
air is not sufficient with the head in position
1, reduce the opening of the air valve).
2) dose the air by moving the combustion
head (figure) to suit the power required (as
shown in figure).
3) dose the gas by regulating the gas ramp
(see figure in the ramp manual).
Low flame setting:
1) after regulating the maximum power
and determining the working pressure of
the gas in the head, position the valve on
the low flame setting, 25° through the di-
spaly, and dose the gas using the regula-
tion screw on the butterfly valve of the gas.
(figure).
2) if the minimum charge obtained in this
way is too low for the heat generator, in-
crease the opening of the air valve, adju-
sting the flow of gas using the butterfly
valve of the gas to obtain the minimum ap-
propriate power.

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Start up - Adjusting burner output
Gas pressure diagrams in appendix
Minimum gas pressure required are
indicated in the diagrams in the appendix.
These values have been determined in
our test labs and are useful for the first
switch-on as final setting must be done
using a combustion analyzer.
How to read and adjust the values:
- determine the output required
- determine the combustion chamber back-
pressure
- read the minimum gas pressure required
in the diagrams in appendix.
Optimising combustion values
The factory setting shall be modified
according to the output requeired.
The diagrams of air/head setting
that are available in the appendix
of this manual are a guide for ensuring
that the burner functions as well as
possible.
N.B. observe the minimum required
flue gas temperature specified by the
boiler manufacturer and the requirements
demanded of flue gas ducts for avoiding
condensation.
Adjustment of gas solenoid valve
Refer to the gas train manual for the gas
setting of the gas train selected.
head gas pressure (on elbow) (mbar)
head position
air damper position
Warning: the pre-calibration values have
been determined on EN676 test combu-
stion chambers in ideal conditions, and
are useful for the first switch-on but must
be checked and corrected with calibration
for the individual system.
Example in figure:
Power required by the generator: 380 kW.
Pressure envisaged in combustion cham-
ber: 3.5 mbar. Combustion head chamber:
2.5 (between 2 and 3). Gas pressure in
head: 13 mbar.
pressure in the combustion chamber (mbar)
output (kW)
-1,0
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
9,0
10,0
50 100 150 200 250 300 350 400 450 500 550 600
16 15 14 13
12,5
12
11,5
1
90°
2
90°
3
90°
4
90°
5
90°
EXAMPLE OF PRE-CALIBRATION MAX GAS 500 PR
12
Regulation capacity air
- To act on the screws in figure.
- To move the lever , selector on the
electrical control panel.

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Start up - Setting the flame
• If the boiler heating request is not
present, the boiler remains on standby.
In this case, it is still possible to return to the
previous setting menu "Pre-setting without
flame". To do this, position the cursor on the
symbol and confirm with the button .
• If a boiler heating request is present
(T1- T2 contact closed), the burner starts.
The air flap is opened to move to the pre-
ventilation position.
Air pressure switch test
Pre-ventilation
The air flap switches to the ignition/pre-
ignition position.
The control unit awaits the regulation
authorisation.
The fuel valve opens.
Awaiting flame signal.
If no flame is detected at the end of the
safety time, the control unit switches to
malfunction mode.
Setting the minimum pressure.
If the flame has been detected, the control
unit sets the burner to minimum power as
soon as it receives the regulation
authorisation.
- Adjust the gas pressure on the required
output, using the regulator on the gas valve.
Monitor the combustion values continuously
as you do so (CO, CO2, soot test). If
necessary, adjust the airflow.
- To do this, modify the position of the
servomotor to minimum power. Proceed as
described, in the paragraph "Modifying the
value of a servomotor position setting"
- Precautions: when modifying the setting
value, the servomotor will move in real time.
As a consequence, the combustion values
must be constantly checked.
Flame detected.
Flame stabilisation.
Modification of the air flow via the
"manual output control"
The "manual output control" function allows
the burner output to be modified.
To do this, position the cursor on the
corresponding line on the display and
confirm with the key. It is then possible to
adjust the burner output upwards or
downwards using the , keys.
Setting the maximum output
Slowly increase the burner to the maximum
output using the "manual power control"
function. At this point, adjust the gas flow
using the regulator on the gas train.
The preset limit values for the minimum
output and the maximum output cannot be
exceeded. If necessary, exit the "manual
output control" function again using the
key and modify the limit value for the
maximum or minimum output.
Definitive limitation of the maximum
output position
Limit the maximum opening of the air flap
according to the position determined for the
maximum output. In this example, the new
position determined for the maximum output
is below the value set manually. Using the
"manual output control" function, it is now
possible to reduce the burner output, but
this cannot be set above the new maximum
position, which here is 50°.

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Closing the "Setting the flame" menu.
The burner setting is now complete. If
necessary, it is possible to again correct
each of the settings values. To do this,
position the cursor on the value to be
modified, using the button or .
Otherwise, at all times, the following
possible ways of closing the "Setting the
flame" menu are available:
- Either restart the burner setting procedure,
passing through the presetting phase
(without entering a password). To do this,
position the cursor on the symboland
confirm with the button . All the settings
values already saved therefore remain
available. This is essential for testing a new
ignition position.
- Saving the fixed values and ending the
setting procedure. To do this, position the
cursor on the symboland confirm with the
button . The burner is then ready to
operate and can now be controlled by the
boiler regulation.
- Quitting the settings menu without
reaching the end of the setting procedure.
To do this, position the cursor on the symbol
and confirm with the button . All the
servomotor positions saved up to this point
are recovered by calling up the settings
menu again.
Operating mode - Display of the
operating status, the flame signal and
the operating time.
After setting of the burner has been
completed, it switches to operating mode.
The current operation of the burner
(operation at minimum or maximum power)
is indicated by the cursor.
The lower cell shows the intensity of the
signal. The display range is from 0 μA to 7
μA. For a good quality signal is one above
7μA. The following limit values are valid:
• When checking an unwanted flame: the
signal must be < 0.7μA.
• During the safety time: the signal must be
> 1.0μA.
• During operation: the signal must be >
8μA.
The cell at the bottom right displays the
current operating time of the burner.
Start up - Setting the flame - Operating mode
Specific function: ignition checking.
If the ignition position has been modified, it
is possible to carry out a new burner start-
up to check the new ignition position,
without having to quit the settings menu.
To do this, after modifying the ignition
position, position the cursor on the
symbol, and initiate the new start-up using
the key.
Definitive limitation of the minimum
output position
Using the "manual output control" function,
reduce the burner output to the minimum
output. If necessary, limit the minimum
output position, in the same way as for the
maximum output.