Sime MACK 3 Quick start guide

2902683 (0)
Manuel d’entretien
Installatie-, gebruiks- en onderhoudsvoorschriften
Installation, use and maintenance instructions
Oil burners
Brûleurs fioul
Stookoliebranders
CODE MODEL - MODELE TYPE
8099000 SIME MACK 3 514 T1R
8099010 SIME MACK 4 515 T3R
8099030 SIME MACK 5 515 T5R
GB
F
NL
One stage operation
Fonctionnement à 1 allure
Eentrapsbranders

4

2683
1GB
INDEX
1. BURNER DESCRIPTION
One stage light oil burner.
1.1 BURNER EQUIPMENT
Flange with insulating gasket . . . .No. 1 Screws and nuts for flange to be fixed to boiler . . No. 4
Screw and nuts for flange . . . . . .No. 1 Flexible oil pipes with nipples . . . . . . . . . . . . . . . . No. 2
Grommet . . . . . . . . . . . . . . . . . . .No. 1 7 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1
1. BURNER DESCRIPTION . . . . . . . . . . . . . 1
1.1 Burner equipment . . . . . . . . . . . . . . . . . . 1
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . 2
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . 2
2.2 Working fields . . . . . . . . . . . . . . . . . . . . . 2
2.3 Overall dimensions . . . . . . . . . . . . . . . . . 3
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . 3
3.1 Boiler fixing . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Hydraulic systems . . . . . . . . . . . . . . . . . . 4
3.3 Electrical wiring . . . . . . . . . . . . . . . . . . . . 5
4. WORKING . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Combustion adjustment. . . . . . . . . . . . . . 6
4.2 Nozzles recommended . . . . . . . . . . . . . . 6
4.3 Electrodes setting . . . . . . . . . . . . . . . . . . 7
4.4 Air damper adjustment . . . . . . . . . . . . . . 7
4.5 Pump pressure . . . . . . . . . . . . . . . . . . . . 7
4.6 Fuel heating . . . . . . . . . . . . . . . . . . . . . . 7
4.7 Burner start-up cycle. . . . . . . . . . . . . . . . 8
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . 8
6. FAULTS / SOLUTIONS . . . . . . . . . . . . . . 9
The burner meets protection level of IP 40, EN 60529.
Burner with CE marking in conformity with EEC directives: EMC 89/336/EEC, Low Voltage 73/23/EEC,
Machines 98/37/EEC and Efficiency 92/42/EEC.
1– Oil pump
2– Control-box
3– Reset button with lock-out lamp
4– Hydraulic jack with air-damper
5– Screws fixing air-damper
6– Flange with insulating gasket
7– Grommet
Fig. 1
D6272
1
2
3
4
6
5
5
7

2683
2GB
2. TECHNICAL DATA
2.1 TECHNICAL DATA
2.2 WORKING FIELDS (as EN 267)
Model MACK 3 MACK 4 MACK 5
Output kg/h 1.4 – 2.2 2.0 – 3.2 2.8 – 3.9
Thermal power kW 16.6 – 26 23.8 – 37.9 33.3 – 46.2
(Hi= 11.86 kWh/kg)
Fuel Light oil, max. viscosity at 20°C: 6 mm2/s
Electrical supply Single phase, ~50Hz 230 V ±10%
Motor Run current 0.7 A – 2850 rpm – 298 rad/s
Capacitor 4 µF
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure: 7 – 15 bar
Absorbed electrical power 0.165 kW 0.185 kW
0.8
0
0.4
Pressure in the combustion
chamber – mbar
Light oil output – kg/h
16 18 Thermal power – kW
D6282
20 22 24 26 28
0.2
0.6
1.81.61.4 2 2.2 2.41.2
Light oil output – kg/h
23 Thermal power – kW25 27 29 31 33 35 37
2 2.2 2.4 2.6 3 3.6
39 41
1.2
0
0.4
D6283
0.2
0.6
2.8 3.2 3.4 3.8 4
43 45 47
0.8
Pressure in the combustion
chamber – mbar
1.0
MACK 3
MACK 4 MACK 5

2683
3GB
2.3 OVERALL DIMENSIONS
3. INSTALLATION
3.1 BOILER FIXING
➤Put on the flange (1) the screw and two nuts, (see fig. 2).
➤Widen, if necessary, the insulating gasket holes (5).
➤Fix the flange (1) to the boiler door (4) using screws (2) and
(if necessary) the nuts (3) interposing the
insulating gasket (5), (see fig. 3).
Model A B C D øE F G
MACK 3 268 229 208 86 89 170 10
MACK 4 - MACK 5 285 249 230 86 89 186 16
Flange Burner
A D C
130
=
G
45°
øE
B
11
F
D6262
=
91
72 72
150
45°
180
D5908
Fig. 2
E9132
1
1
E9131
Fig. 3
4
3
2
2
5

2683
4GB
3.2 HYDRAULIC SYSTEMS
The burner is designed to allow entry of the flexible oil-lines on either side of the burner.
H= difference of level; L= max. length of the suction line; I. D. = internal diameter of the oil pipes.
PRIMING PUMP:
On the system in fig. 5 it is sufficient to loosen the suction gauge
connection (6, fig. 4) and wait until oil flows out.
On the systems in fig. 6 and 7 start the burner and wait for the priming.
Should lock-out occur prior to the arrival of the fuel, await at least 20 seconds
before repeating the operation.
The pump suction should not exceed a maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from the oil. Oil pipes must be completely tight.
In the vacuum systems (fig. 7) the return line should terminate within the oil tank
at the same level as the suction line. In this case a non-return valve is not re-
q
uired. Should however the return line arrive over the fuel level, a non-return
v
alve is required.
This solution however is less safe than previous one, due to the possibility of
leakage of the valve.
It is necessary to install a filter on the fuel supply line.
The standard filter code 6276200 and that one with recirculation
code 6276201 are available on request.
The pump is designed to allow working with two pipes.
In order to obtain one pipe working it is necessary to unscrew the
return plug (2), remove the by-pass screw (3) and then screw
again the plug (2), (see fig. 4).
Before starting the burner make sure that the return pipe-line is
not clogged. An excessive back pressure would cause the
damage of the pump seal.
WARNING:
1- Suction line
2- Return line
3- By-pass screw
4- Gauge connection
5- Pressure adjuster
6- Suction gauge connection
7- Oil valve
8- Auxiliary pressure test point
Fig. 4
D5912
2
3
4
7
6
5
18
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
H
meters
L meters
I. D.
8 mm
I. D.
10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
SYSTEM NOT
IN GERMANY
H
max. 4 m max. 4 m
H
H
H
D6285
Fig. 6 Fig. 7
Fig. 5
H
max. 4 m
D6284
PERMITTED

2683
5GB
3.3 ELECTRICAL WIRING
Fig. 8
E9040
A
CARRIED-OUT IN THE FACTORY
7 pin plug
7 pole socket
Black
White
Blue
Capacitor
Burner-earth
T6A
CONTROL BOX
555SE
~50Hz 230V
D1847
Photoresistance
Oil valve
Hour counter
(230V - 0.1A max.)
Regulating
thermostat
Remote lock-out lamp
(230V - 0.5A max.)
Ignition
electrodes
Start thermostat
Heater
L NPE
Motor
Main switch
Limit thermostat
with manual
resetting
TESTING
Check the shut-down of the
burner by opening the ther-
mostats.
CONTROL BOX
To remove the control-box
from the burner, loosen screw
(A, fig. 8) and pull to the arrow
direction, after removing all
components, the 7 pin plug
and earth wire.
NOTES:
– Wires of 1 mm2 section.
– The electrical wiring carried out by the installer
must be in compliance with the rules in force in the
Country.
DO NOT EXCHANGE NEUTRAL WITH PHASE
WARNING
ACCESS TO THE PHOTORESISTANCE
(See fig. 9)
The photoresistance is fitted directly into the con-
trol-box
(underneath the ignition-transformer) on a
plug-in support.
Ignition
trasformer
Fig. 9
E9102
Photoresistance

2683
6GB
4. WORKING
4.1 COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjustment and test-
ing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO2
concentration in the flue gases, their temperatures and the average temperature of the water in the boiler.
To suit the required appliance output, fit the proper nozzle, then adjust the pump pressure and the air damp-
er opening in accordance with the following table.
ADJUSTMENTS CARRIED OUT IN FACTORY FOR SIME BOILERS
The values shown in the table are measured on a SIME boiler (as per EN 267).
They refer to 12.5% CO2at sea level and with light oil and room temperature of 20 °C.
Table B
APPROXIMATE ADJUSTMENTS FOR INSTALLATION ON OTHER BOILERS
The values shown in the table are measured on a CEN boiler (as per EN 267).
They refer to 12.5% CO2at sea level and with light oil and room temperature of 20 °C.
BOILER BURNER Nozzle Pump
pressure
Burner
output
Air damper
adjustment
Code Model GPH Angle bar kg/h ±4% Set-point
Rondò-Estelle 3 8099000 MACK 3 0.55 60° S 12 2.1 3.7
Rondò-Estelle 4 8099010 MACK 4 0.75 60° W 12.5 2.9 2.9
Rondò-Estelle 5 8099030 MACK 5 0.85 60° W 14 3.5 3.8
4.2 NOZZLES RECOMMENDED:
Monarch type R - NS ; Delavan type W-E
Steinen type H - Q ; Danfoss type H - S.
MAINTENANCE POSITION
Access to the combustion head, electrodes and nozzle, (see fig. 10).
➤Remove the burner out of the boiler, after loosing the fixing nut to the flange.
➤Hook the burner to the flange (1), by removing the combustion head (2) after loosing the fixing screws (3).
➤Remove the electrodes assembly (5) from the nozzle-holder (4) after loosing its fixing screw (B, fig. 11,
page 7).
➤Screw the nozzle (6).
Model
Nozzle Pump
pressure
Burner
output
Air damper
adjustment
GPH Angle bar kg/h ±4% Set-point
MACK 3
0.40 80° 10 1.4 1.7
0.40 80° 12 1.5 1.8
0.50 60° 12 1.9 2.4
0.55 60° 13 2.2 3.5
MACK 4
0.55 60° 11 2.0 1.6
0.60 60° 12 2.3 1.7
0.65 60° 12 2.5 2.2
0.75 60° 12 2.9 2.5
0.85 60° 11.5 3.2 3.2
MACK 5
0.75 60° 11.5 2.8 2.2
0.85 60° 12 3.3 2.5
1.00 60° 12.5 3.9 3.6
E9155
2
54
Fig. 10
1
3
6

2683
7GB
4.3 ELECTRODES SETTING
4.4 AIR DAMPER ADJUSTMENT, (see fig. 12)
The mobile air damper (1) operated by the jack (2) assures the com-
plete opening of the air intake.
The regulation of the air-rate is made by adjusting the fixed air
damper (3), after loosing the screws (4). When the optimal regula-
tion is reached, screw tight the screws (4) to assure a free move-
ment of the mobile air damper (1).
The settings, indicated in the table (page 6), refer to the burner with
its cover fitted and combustion chamber with depression zero.
These regulations are purely indicative.
Each installation however, has its own unpredictable working condi-
tions: actual nozzle output; positive or negative pressure in the com-
bustion-chamber, the need of excess air, etc.
All these conditions may require a different air-damper setting.
It is important to take account of the fact that the air output
of the fan differs according to whether the burner has its
cover fitted or not. Therefore we recommended to proceed as
follows:
➤Adjust the air damper as indicated in the table.
➤Mount the cover.
➤Check smoke number and CO2.
➤Should it become necessary to modify the air output, remove the cover by loosening the screw, adjust
the air damper, remount the cover and finally recheck the smoke number.
4.5 PUMP PRESSURE:
The pump is set in factory according to the value indicated in the table B at page 6.
4.6 FUEL HEATING
In order to assure regular ignition and working also at low temperatures the burner has an oil pre-heater fit-
ted in combustion head. The pre-heater starts when thermostats close and it is indicated by the ignition of
an orange led placed on the control box.
When the required temperature for ignition is reached the thermostat fitted on the nozzle holder starts the
burner the orange led switches off, the green led switches on and the motor starts. The pre-heater remains
energised during working and cuts out when burner shuts-down.
Before removing or assembling the
nozzle, loosen the screw (B, fig. 11)
and move the electrodes ahead.
ATTENTION Fig. 11
2–2.5 mm
4±0.3 mm
IMPORTANT:
THESE DIMENSIONS
MUST BE OBSERVED
D5230
B
Fig. 12
4
3
D6286
4
12

2683
8GB
4.7 BURNER START-UP CYCLE
Lock out is indicated by a lamp on the control box (3, fig. 1, page 1).
5. MAINTENANCE
Burner requires a periodic maintenance carried out by a qualified and authorized technicians.
Maintenance is essential for the reliability of the burner, avoiding the excessive consumption of fuel and
consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to the
burner acting on the main switch of the system.
THE BASIC CHECKS ARE:
➤Check that there are not obstructions or dents in the supply or return oil pipes.
➤Clean the filter in the oil suction line and in the pump.
➤Clean the photoresistance, (see fig. 9, page 5).
➤Check for correct fuel consumption.
➤Replace the nozzle (see fig. 10, page 6) and check the correct position of electrodes (fig. 11, page 7).
➤Clean the combustion head in the fuel exit area, on the diffuser disc.
➤Leave the burner working without interruptions for 10 min. and set rightly all the components stated in
this manual. Then carry out a combustion check verifying:
●Smoke temperature at the chimney; ●Content of CO2( % ); ●Content of CO (ppm);
●Smoke value according to opacity smokes index according to Bacharach scale.
Thermostat
Heater
Green led and motor
Ignition transformer
Oil valve
Flame
~ 120 s
D5927
~ 120 s~ 12 s
Lock-out lamp
~ 12 s~ 5 s
Lock-out due to failure to light
C
Normal
Orange led
C

2683
9GB
6. FAULTS / SOLUTIONS
Here below you can find some causes and the possible solutions for some problems that could cause a failu-
re to start or a bad working of the burner.
A fault usually makes the lock-out lamp light which is situated inside the reset button of the control box
(3, fig. 1, page 1).
When lock out lamp lights the burner will attempt to light only after pushing the reset button. After this if the
burner functions correctly, the lock-out can be attributed to a temporary fault.
If however the lock out continues the cause must be determined and the solution found.
WARNING
The manufacturer cannot accept responsibility for any damage to persons, animals or property due to error in
installation or in the burner adjustment, or due to improper or unreasonable use or non observance of the
technical instruction enclosed with the burner, or due to the intervention of unqualified personnel.
FAULTS POSSIBLE CAUSES SOLUTION
All led are off and
the burner does not
start.
Lack of electrical supply.
Check presence of voltage in the
L1 - N clamps of the 7 pin plug.
Check the conditions of the fuses.
Check that thermostat limit is not
lock out.
The connections in the control box are
wrongly inserted.
Check and connect completely all the
plugs.
The orange led is al-
w a y s o n a n d t h e
b u r n e r d o e s n o t
start.
Heater and start thermostat are faulty. Replace them.
The green led is on
and the burner re-
m a i n s i n t h e p r e -
purge phase.
The photoresistance sees false light. Eliminate the light.
Burner runs normal-
ly in the prepurg e
and ignition cycle
and locks out after 5
seconds ca.
The photoresistance is dirty. Clear it.
The photoresistance is defective. Change it.
Flame moves away or fails.
Check pressure and output of the fuel.
Check air output.
Change nozzle.
Check the coil of solenoid valve.
Burner starts with an
ignition delay.
The ignition electrodes are wrongly
positioned.
Adjust them according to the
instructions of this manual.
Air output is too high. Set the air output according to the
instructions of this manual.
Nozzle dirty or worn. Replace it.

Fonderie Sime S.p.A. - via Garbo, 27 - 37045 Legnago (Vr) - Italy
Tel. [phone] - Export Division fax number +39/0442 631293 - Sime Service fax number +39 /0442 631292