Ecoflam MULTICALOR 500.1 PRE Series User manual

GAS/LIGHT OIL BURNERS
EN
MULTICALOR 500.1 PRE TC 3145148
MULTICALOR 500.1 PRE TL 3145149
MULTICALOR 600.1 PRE TC
MULTICALOR 600.1 PRE TL 3145151
Technical data
Operating instructions
Electric diagrams
Spare parts list
MULTICALOR 500.1 PRE
MULTICALOR 600.1 PRE
Gas train manual is separate
www.ecoflamburners.com
28-02-2019

INDEX
General warnings  Conformity declaration 3
Burner designation  Modular delivery system 4
Burner description 5
Electrical control panel 5
Gas train - Kit - Accessories: assembly to the burner 6
Technical data 7
Gas category by country 7
Working diagrams 8
Test boiler  Flame dimension 8
Overall dimensions 9
Oil operating mode  General safety functions 10
Gas operating mode  General safety functions 11
Installation 12
Fitting the burner to the boiler 12
Oil connection 13
Feeding and suction line for light oil 14
Gas line 15
Pilot gas train, kit and accessories connection - Head loss diagram 16
Gas pressure loss diagrams 17
Electrical connections 19
Startup: Checking procedure, Recording commissioning data 20
Exhaust gas test 21
Startup oil side 22
Fuel selection - Start-up 22
Adjusting the max air flow rate 22
Firing head setting 22
Adjusting the max oil flow rate 23
Servomotor Lamtec - Air damper motor pre-setting 23
Adjusting the pump pressure 23
Adjusting the intermediate burner capacity 24
Startup gas side 25
Fuel selection - Start-up 25
Adjusting the max air flow rate 25
Firing head setting 25
Servomotor Lamtec - Air damper motor pre-setting 25
Adjusting the intermediate burner capacity 26
Pressure switch adjustment 26
Maintenance program 27
Troubleshooting instructions 29
Operating troubles 29
Appendix 29
Control box - Damper actuators 29
Fluidics nozzle chart 30
Bergonzo nozzle tables 33
Pump and pressure regulators 36
Electrical diagrams 37
Spare parts list 44
420011028200
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MULTICALOR 500.1
MULTICALOR 600.1
0 1000 2000 3000 4000 6000 kW5000

GENERAL WARNINGS  CONFORMITY DECLARATION
420011028200
EN
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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.
Declaration of conformity
for dual fuel burners
We,
Ecoflam Bruciatori S.p.A.
declare under our sole responsibility
that the dual fuel burners named
MULTICALOR
conform to the following standards:
EN 267
EN 676 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
(EU) 2016/426 Gas Appliance
Regulation.
Important notes
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 burner must not operate out
side the working range.
The quality is guaranteed by a quality and
management system certified in
accordance with ISO 9001:2008.
MULTICALOR burners are designed for
the low-pollutant combustion of natural gas
or LPG with kit and light oil.
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
MULTICALOR PRE burners are
progressive electronic fully automatic
monoblock devices. Burner head is
designed to get the lowest emissions in
terms of NOx and unburnt particles in
order to maximize the heat generator
efficiency. Emissions can be different
respect to the ones recorded in the lab
because they depends a lot on the
generator on which the burner is fit.
The installer must comply with compulsory
rules. Avoid for instance dangerous
atmosphere or not ventilated rooms.
Packaging and handling
Move the burner still in its packaging using
a trolley or forklift, taking care not to drop it
and elevating it no more than 20cm from
ground level. After having removed the
packaging, check that the contents are in
good condition and correspond with what
was ordered. If in doubt, contact the
manufacturer.
The burner must be installed by a
qualified individual.
If the weight and dimensions do not allow
for manual lifting, ask another operator for
help or use a forklift, harness the burner
using belts if no eyebolts are available.
Use the accessories provided
(flange, gasket, pins and nuts) to
install the burner onto the boiler,
taking care not to damage the
isolating gasket.
We can accept no warranty liability
whatsoever for loss, damage or injury
caused by any of the following:
- Inappropriate use.
- Incorrect assembly or repair by the
customer or any third party, including the
fitting of non-original parts.
- non authorised modifications made on
the burner.
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.
WARNING
DANGER
WARNING
WARNING
WARNING
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.
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.
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.
Ø r
Installing the gas train
The gas train is supplied
separately, for fitting refer to the
instructions in the gas train
manual.
WARNING

BURNER DESIGNATION
MODULAR DELIVERY SYSTEM
Dual fuel burners
All dual fuel burners are delivered in separate set/box, i.e. burner body including
combustion head and separate gas train with separate additional kit and accessories
that shall complete the gas train or the burner according to the applicable standard.
Kit and accessories are delivered separately.
Gas train  GTCP  KITS  Accessories
All gas and dual fuel burners gas trains are delivered separately in different models and
configuration.
Export configuration gas train completion are available but it is mandatory for the local
installer in this case to comply to the local safety regulations.
For burners over 1700 kW gas train connection pipe must be ordered.
Kits and accessories are managed and delivered separately.
Component type
BBCH Burner Body with Combustion Head (without gas train)
GTCP Gas Train Connection pipe
GT Gas Train (delivered separately)
420011028200
EN
www.ecoflamburners.com
4
MULTICALOR 500.1 PRE TC
MULTICALOR Dual fuel (Gas / Light oil)
RANGE NAME BY FUEL TYPE
MULTICALOR 500.1 423 kg/h - 5000 kW
MODEL SIZE (Gas: kW; Oil: kg/h)
Standard Class 2 - GAS EN676 (<120 mg/kWh)
Стандартная, класс 1 -
Дизтопливо
EN267 (<250 мг/кВтч)
EMISSIONS
PR 2 stages progressive mechanical gas / oil
PRE 2 stages progressive electronic with PID
OPERATION TYPE
TC Short head
TL Long head
HEAD TYPE
Natural gas
LPG Liquid gas
BIOGAS Biogas
FUEL

GTCP
20
23
19
BURNER DESCRIPTION
420011028200
EN
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LEGENDA
1. Housing
2. Electrical control panel
3. Blower motor
4. Pump and pump motor
6. Blast tube
8. Burner fixing flange
9. Air flap regulation
11. Silencer
12. Lifting eyebolts
14. Mechanical cam oil
15. Servomotor for gas and air
16. Gas train
17. Pilot gas train
18. Oil pressure regulator
19. Gas filter
20. Ball valve
21. Oil coil
23. Antivibration coupling
GTCP. Gas train connection pipe
16
1
6
8
12
9
11
3
4
18 15
14
2
21
Control panel
HLBT
R
FF - termal lock-out lamp
B - operating lamps (orange=light-oil; green= gas)
C - selector:
0 = STOP
1= light-oil operation
2= gas operation
D - ON/OFF switch
E - display
D
C
BE
SAL
HLoil
HLgas
V
R
0 I
POS 2: GAS
POS 1: NAFTA
POS 0: STOP
SA
o-G
I 0 II
DISPLAY BCU LAMTEC
RWF 50

M
Air
Gas
313
170
144
142
141
120
150
314
349
M
349
151
155
100
143
Tobesupplied bythe installer
Tobesupplied bythe installer
107
143
Antivibration
coupling
144 Gas governor
150 Batterflyvalve
151 Gas train Siemens VGD....
155 Pilot gas train
170 Kit tightness control for pilot gas valve(optional)
313 Min.gas pressure switch
314 Max.gas pressure switch (optional)
349 Air/gas damper motor
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EN
420011028200
BURNER DESCRIPTION
Gas train  Kit  Accessories: assembly to the burner
MATCHING GAS TRAIN WITH DIAGRAM OF PRESSURE DROPS
ARE IN THE DEDICATED SECTION OF THIS MANUAL
VGD 20.503 Rp 2” / VGD 40.065  40.080  40.100  40.125 1. Main gas pipe
2. Ball valve ACS
3. Antivibration coupling ACS
5. Min gas pressure switch
EXPORT
GAS TRAIN
EN676
6. Safety gas valve + 10. Actuator
7. Working gas valve + 11. Actuator
8. Gas leakage control KITTC *
9. Gas filter ACS
KIT - MAX Gas pressure switch KITPRES
ACS - Gas train connection pipe GTCP **
Ecoflam gas trains are delivered separately for all gas and dual fuel burners and are available in different configurations:
Double gas valves with actuators and regulator VGD Siemens and min pressure switch + ACS gas filter
12 3 910 115
76
!WARNING: EN676 compulsory kit and accessories in order to comply to the safety regulations. Additional accessories and kits
shall be installed by the installer in accordance to the local safety regulations and codes of practise.
HOW TO INSTALL THE GAS TRAIN INTO THE BURNER AND CALCULATE THE OVERALL DIMENSIONS:
refer to the dimension page and the gas train manual for all detailed information
Gas governor / Filter
FGDR - FILTER
Compulsory EN676
Max Pressure switch
KITPRES50
KITPRES150
Other accessoriesModulation Kit
KITMD-RWF50
Probe-...
!GTCP...* WARNING: in order to fit the gas train, the corresponding connection pipe must be ordered (GTCP size and fitting depend on the
burner and the gas train selected). Upon the installer responsibility it is mandatory to install additional support(s) in order to not overload the
burner body with the dead load of full gas train, accessories, piping and so on.
The burner body can stand just the gas valve and the piping between the gas valve and the body.

7
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EN
420011028200
TECHNICAL DATA
GAS CATEGORY BY COUNTRY
MODEL MULTICALOR 500.1 PRE MULTICALOR 600.1 PRE
Thermal power max.
kW 5.000 5.800
kcal/h 4.300.000 4.988.000
kg/h 423 490
Thermal power min.
kW 1.200 1.500
kcal/h 1.032.000 1.290.000
kg/h 101 126
Operation mode Type Progressive electronic oil / gas - Modulating with PID
Regulation ratio nominal Type 1÷4 GAS - 1÷3 OIL
Fuel Type
G20 (L.C.V. 8.570 kcal/Nm3), G25 (L.C.V. 7.370 kcal/Nm3)
G31 (L.C.V. 22.260 kcal/Nm3), G30 (L.C.V. 29.320 kcal/Nm3)
Light oil (L.C.V. 10.200 kcal/kg max visc. 1,5°E at 20°C)
Emission class std Standard Class 2 GAS EN676 (<120 mg/kWh) -
Standard Class 1 OIL EN267 (<250 mg/kWh)
Control unit Type LAMTEC BT3xx
Gas train GT VGD separate gas train + Filter + Other KIT/ACS
Gas connection GTCP Gas connection range RP 50 to DN 125 depending on the gas train selected
NATURAL GAS pressure mbar 35÷500 50÷500
LPG pressure mbar 65÷500 90÷500
Air regulation Type Air flap Air flap
Air flap control with servomotor Model STE....
Air pressure switch mbar 1…10 mbar
Flame monitoring Type UV cell QRA
Ignitier Model BRAHMA
Motor kW 11 18
Rpm N° 2.800 2.800
Voltage V/Hz 230/400 V - 50 Hz
Total power consumption operation kW 13,5 17,5
Weight body BBCH Kg
Electrical panel protection level IP IP55 IP55
Sound pressure level
without silencer dB(A)
Lab
tests
91,4 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 TA4 TA4
Oil pump motor kW 1,1 1,1
Nozzles Type according to the output requested
Gas category Country
II2R3R BE CH CZ DE DK ES FI FR GB GR HU IE IT LU NL PT SE EE LT LV NO PL SK SI -
II2H3B/P AT - - - - - - - - - - - - - - - - - - - - - - - -
I3R CY MT - - - - - - - - - - - - - - - - - - - - - - -

0
5
1
0
1
5
2
0
2
5
0 1000 2000 3000 4000 5000 6000
0 1000 2000 3000 4000 5000
0 100 200 300 400 500
kW
mbar
kg/h
kcal/h*1000
MULTICALOR 500.1
MULTICALOR 600.1
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EN
420011028200
WORKING DIAGRAMS
TEST BOILER  FLAME DIMENSIONS
The burner/boiler matching does not pose
any problems if the boiler is CE type-
approved.
If the burner must be combined with a
boiler that has not been CE type-approved
and/or its combustion chamber dimensions
are clearly smaller than those indicated in
diagram, consult the manufacturer.
The firing rates were set in relation to
special test boilers, according to EN676 -
EN267 regulations.
The sizes are indicative and dipend on
the configuration, to the combustion
chamber pressure and to the draught.
The values have been taken out from
tests executed with flame tubes.
The dimensions of the flame are made
in test boiler in laboratory without
resistence therefore exists max and
min lenght that take into account the
difference in lenght that comes from the
boiler backpressure.
Example:
Burner thermal output = 8000 kW;
L flame (m) = 5 m (medium value)
D flame (m) = 1 m (medium value)
WARNING: Some flame modifications
can be done in our FLEXSHOP in the
factory in order to shape the flame and
adapt it to some special boiler
or application.
L (m)
2000 3000 4000 5000 6000 7000 8000 9000 10000
4
5
1000
2000 3000
1000
6
11000
0
2
3
7
8
12000 kW
13000
9
10
11
Nm3/h
100 200 300 400 500
kcal/h
x 1000
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
14000 15000 16000 17000
Ø (m)
2000 3000 4000 5000 6000 7000 8000 9000 10000
0,6
0,8
1000
2000 3000
1000
1
11000
0
0,2
0,4
1,2
1,4
12000 kW
13000
1,6
1,8
2
kcal/h
x 1000
4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
14000 15000 16000 17000
FLAME LENGHTGAS BURNERS
FLAME DIAMETER GAS BURNERS
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
Nm3/h
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
Working fields
The working field shows burner
output as a function of
combustion chamber pressure.
It corresponds to the maximum
values specified by EN 676
measured at the test fire tube.
Boiler efficiency should be
taken into consideration when
selecting the burner.
Calculation of
burner output
QF= Burner output (kW)
QN= Rated boiler output(kW)
η = Boiler efficiency (%)
QF= QNx 100
η

I
M
L
ED-D1
F
C
B
A
G
N
O
SUNTEC
H1
9
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EN
420011028200
OVERALL DIMENSIONS
HOW TO INSTALL THE GAS TRAIN
INTO THE BURNER AND CALCULATE
THE OVERALL DIMENSIONS:
refer to the dimension page and the gas train
manual for all detailed information.
Fixing hole dimensions
are “I” and “L” as per
dimension table.
Boiler hole shall be done
according to the blast
tube dimension “F” plus
15-25 mm in order to be
able to extract it during
maintenance.
Burnerboiler mounting flange
Packaging (only burner)
WARNING: Please follow the suggested dimension for the hole on
the boiler flange in order to fit the burner. Make sure that between
the boiler and the blast tube proper insulation is fitted.
Model X Y Z kg
MULTICALOR 500.1 1580 1630 1090
MULTICALOR 600.1 1580 1630 1090
Dimensions (mm)
D = Short head
D1= Long head
X
Y
Z
Model A B C D D1 E F G H1 I L M N O
MULTICALOR 500.1 1200 580 610 355 555 1000 320 570 965 330 330 M16 195 250
MULTICALOR 600.1 1200 580 620 355 555 1095 320 570 975 330 330 M16 195 250
330 420
330
420
Burner gas flange
Model ø A1 B1
MULTICALOR 500.1 145 4 x M16
MULTICALOR 600.1 145 4 x M16
A1
B1

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EN
420011028200
OIL OPERATING MODE  GENERAL SAFETY FUNCTIONS
STARTUP MODE
As soon as the furnace system is required
to supply heat, the burner control circuit
will close and the program flow started.
When the program has come to its end,
the burner will be turned on.
An automatic test is made for the tightness
of the gas valves prior to each burner start.
The air damper is in its closed position
when the burner is out of operation.
The electric actuator will open the closed
air damper to its full-load position so that
the burner will ventilate the furnace and
the exhaust hoods with the specified air
rate.
Shortly after the preventilation process has
been started the lack-of-air cut-out must
change over to operating position within a
certain time, i.e. the minimum air pressure
setting must be reached and maintained
until the burner is turned off. At the end of
the specified pre-ventilation time the air
damper will be moved into its partial-load
position in a linked control concept with the
gas damper. 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 control box 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.
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.

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EN
420011028200
GAS OPERATING MODE  GENERAL SAFETY FUNCTIONS
Scheme of functioning
LEGENDA
107: pilot gas filter/governor
141: ball valve
142: filter
143: antivibration coupling
150: butterfly valve
151: gas train Siemens VGD
155: pilot gas train
176: oil pump
178: solenoid valve
184: output control valve
311: return oil pressure switch
313: min gas pressure switch
CV: check valve
RL: return line
VL: suction line
VLO: working oil valve
STARTUP MODE
As soon as the furnace system is required
to supply heat, the burner control circuit
will close and the program flow started.
When the program has come to its end,
the burner will be turned on.
An automatic test is made for the tightness
of the gas valves prior to each burner start.
The air damper is in its closed position
when the burner is out of operation.
The electric actuator will open the closed
air damper to its full-load position so that
the burner will ventilate the furnace and
the exhaust hoods with the specified air
rate.
Shortly after the preventilation process has
been started the lack-of-air cut-out must
change over to operating position within a
certain time, i.e. the minimum air pressure
setting must be reached and maintained
until the burner is turned off. At the end of
the specified pre-ventilation time the air
damper will be moved into its partial-load
position in a linked control concept with the
gas damper.
The ignition transformer will be started.
At the end of the pre-ignition time the
ignition gas solenoid valves will be opened
to allow gas to flow into the pilot burner.
The ignition electrodes incorporated in the
pilot burner will ignite the ignition gas.
The ionization probe gives flame signal to
control box so that the safety shut-off
valves will be opened.
The gas will be fed to the gas nozzles via
the gas damper while combustion air is
supplied by the fan.
Gas and air will be intensively mixed in the
mixing unit and ignited by the pilot flame
with a specified safety period (minimum
furnace heat generating rate).
After the safety period has run down the
pilot burner will be turned off.
Attention:
If there are shut-off dampers in the flue
gas tract they must be completely open.
Otherwise there will be a high danger of
low-speed detonation or explosion!
GAS OPERATING MODE
After the flame has developed the load
regulator will be enabled which brings the
burner into its operating position.
The load regulator will now control the
burner automatically between its partial-
load and full-load stages. Depending on
the heat demand, the electric actuator of
the compound control system will be fed
with the OPEN or CLOSE command via
the regulator and thus increase or
decrease the gas and air flow rates.
This compound control system will vary
the positions of the gas control valve and
air damper and thus regulate the gas flow
rate in a linked concept with the air flow
rate. The burner can either be controlled
by a 2-stage sliding or, if a respective
controller is provided, a stepless control
concept.
The stepless control will allow the burner
to be operated at any desired stage
between its partial-load and full-load
positions.
The burner will always be turned off out of
its partial-load position.
The air damper will be closed when the
burner is out of operation and will thus
prevent cold air flowing through the burner
chamber, heat exchanger and chimney.
The interior cooling losses will thus be
greatly minimized.
VLO
311
313
155
151
150
143141 142
178
176
107
CV
184
VL
RL

!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
3 ÷ 4 mm
5 ÷ 6 mm
Ignition Electrode
420011028200
EN
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12
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
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. 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
420011028200
EN
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8
8
9
10
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 CV
184
VL
RL

14 www.ecoflamburners.com
EN
420011028200
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
Tonozzle
Pressure
adjustment
By-pass
plug
inserted
By-pass
plug
removed
Return
Intake from Tank
TWOPIPE
INSTALLATION
Vacuum or
inlet pressure
gauge port
By-passed oil
returned to tank,
or to suction
Intake from Tank
ONE PIPE
INSTALLATION
Return
plugged
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)
TA4
ø 20 mm ø 30 mm
3 65 150
2,5 60 150
2 55 150
1,5 50 150
1 45 150
0,5 40 150
0 35 150
-0,5 28 150
-1 22 150
-1,5 12 150
-2 7 150
-2,5 -- 150
-3 -- 123
-3,5 -- 78
-4 -- 38

15
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EN
420011028200
INSTALLATION
Gas line
GAS VALVES AND INSTRUMENTS
GROUP
The gas valves and instruments group used
with the furnace will be selected according to
the specific requirements to be met by a
burner system.
The following factors must be taken into
account:
• burner output
• furnace back pressure
• gas pressure loss of the burner head
• gas pressure losses of the gas valves and
instruments group
NOTE: Only gas trains assembled by the burner manufacturer and approved in
accordance with the burner test specifications.
EN676 compulsory kit and accessories in order to comply to the safety regulations.
Additional accessories and kits shall be installed by the installer in accordance to the
local safety regulations and codes of practise.
GAS CONNECTION PRESSURE
A minimum connection pressure must be
available upstream of the burner gas valve
to ensure the proper functioning of the
burner.
WARNING: the total gas pressure loss
must always be smaller than the available
gas flow pressure.
For the installation of the valves and
instruments group take care to observe the
mounting instructions supplied by their
manufacturers (these are packed with the
equipment).
The gas line installed to the burner must
be dimensioned in accordance with the
throughput rate and the available
pressure.
For selecting the nominal bore “DN” of the
gas valves and instruments group care
should be taken to observe the flue
resistance of the boiler and the gas
pressure loss of the burner and valves and
instruments group.
GAS VALVES AND INSTRUMENTS
GROUP
The gas valves and instruments group can
be connected directly to the gas feed line.
Take care to observe the correct order of
installation and direction of flow (arrow on
housing).
Check the valves and instruments and
connection pieces for absence of dirt
particles and foreign matter before
installation and initial operation. To provide
effective conditions for start-up make sure
the distance between the burner and the
gas stop valve is as short as possible.
LEAK TEST
The gas line upstream of the burner gas
valves and instruments group must be
installed in accordance with the applicable
regulations, checked for absence of leaks,
vented and certified accordingly by the gas
installation company. The screwed unions
and flanged joints must be checked for
proper tightness (by making a pressure
test). The leak test must be made under
pressure using approved foaming agents
which do not cause corrosion. For steam
boiler furnaces the result of the leak test
must be duly certified.
VENTING
Prior to taking the burner into operation or
after any repair work make sure to vent the
complete gas feed line and the gas valves
and instruments group into the open
atmosphere (e.g. by means of a hose)
taking care to avoid any hazards.
In no case should the gas line be vented
into the heating or furnace chambers.
Make use of a test burner to check the
gas-carrying spaces are free from an
inflammable gas mixture.
SUPPORT
The valves and instruments group must be
supported with a telescopic jacking
member or similar during and after
installation (e.g. on filter and valve).
JOINT
It is recommended to provide an easy to
disconnect joint (with planar sealing faces)
to facilitate repair work on the boiler
(furnace) and allow the boiler door to be
swivelled out if required.
CONNECTION DIAGRAM FOR BURNERS WITH
SEPARATE PILOT (GAS TRAIN SIEMENS VGD...)
M
Air
Gas
313
170
144
142
141
120
150
314
349
M
349
151
155
100
143
Tobesupplied bythe installer
Tobesupplied bythe installer
107
143
Antivibration
coupling
144 Gas governor
150 Batterflyvalve
151Gas train Siemens VGD....
155 Pilot gas train
170 Kit tightness control for pilot gas valve(optional)
313Min.gas pressure switch
314Max.gas pressure switch (optional)
349 Air/gas damper motor

INSTALLATION
Pilot gas train, kit and accessories connection  head loss diagram
KITPRES... Maximum pressure switch assembly
Maximum pressure switch is provided as a kit and
shall be assembled into the main gas train
according to the instructions of the gas train
separate manual.
KITMDRWF50 PID regulator
All progressive burner can be turned modulationg
with the installation of the PID that regulates the
output combined with a probe.
Max Pressure switch
KITPRES50
KITPRES150
GAS PRESSURE LOSS DIAGRAM:
combustion head  platform 380
The diagram provides combustion head
pressure loss. To have pressure loss
combined with the different type of gas
train you must refer to the pressure loss
diagrams.
WARNING:
Note that the head loss diagram
is only indicative and does vary
depending on the setting of the head.
420011028200
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16
PILOT GAS TRAIN CONNECTION
The pilot gas train is already installed to the burner and shall be connected to
the main gas supply line preferebly with flexible pipe.
The pilot gas train is composed of n° 2 safety valves and n°1 gas governor and
filter. Max inlet pressure 1 bar.
WARNING: Pilot gas train must be connected according to the drawing of the
gas line.
GAS VALVES ADJUSTMENT
Note : the pilot valves are pre-adjusted in the factory. To increase or reduce the
gas flow act on the gas governor.
GAS GOVERNOR ADJUSTMENT
The gas governor, with built-in filter, must be installed so as
to stabilise the outlet gas pressure and to avoid that
eventual impurities reach the gas valve. To increase gas
pressure, remove the cover of governor and turn screw C.
Unscrew screw C to reduce pressure, then fit the cover.
Note: the inlet gas pressure must not be higher than the
specified max. gas pressure.
+
–
C
14
16
18
20
22
24
26
28
30
32
34
36
280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620
pressure mbar
OUTPUT - Stm3/h
Multicalor 600.1
Multicalor 500.1
Modulation Kit
KITMD-RWF50
Probe-...

Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 5000.1 PR
MULTICALOR 500.1
MULTIFLAM 500.1
VGD 40.125 no yellow 33 500
3C
FILTER DN 125 35 500
VGD 40.100 no yellow 40 500
FILTER DN 100 45 500
VGD 40.080 no yellow 60 500
FILTER DN 80 75 500
VGD 40.065 no yellow 110 500
FILTER DN 65 140 500
VGD 20.503 no yellow 210 500
FILTER 2" 250 500
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
200 250 300 350 400 450 500 550 600
perdite di carico (rampa gas + testa di combustione / pressure drop (gas train + firing head) mbar
VGD 40.080 + F- DN 80
VGD 40.065 + F- DN 65
VGD 20.503 + F- 2"
natural gas
VGD 40.080
VGD 40.065
VGD 20.503
VGD 40.100 + F- DN100
VGD 40.100
VGD 40.125 + F- DN125
VGD 40.125
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
420011028200
EN
www.ecoflamburners.com 17
3C
flow m3/h
pressure drop (gas train + firing head) mbar

18 www.ecoflamburners.com
EN
420011028200
INSTALLATION
Gas pressure loss diagrams
!PRESSURE DROP includes: “COMBUSTION HEAD + GAS TRAIN + GAS GOVERNOR & FILTER” as per EN676 Standard.
Back pressure of boiler (or other applications) must be added/included in order to have the total min pressure drop.
LEGENDA
Pf: Back pressure of furnace
Pb: Pressure of burner (combustion head + complete gas train)
Pin: Minimum inlet pressure
Burner Gas train Advisable gas
governor & filter Spring color Inlet gas pressure MIN [mbar]
Inlet gas pressure
MAX [mbar] Diagram
BLU 6000.1 PR
MULTICALOR 600.1
MULTIFLAM 600.1
VGD 40.125 no yellow 45 500
4C
FILTER DN 125 50 500
VGD 40.100 no yellow 55 500
FILTER DN 100 60 500
VGD 40.080 no yellow 80 500
FILTER DN 80 100 500
VGD 40.065 no yellow 150 500
FILTER DN 65 180 500
VGD 20.503 no yellow 275 500
FILTER 2" 340 500
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
300 350 400 450 500 550 600 650 700
perdite di carico (rampa gas +testa di combustione / pressure drop (gas train +firing head) mbar
VGD 40.080 +F- DN 80
VGD 40.065 +F- DN 65
VGD 20.503 +F- 2"
natural gas
VGD 40.080
VGD 40.065
VGD 20.503
VGD 40.100 +F- DN100
VGD 40.100
VGD 40.100 +F- DN125
VGD 40.125
4C
flow m3/h
pressure drop (gas train + firing head) mbar

19
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EN
420011028200
INSTALLATION
Electrical connections
!WARNING: Electrical wiring must be carried out with electrical supply disconnected and with burner switch in position OFF.
Electrical supply must correspond to the one shown on the burner label.
APPLICABLE STANDARD
The electrical connection work comprising
all the installation materials, terminals and
earth connections must be carried out in
accordance with the applicable
regulations. For the electrical installation of
the burner care must be taken to observe
the circuit diagram made out for the
furnace system.
The electrical connection of the burner and
gas valves and instruments shall be
entrusted to authorized specialists only.
NOTE: For the installation of the
connection cables care must be taken to
provide cable loops of sufficient length to
allow for the swing-out of the boiler door
and burner.
Make sure after the completion of the
electrical connection work to check the
wiring of the electrical system of the
burner. This should include a check of the
direction of rotation of the burner motor
(fan).
GENERAL WARNINGS:
All applicable electrical safety regulations
must be followed. Failure to correctly
dimension the suitable input power and
earth the equipment may cause damages
to person and compromise the correct
function of the burner therefore the
electrical system shall be checked by
qualifed personnel.
The manufacturer declines all
responsibility for modifcations or
connections different from those shown in
the electrical scheme.
Adapters, multiple plugs and extension
cables may not be used for the
equipment’s power supply.
An omnipolar switch in accordance with
current safety regulations is required for
the mains supply connection.
ELECTRICAL CONNECTION
1) of the burner
- Built-in electrical cabinet
Use cable gland in order to secure the
required level of protection. All the links,
power and control, are connected to the
terminal block of the cabinet. Provide
cables in sufficient length to secure the
rotation of the burner body according to
the assembly.
Check and adjust the size of the
contactors and thermal relays and the
wires section according to the motor and
supply voltage specs.
ATTENTION: Wiring is not supplied.
2) of the gas train
- Connect the plugs pending to the valve:
either on the cabinet,
or on the coupling case on the body of the
burner.
3) of the fuel oil motorpump unit
- Connect the power circuit of the motor
(hanging wires) to the plugs on the fuel oil
valves.
- Check the rotary direction.
The burners are produced with
connections suitable for power supply
230/400 V threephase.
The burners with electric motors of an
output lower or equal to 3 kW can be
adapted to 230 V (please follow the
instructions on the backside); motors with
higher output can only work 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 230/400 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.
PROBES CONNECTION
913121110
SA
QBE....
GLMU1
ACTIVE PROBE CONNECTION
(FOR MODULATING VERSION)
12 1311910
SP
QAE...
MB
PASSIVE PROBE CONNECTION
(FOR MODULATING VERSION)
LEGENDA
SA: active probe
SP: passive probe
230V
400V
fig.1

STARTUP: CHECKING PROCEDURE
420011028200
EN
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20
CHECKS BEFORE COMMISSIONING:
• That the burner is assembled in
accordance with the instructions given
here.
• Setting the combustion components.
• All electrical connections must be correct.
• Check the burner motor for correct
direction of rotation.
• The heat generator must be ready for
operation, and the operating regulations
for the heat generator must be observed.
• The heat generator and heating system
must be filled with water and the
circulating pumps must be in operation.
• The temperature regulator, pressure
regulator, low water detectors and any
other safety or limiting devices that might
be fitted must be connected and
operational.
• The exhaust gas duct must be
unobstructed and the secondary air
system, if available, must be operational.
• An adequate supply of fresh air must be
guaranteed.
• Make a test of the all gas-carrying
elements for absence of leaks.
• 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.
GAS STARTUP
NOTE: Adjust the gas unit according to the
fuel oil unit. Set the fuel selector switch to
its “Gas” position.
• Connect the measuring instruments for
the gas head pressure on the test
connection downstream of the gas damper
and the air pressure on the burner test
connection.
• Open the gas shut-off valve before the
gas-armatures and test the gas pressure
on the pressure gauge
• Set the “Manual-Automatic” selector
switch to “Manual”.
If the gas valves are tested for absence of
leaks, this should be continued until a
positive result is obtained. If a valve is
found to leak, the program will not step
forward to the control box.
The burner will start according to the
program flow of the control box.
Prior to the initial fuel feed start make
a functional test of the burner program
flow:
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. Shut-off upon trouble after expiry of
safety period (see control box).
• Reconnect the valve.
• Unlock the control box.
Gas system:
• Shortly open the gas shut-off valve
before the gas train until pressure is
available and close again.
• Start burner and check program flow for
correct start-up sequence:
1. Fan.
2. Pre-ventilation damper.
3. Check air pressure.
4. Partial-load damper.
5. Ignition.
6. Valves open.
7. Shut-off upon trouble after expiry of
safety period (see control box) or shut-off
because of gas supply failure.
7. The burner will either stop as the gas
valves open (due to gas pressure
decrease) or lock out at the end of the
safety time.
• Unlock the control box.
Recording commissioning data
Test n°1 n°2 n°3 n°4
Date
Model
Type gas
Type oil
Gas calorific value
Oil calorific value
Gas inlet pressure mbar
Adjustment gas pressure
Volumetric gas flow rate Nm3/h
Burner output min kW
Burner output max kW
Flue gas temperature C°
Air temperature C°
CO2 %
CO ppm
NOx ppm
Performance %
Corrective action
Operator name
Company
WARNING