Ecoflam OILFLAM 700.1 PR User manual

EN
OILFLAM 700.1 PR TC 230-400-50
OILFLAM 800.1 PR TC 230-400-50 3142127
OILFLAM 1000.1 PR TC 230-400-50
OILFLAM 1200.1 PR TC 230-400-50
Technical data
Operating instructions
Electric diagrams
Spare parts list
OILFLAM 700.1 PR
OILFLAM 800.1 PR
OILFLAM 1000.1 PR
OILFLAM 1200.1 PR
www.ecoflam-burners.com
HEAVY OIL BURNERS

INDEX
420010513700
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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 fields 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
Heavy oil preparating ring 11
Oil connection 12
Heavy oil preparating ring scheme 13
Feeding line for heavy oil 14
Electrical connections 15
Start-up: checking procedure 16
Exhaust gas test 17
Start-up 18
Fuel selection - Start-up 18
Adjusting the max air flow rate 18
Firing head setting 18
GEFRAN Setting 19
Adjusting the max oil flow rate 20
Servomotor SQM50 - Air damper motor pre-setting 20
Adjusting the pump pressure 20
Adjusting the intermediate burner capacity 21
Servomotor SQM50 - Final setting 21
Maintenance program 22
Troubleshooting instructions 24
Operating troubles 25
Appendix 26
Control box - Damper actuators 26
Fluidics nozzle chart 27
Bergonzo nozzle tables 28
Pump and pressure regulators 31
Electrical diagrams 34
Spare parts list 37
OILFLAM 700.1
OILFLAM 800.1
OILFLAM 1000.1
OILFLAM 1200.1
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 14000 kW
10000 11000 12000 13000

GENERAL WARNINGS - CONFORMITY DECLARATION
OILFLAM burners are designed for
the combustion of heavy 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
OILFLAM 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.
Declaration of conformity
for dual fuel burners
We,
Ecoflam Bruciatori S.p.A.
declare under our sole responsibility
that the products:
OILFLAM 700.1 PR
OILFLAM 800.1 PR
OILFLAM 1000.1 PR
OILFLAM 1200.1 PR
conform to the following standards:
EN 267: 2010
EN 60335-1: 2008
EN 60335-2-30: 2006
EN 60335-2-102: 2007
EN 55014-1: 2008 + A1: 2009
EN 55014-2: 1998 + A1: 2001 + A2: 2008
These products are built in accordance
with the following directives
2006/42/EC Machinery directive
2004/108/EC EMC directive
2006/95/EC Low voltage directive
CE certification, when required, must be
done at installation site by the end user
Resana, 20th December 2010
M. PANIZZON
420010513700
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BURNER DESIGNATION
MODULAR DELIVERY SYSTEM
OILFLAM 300.1 PR TC 230-400-50
OILFLAM Heavy oil
RANGE NAME BY FUEL TYPE
OILFLAM 300.1 264 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
MD 2 stages modulating mechanical with PID
E2 stages modulating electronic
OPERATION TYPE
TC Short head
TL Long head
HEAD TYPE
Heavy oil
FUEL
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4
230-400V/50Hz 230-400 Volt, 50 Hz
ELECTRICAL POWER SUPPLY
Heavy oil burners
All heavy oil burners are delivered with electrical pre-heater preassembled into the
burner body, 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
Control panel
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RWF 40
HLF
HLR
HLBT
SAMA
RA
GEFRAN
SA
S.RSA
SAL
0=STOP
1=UP
2=LOW
3=AUTO
0: OFF
1: ON
Modulating unit RWF 40 (optional)
Main switch I/0
Working lamp
GEFRAN regulator
Selector (0-STOP / 1-Hight Flame /
2-Low Flame / 3-Automatic)
Resistor lamp
Lock-out lamp
Reset button
Auxiliaries Resistances switch
LEGENDA
1. Housing
2. Electrical control panel
3. Blower motor
4. Pump
6. Blast tube
8. Burner fixing flange
9. Air flap regulation
11. Silencer
12. Lifting eyebolts
14. Mechanical cam oil
15. Servomotor
18. Oil pressure regulator
1
6
8
9
11
3
4
18 15
14
12
2

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420010513700
TECHNICAL DATA
MODEL OILFLAM 700.1 OILFLAM 800.1 OILFLAM 1000.1 OILFLAM 1200.1
Thermal power max.
kW 7.500 8.500 10.500 12.500
kcal/h 6.465.000 7.328.000 9.052.000 10.776.000
kg/h 660 748 924 1.099
Thermal power min.
kW 2.417 2.750 3.300 4.367
kcal/h 2.096.000 2.385.000 2.862.000 3.788.000
kg/h 214 243 292 386
Operation mode Type Progressive mechanical heavy oil - Modulating with PID
Regulation ratio nominal Type 1÷3 HEAVY OIL
Fuel Type Heavy oil (L.C.V. 9.800 kcal/kg max visc. 50°E at 50°C) - (S) Hu = 10,97 kWh/kg
Emission class std N/A
Control unit Type LAL
Air regulation Type Air flap Air flap Air flap Air flap
Air flap control with servomotor Model SQM50
Air pressure switch mbar 2,5…50 mbar
Flame monitoring Type photoresistor
Ignitier Model BRAHMA / COFI
Motor kW 15 18,5 22 37
Rpm N° 2.800 2.800 2.800 2.800
Voltage V/Hz 230/400 V - 50 Hz
Total power consumption operation W45.200 49.000 71.000 98.000
Weight body BBCH Kg 683
Electrical panel protection level IP IP55 IP55 IP55 IP54
Sound pressure level
without silencer dB(A)
Lab
tests
95 95,6 96,5 96,5
Sound pressure level
with silencer 87,9 88,8 89,1 89,1
Ambient temperature storage
Min/Max
-20°…+70° C
Ambient temperature use -10°…+60° C
Oil pump Model TA5 TA5 T5+TV T5+TV
Oil pump motor kW - - 5,5 kW 5,5 kW
Nozzles Type according to the output requested
Fuel thermo regulator Type GEFRAN
Electrical pre-heater kW 30 30 44 30 x2

OILFLAM 700.1
OILFLAM 1200.1
OILFLAM 1000.1
OILFLAM 800.1
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420010513700
WORKING FIELDS
TEST BOILER - FLAME DIMENSIONS
The burner/boiler matching does not pose
any problems if the boiler is CE type-
approved.
If the burner must be combined with a
boiler that has not been CE type-approved
and/or its combustion chamber dimensions
are clearly smaller than those indicated in
diagram, consult the manufacturer.
The firing rates were set in relation to
special test boilers, according to 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
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 LENGHT HEAVY OIL BURNERS
FLAME DIAMETER HEAVY OIL BURNERS
kg/h
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
kg/h
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Working fields
The working field shows burner
output as a function of
combustion chamber pressure.
It corresponds to the maximum
values specified by EN 267
measured at the test fire tube.
Boiler efficiency should be
taken into consideration when
selecting the burner.
Calculation of
burner output
QF= Burner output (kW)
QN= Rated boiler output(kW)
η= Boiler efficiency (%)
QF= QNx 100
η

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420010513700
OVERALL DIMENSIONS
Packaging (only burner)
X Y Z kg
OILFLAM 700.1 1750 2380 1460
OILFLAM 800.1 1750 2380 1460 883
OILFLAM 1000.1 1750 2380 1460
OILFLAM 1200.1 1750 2380 1460
X
Y
Z
A B C D D1 E F G G1 H1 I L M
OILFLAM 700.1 1390 660 730 525 - 1240 385 775 520 1270 460 460 M20
OILFLAM 800.1 1480 660 820 535 - 1240 430 775 520 1270 460 460 M20
OILFLAM 1000.1 1505 685 820 535 - 1240 460 775 520 1270 460 460 M20
OILFLAM 1200.1 1750 800 950 535 - 1410 460 775 900 1270 460 460 M20
R R1 S S1
OILFLAM 7-1200.1 360 360 290 400
Dimensions (mm)
D = Short head
D1= Long head
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
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.
640
RR1
SS1
M
N °4 fori Ø23
640
RR1
SS1
M
N °4 fori Ø23
ED - D1
F
G1
C
B
A
1
0
2
3
I
O
H1
G

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420010513700
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 be started. After the
program has run down the burner will start.
The air damper is closed when the burner
is 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. Shortly after the
pre-ventilation 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. 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.
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.
Zündung/Ventile
Pumpe
Teillast
EIN
Betriebsstellung
Leistungsregulierung
Freigabe
Vollast
AUS
Zündung/Ventile
Pumpe
Teillast
EIN
Freigabe
Leistungsregulierung
Betriebsstellung
Vollast
AUS
Oil control:
2-stage sliding Stepless
Full load
Operatingposition
Load regulator
Release
Partial load
Ignition/valves
Pump
Full load
Operatingposition
Load regulator
Release
Partial load
Ignition/valves
Pump
ON OFF ON OFF

5 ÷ 6 mm
3 ÷ 4 mm
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420010513700
!WARNING: handling and moving operations must be carried out by specialised personnel.
Use the eyebolts to lift the burner in order that it will not overturn and fall down.
INSTALLATION
Fitting the burner to the boiler
To perform the installation of the burner
into the boiler drill the boiler plate
according to the dimension given on this
manual and place the burner towards it by
lifting and moving the burner by means of
eyebolts.
Place the gasket on the burner flange and
install the burner into the boiler by fixing
nuts into the bolts.
The space between the blast tube and the
boiler lining must be sealed with
appropriate insulating material.
Position of the electrodes - nozzle installation
Ignition Electrode
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%.
SAL
01
MAIN SWITCH
0 - OFF
1 - ON

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!WARNING: make sure that the feeding line is properly dimensioned and is in compliance the local safety rules and code of practise in the
country of installation.
INSTALLATION
Heavy oil preparation ring, kit and accessories connection
All installations using heavy oil burners have
to be completed with a forced oil preparation
ring in order to guarantee oil supply to the
burner at suitable temperature and pressure
(temperature +/- 50° C, pressure 3 bar).
For heavy oil with more than 50°E at 50°C
Ecoflam recommends to lower the maximum
output of 10-20% and work in excess of air in
order to grant better operation and reduce
maintenance.
Installation with heavy oil must provide to
the burners:
- CONSTANT PRESSURE
- CONSTANT TEMPERATURE
To size correctly the ring for the heavy oil supply
consider the diagram of the pre-heating
temperature of the heavy oil according to
viscosity and the pump pressure according to
temperature.
Ecoflam heavy oil and dual fuel heavy oil
burners do have in the electrical panel the fuel
temperature device GEFRAN that adjusts the
temperature of the heavy oil and grants
temperature stability.
Service tanks + Pumps units.
Quotation on request depending on
output and configuration.
Ecoflam heavy oil burners are delivered
with electrical pre-heater assembled into
the burner body or in a separate skid.
Additional Forced system “OIL RING”
can be design and delivered assembled
on skid/frame or offered as single
component.
I. Feeding and filtering system
II. Fuel heating system for reducing oil viscosity plus service tank
III. Forced oil supply system “RING”
STANDARD SYSTEM COMPOSITION FOR LIGHT OIL
AND HEAVY OIL HEATING AND PUMPING UNIT
ACCESSORIES
OIL PREPARATION UNIT
1
2
3
4
5
0
bar 6
05100105
Oil temperature
C°
Pump inlet pressure
RACOMMENDED OIL SUPPLY PRESSURE
Modulation Kit
KITMD-RWF40
Probe-...
KITMD-RWF40 PID regulator
All progressive burner can be turned modulationg
with the installation of the PID that regulates the
output combined with a probe.

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420010513700
!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
HEAVY OIL FEEDING
176: oil pump
178: solenoid valve
180: nozzle rod
184: output control valve
311: return oil pressure switch
CV: check valve
RL: return line
VL: suction line
VLO: working oil valve
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.
When taking the burner into operation pro
ceed by gradually increasing the pressure
to operating level (25 bar).
CHECKING OIL RING PRESSURE
Refer to diagram at page 11 to define
racommended oil pressure.
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
VLO
311
178
180
176
184
VL
RL
CV
CV
VLO
176
VL
178
180
RL
VL
113
184
CV
CV

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INSTALLATION
Heavy oil preparation ring scheme
Hot water
Hot
water
Return
hot water pipe
hot water pipe
oil pipe oil pipe
heating cableinsulation
section
13
12
LEGENDA
1 - Burners
2 - Service tank
3 - Electric heaters
4 - Safety and operation thermostat
5 - Level switch (working + safety )
6 - Heating coil
7 - Self-cleaning oil filter
8 - Load pumps
9 - Ring pumps
10 - Oil ring control pressure device
11 - Heating cable
12 - Main heavy oil storage tank
13 - Heating coil

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INSTALLATION
Feeding line for heavy oil
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 undersuction
Oil underpressurePressure
gauge port
Tonozzle
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 totank,
or tosuction
Intake from Tank
ONEPIPE
INSTALLATION
Return
plugged
SUNTEC T
Pressure
gauge port
To
pressure
regulating
valve
Plug inserted between
high pressure and shaft seal
Intake
from Tank
Vacuum or
inlet pressure
gauge port
Oil underpressure
Oil undersuction
Intake from Tank
To
pressure
regulating valve

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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 multi-pole 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 fuel oil motor-pump unit
- Connect the power circuit of the motor
(hanging wires) to the plugs on the fuel oil
valves.
- Check proper motor rotation.
The burners are produced with
connections suitable for power supply
400 V three-phase.
The burners with electric motors of an
output lower or equal to 7,5 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
7,5 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);
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
STAB
50 Hz 400 V
50 Hz 400 V
RP
TP
STS
TV
TP
STC
HLB
B
RA RA
HLF
Q1
Q2
PE
S
T
R
R
S
T
PE
N
N
13 503 N51 2221N858476 84 5 9 10 11R1TSR N S1 T1 N 1 2 12
PROBES CONNECTION
9 13
12
11
10
SA
QBE....
GLM U1
ACTIVE PROBE CONNECTION
(FOR MODULATING VERSION)
12 13
11
9 10
SP
QAE...
MB
PASSIVE PROBE CONNECTION
(FOR MODULATING VERSION)
230V
400V
fig.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 7.5 kW.
For more information, please contact the
Ecoflam staff.

16 www.ecoflam-burners.com
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420010513700
START-UP: CHECKING PROCEDURE
CHECKS BEFORE COMMISSIONING:
• That the burner is assembled in
accordance with the instructions given
here.
• Setting the combustion components.
• All electrical connections must be correct.
• Check the burner motor for correct
direction of rotation.
• The heat generator must be ready for
operation, and the operating regulations
for the heat generator must be observed.
• The heat generator and heating system
must be filled with water and the
circulating pumps must be in operation.
• The temperature regulator, pressure
regulator, low water detectors and any
other safety or limiting devices that might
be fitted must be connected and
operational.
• The exhaust gas duct must be
unobstructed and the secondary air
system, if available, must be operational.
• An adequate supply of fresh air must be
guaranteed.
• 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.

17
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420010513700
QF= QN= 1000 = 1136 kW
Volumetric gas flow rate at STP:
vBn = QN= 1000 = 125 m3/h
Volumetric gas flow rate in operating
condition:
vBB = vBn
T= pn=
= 125 273+15 1013,25 = 123,9 m3/h
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.
Secondary air will falsify the measured
results
Check that the exhaust gases have a
residual oxygen (O2) content as low as
possible and a carbon dioxide (CO2)
content as high as possible.
The carbon monoxide content of the
exhaust gases must be below the currently
applicable specifications in all load stages.
In the fuel oil combustion mode the
permissible soot number in the exhaust
gas is not allowed to be exceeded
DETERMINING THE VOLUMETRIC GAS
FLOW RATE
The thermal furnace output of a boiler (QF)
is the amount of heat supplied with the gas
in a unit of time.
When taking the burner into operation the
volumetric fuel flow rate should be
selected according to the nominal thermal
capacity of the boiler.
Example:
Nom. thermal output QN1000 kW
Boiler efficiency nK0,88
Calorific value of gas Hu9,1 kWh/m3
Gas pressure pU100 mbar
Barometer reading pamb 980 mbar
Gas temperature
relative tgas 15°C
Gas temperature
absolute T (tgas+273)
Standard atmosferic
pressure pn1013 mbar
0,88
nK
Hu*nK9,1*0,88
273 pamb+ pu
273 980+100
Recommended combustion parameters
Ratio between O2- and CO2-
for natural gas H (CO2max = 11,7%)
Ratio between O2- and CO2-
for light oil EL (CO2max = 15,40%)
Ratio between O2- and CO2-
for heavy oil S (CO2max = 15,60%)
O2= 21 CO2max - CO2gem = %
CO2max
WARNING: if the installation is above sea level the output of the burner
vary base on the diagram.
The regulation of the burner in this case shall take into account the
reduced power of the burner due to the missing air.
Fuel Recommended
(%) CO2
Recommended
(%) O2
Natural gas 10 ÷ 9 3,1 ÷ 4,8
Light oil 13 ÷ 11,5 3,3 ÷ 5,3
Heavy oil 12,5 ÷ 11 4,2 ÷ 6,2
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5 10 15 20 25 30 35 40 45 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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420010513700
START-UP
Select the oil operation in order to proceed with start up on the oil side. On the selector put the operation on minimum capacity.
Adjusting the maximum air flow rate
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 servomotor 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 go step by step using the selector on positon 0 to stop the flame, from the low flame to the high flame in order to have
a stable flame. For each position from 0 to 90° do oil setting adjusting oil return pressure as described in the next pages. When the
servomotor arrives at 90° you have completed first tuning of air and oil flow according to the boiler capacity required. Check the
combustion values and adjust the oil pressure.
Firing head setting
In order to adjust the maximum air flow rate see figure with
selector in maximum operation. Loosen the nut holding the air
damper transmission rod and correct air flow till you reach
the combustion values suggested by reading the value on the
combustion analyser. If you do not reach acceptable air flow
rate you shall adjust the firing head. Move the blast tube
backwards to increase air flow forward to reduce.
+
+
-
-
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.
Fuel selection - Start-up
SAMA
3=AUTO
2=LOW
1=UP
0=STOP
01
2
3
0 : operating elements locked in an intermediate
position.
1 : operation on maximum capacity
2 : operation on minimum capacity
3 : automatic operation
+-
MAIN SWITCH
0 - OFF
1 - ON
SAL
01
KMV
KMP
!KMP - KMV contactor: check the oil pump motor and air fan motor
rotation and keep KMP pressed till the oil circuit is loaded.
If the rotation if not correct invert the two phases on the power supply.

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START-UP
Gefran setting
The display shows oil temperature.
The 4 leds are related to the following functions:
• Out 1: contact driving working heaters
• Out 2: contact driving upper heaters KMRL1
• Out 3: contact driving upper heaters KMRL2
• Out 4: burner start driving contact (as the oil reaches this temp the pump is activated)
The temperatures are already properly factory setted:
• Out 1 (113°)
• Out 2 (115°)
• Out 3 (120°)
• Out 4 (105°)
WARNING: Burner will start only when the first three led of the temperature will be off so that heavy oil will be in temperature.
To modify factory temperature setting act as follow:
• press key “F”
• the led Out 1 starts to ash, if You need to modify minimum oil temperature press increase or decrease button, after confirm the new
value pressing again “F”
• if you need to modify an other temperature press again “F” untill You the relevant led ashes.
Please take care: if key “F” is pressed for a too long time, you enter in “configuration level” phase 1, (see “CF1” on the display);
these parameters are factory setted and they have not to be modified: if you enter this function – you see CF1 ashing on the display –
wait 10 seconds until the regulator automatically goes out from “configuration level”.
Increase key
Decrease key
“Function” key
Display
ADJUSTMENT OF FUEL THERMOSTATS
Inside the electrical panel there is a safety termostat
that is set up at 160°C.
Said adjustments can be slightly modified following
the type of fuel and particular uses.

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START-UP
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 heavy 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.
NOTE: before starting the burner, check that the return pipe is open. An eventual obstruction could damage the pump sealing device.
SUNTEC TA....
1 - INLET
2 - RETURN
3 - BLEED AND PRESSURE
GAUGE PORT.
4 - INLET GAUGE PORT
5 - PRESSURE ADJUSTMENT
6 - TO NOZZLE
1
2
5
6
34
Servomotor SQM50 - Air damper motor pre-setting
The cams of the servomotor are set from the factory in order to start the burner and
reach the maximum output.
The following setting are the standard one:
I. High flame position 90° (maximum value 70°).
II. Air flap position in standby 0° (minimum value 0°).
III. Ignition position 15°.
IV. Low flame position 40° (can be modified depending on the minimum output of the boiler).
V. To VIII not used
Cam VIII
is never used
1
436
TV
2
5
SUNTEC T.... + TV
Adjusting the valve TV
1. Remove the cap A of the pressure regulating valve TV.
2. Loosen the fixing nut B and use an Allen wrench on the screw C to
adjust the delivery oil pressure. To increase the pressure turn clockwise, to
decrease the pressure turn anticlockwise.
3. Tighten the nut B and pay attention not to turn also the adjusting screw.
4. Screw on the cap A, back to its previous position.
A
B
C
B
A
12
34