Ecoflam Multicalor 45 Manual de usuario

420010331102

25.05.2011

Multicalor 45

Multicalor 70

Multicalor 100

Multicalor 140

P AB / P AB

BRUCIATORI MISTI GAS + GASOLIO

GAS/LIGHT-OIL DUAL BURNERS

BRULEURS MIXTE GAZ + MAZOUT

QUEMADORES MIXTOS GAS + GASOLEO

!О#$%&%'О(А&&*+ ,О'+-!% ,А.//%.0О1-%(О

FUEL CHARACTERISTICS

Model : Multicalor 45-70-100-140 Gas family - II 2H 3P

G20 G25 G31 G30

Max. pressure mbar 25 - 45 -

Min. pressure mbar 17 - 25 -

Gas Low Heat Value: kcal/Nm38.570 - 22.260 -

Light-oil Low Heat Value = 10.200 kcal/Kg max 1,5° E a 20° C

TECHNICAL FEATURES

OVERALL DIMENSIONS

MODELS A B C D D1 E F G H1 I L M N O

Multicalor 45 PAB 1045 510 535 175 335 555 160 390 600• 190 190 M10 140 165

Multicalor 70 PAB 1045 510 535 175 395 555 180 390 600• 190 190 M10 140 165

Multicalor 100 PAB 1045 510 535 175 395 555 190 390 600• 190 190 M10 140 165

Multicalor 140 PAB 1070 510 560 307 457 555 215 390 600• 190 190 M10 140 165

D = short head D1 = long head

• = ( Optional)

Dimensions (mm)

420010331102 Multicalor 45 ÷ 140 AB/AB

Multicalor 45 70 100 140

Max. Thermal Output kW 500 700 1000 1300

kcal/h 430.000 602.000 860.000 1.118.00

Min. Thermal Output kW 190 250 300 400

kcal/h 163.400 215.000 258.000 344.000

Power.3phase + neutral 50 HzV 230 / 400 230 / 400 230 / 400 230 / 400

Motor kW 0,55 0,74 1,1 2,2

Motor RPM N° 2800 2800 2800 2800

mbar

Multicalor 70 AB Multicalor 100 AB

Multicalor 140 AB

100

100 200 300 400 500 600 700 800 900 1000 1100

200 300 400 500 600 700 800 900 1000 1100 1200 1300 kW

kcal/h

x 1000

Multicalor 45 AB

30 40 50 60 70 80 90 100 110

20 kg/h

WORKING FIELDS

BACKPRESSURE IN COMBUSTION CHAMBER

OUTPUT

D - D1E CB

420010331102 Multica lor 45 ÷ 140 AB/AB

ELECTRICAL CONNECTIONS

All burners are factory tested and set at 400 V 50 Hz three-phase for motors and 230 V 50 Hz monophase with neu-

tral for auxiliaries. If it is necessary to supply the burner at 230 V 50 Hz without neutral,make the necessary altera-

tions referring to the wiring diagram of the burner and check that the termal relay is within the absorption range of

the motor. Also check that the fan motor rotates in the correct direction.

CONNECTION TO THE GAS PIPELINE

Once connected the burner to the gas pipeline, it is necessary to control that this last is perfectly sealed. Also verify

that the chimney is not obstructed. Open the gas cock and carefully bleed the piping through the pressure gauge con-

nector, then check the pressure value trough a suitable gauge. Power on the system and adjust the thermostats to the

desired temperature. When thermostats close, the sealing control device runs a seal test of valves; at the end of the test

the burner will be enabled to run the start-up sequence.

0 - STOP

1 - GASOLIO

2 - GAS

ADJUSTING THE COMBUSTION PROCESS

IMPORTANT: to obtain the right adjustment of the combustion and thermal capacity it is important to analyze the

reducts of combustion with the aid of suitable instruments. The combustion and thermal capacity adjustment is done

simultaneously, together with the analysis of the products of combustion, making sure that the measured values are sui-

table and that they comply with current safety standards. On this matter, please refer to the table and figure below.

THESE OPERATIONS MUST BE DONE BY PROFESSIONALLY-QUALIFIED TECHNICIANS.

NOTE:

ALL SAFETY DEVICES (AIR PRESSURE SWITCH, MINIMUM GAS PRESSURE SWITCH, GAS SOLENOID

VALVES AND GAS GOVERNOR) SHALL BE DULY SEALED AFTER CALIBRATION AND BURNER START

UP BY ECOFLAM’S TECHNICIANS.

ECCESSO D'ARIA (%)

FATTORE D'ARIA

10 10 20 30 40 50 60

100 200 300 400

500

600

700

800

900

1000 2000

1,1

1,15

1,2 1,2 1,2

1,25

1,3

POTENZA UTILE NOMINALE (kW)

SUGGESTED REFERENCE VALUES

Natural Gas

CO29,6%

CO <100 ppm

EXCESS AIR (%)

AIR FACTOR

RATED USEFUL CAPACITY (KW)

OPERATION OF BURNER WITH GAS

PRELIMINARY CHECKS

Before starting up the boiler check the following:

• gas type and feed pressure;

• gas valves closed;

• the seals in the pipe fittings;

• gas pipe breather and input pressure;

• that the cable complies with the diagram and the phase and neutral wires correspond;

• that the burner shuts down when the boiler thermostat opens

• the seal of the boiler furnace which prevents air from entering

• the seal on the flue-boiler pipe fitting;

• the condition of the flue (sealed, free from blockage, etc.).

If all these conditions are present, start the burner. The control device starts the motor to carry out prewashing of the

combustion chamber. During this prewash period (about 30 seconds) the device checks that air pressure is correct via

the air pressure switch. At the end, it supplies power to the transformer and opens the gas valves. The flame must be lit

and stabilize within 3 seconds, which is the device's safety time limit. Check to ensure the flame is lit before placing any

control instrument in the flue. Adjust and check the gas flow necessary for the boiler at the meter. Adjust the air flow

according to the gas flow to obtain correct combustion.

IMPORTANT ADVICE

All adjustable parts must be fixed by the installer after making adjustments. Check flue combustion after each adjust-

ment. The CO2values must be approx. 9.7 (G20) 9.6 (G25 11.7 (G30) 11.7 (G31) and the CO must be less than 75

ppm.

420010331102 Multica lor 45 ÷ 140 AB/AB

CONTROL BOXES LANDIS & STAEFA LGB21/LGB22

The Landis control box starts the fan and begins the pre-purging of the combustion chamber. The air pressure switch

controls the correct operation. At the end of the pre-purging phase, the ignition transformer cuts-in followed by the

opening of the gas valves. In case of missed ignition or accidental shutdown, the ionisation probe cuts-in and set the

burner in lockout mode within the safety time.

Description

1¡ STADIO GAS

VgS

Vg2

Vg1

VG2

VG1

VGS

123

2°STADIO GAS

VgS

Vg2

Vg1

VG2

VG1

VGS

123

GAS CIRCUIT

SUCTION

RETURN

SUCTION

RETURN

1 - PUMP

2 - SAFETY OIL VALVE

3 - LOW FLAME OIL VALVE

4 - HIGH FLAME OIL VALVE

5 - LOW FLAME NOZZLE

6 - HIGH FLAME NOZZLE

7-GAS PRESSURE SWITCH

8-SAFETY GAS VALVE

9-LOW FLAME GAS VALVE

10 - HIGH FLAME GAS VALVE

To calculate the burner’s workin g outp ut, in k W, proce ed as fo llows:

- Check at the meter the quantity of supplied litres and the duration,

in seconds, of the reading, then calculate the burner’s output through

the following formula:

CALCULATION OF WORKING OUTPUT OF THE BURNER

e x f = kW

e = Litres of gas

s = Time in seconds

G20 = 34,02

G25 = 29,25

G30 = 116

G31 = 88

420010331102 Multica lor 45 ÷ 140 AB/AB

ADJUSTMENT OF GAS MINIMUM PRESSURE SWITCH

Unscrew off and remove cover M. - Set regulator N to a value equal to 60%

of gas nominal feed pressure (i.e. for nat. gas nom. pressure = 20 mbar, set

regulator to a value of 12 mbar; for L.P.G. nom. pressure of G30/G31-

30/37 mbar, set regulator to a value of 18 mbar).Screw up cover M

ADJUSTMENT OF THE AIR PRESSURE SWITCH

Unscrew screws A and B and remove cover C.- Set the pressure switch to the

minimum by turning regulator D to position 1.

- Start the burner and keep in low flame running, while checking that com-

bustion is correct. Through a small cardboard, progressively obstruct the air

intake until to obtain a CO2 increase of 0,5÷0,8% or else, if a pressure

gauge is available, connected to pressure port E, until reaching a pressure

drop of 1mbar (10 mm of W.G.). - Slowly increase the adjustment value of

the air pressure switch until to have the burner lockout. Remove the

obstruction from the air intake, screw on the cover C and start the burner by

pressing the control box rearm button.

Note: The pressure measured at pressure port E must be within the limits

of the pressure switch working range. If not, loose the locking nut of screw

F and gradually turn the same: clockwise to reduce the pressure; counterclockwise to increase. At the end tighten

the locking nut.

2,5

0,4

0,6

0,9

3,0

1,5

2,1

1,8

2,4

2,7

1,2

ADJUSTEMENT OF THE COMBUSTION AIR

LANDIS & STAEFA SQN 30 151A2700 AIR DAMPER MOTOR

Remove cover to gain access to the adjusting cams.The cams are to be

adjusted through the suitable key provided for. Description:

I - Limit switch for air damper “High Flame” position adjustment

(Max. power)

II - Limit switch for the air damper position at burner’s shut down

III - Limit switch for air damper “Low Flame” position adjustment

(Min. power)

V - Limit switch for 2nd stage’s solenoid valve opening release

NOTE : Cam V (to allow the 2nd stage’s solenoid valve opening) must be

adjusted to an intermediate position between the Low and High Flame

ones (to an angle approximately 5° greater than the low flame position).

MANUAL RELEASE

SWITCH

GAS TRAIN INSTALLATION AND SETTING INSTRUCTIONS

Fix the gas train to burner body by means of the 4 screws of the flange, pay attention to set correctly the gasket ( O-

ring ).

Connect electrically the gas train with the 6 pole plug.

Switch on the burner (it has already been tested in the factory, so it is pre set on average values) and verify the tightness

of gas train connections made during installation.

Act as follows to adapt the burner output to the boiler.

HIGH FLAME

1. Bring the burner in high flame , air inlet must be set at 75 ° (maximum opening position).

To adjust air capacity operate on the combustion head position.

Just in peculiar case it is necessary to reduce the air flow in high flame closing air intake damper.

2. The position of gas butterfly valve must be lower then 90° ( typically 85°. It is important not get over 90° to obtain

a perfect combustion during passage from high to low flame). Eventually adjust this position acting on the screw “1 “,

after loosening nut “ 2 “.

Gas/Light-oil dual burners must always be adjusted for a first light-oil ignition.

Once having installed the burner, check the following items:

- The burner power feeding and the main line protection fuses

- The correct length of pipes and that the same are sealed.

- The type of fuel, which must be suitable for burner.

- The connection of boiler’s thermostats and all the safeties.

- The motor rotation direction.

- The correct calibration of the motor’s thermal protection.

When all the above mentioned conditions are checked and accomplished, it is possible to go on with burner’s tests.

To turn the switch on the position “1” light-oil. Power the burner. The control box feeds the ignition transformer and

the burner’s motor at the same time, which will run a prepurging of the combustion chamber for about 20 sec.

At the end of prepurging, the control box opens the fuel pump and the 1st stage (Low flame)

solenoid valves, the ignition transformer produces a spark and the burner ignites. After a safety

interval of 3 seconds and a correct ignition, the control box turns off the ignition transformer

and, 10 seconds later, sets the motorised air damper to its maximum opening and opens the

2nd stage solenoid valve (High flame). In case of faulty ignition, the control box switches the

burner into safety condition. In such a case, the manual rearming of the burner shall not take

place before 30 seconds have elapsed from the burner’s safety shutdown. In order to obtain an optimal combustion, it is

necessary adjust the LOW - HIGH flame air flow, according to the instruction given further on. During such a phase,

it will be possible to manually switch between HIGH ( II ) and LOW ( I ) flame and viceversa, through the High/Low

flame switch. At the end of the adjusting phase, leave the switch in position II (HIGH flame).

420010331102 Multica lor 45 ÷ 140 AB/AB

3. Regulate gas capacity in high flame through the gas governor, or operate on the adjustable gas valve.

LOW FLAME

4. Choose the first stage position on the servocontrol ( normally between 10° - 30°) on the basis of the reduced charge

output required and switch the burner to low flame.

5. Regulate gas capacity, to obtain optimal combustion, changing the position of the gas valve disc, act on screw “ 3 “,

after loosen nut “ 4 “.

Final operations

6. Bring the burner in high flame again, if necessary adjust again gas flow (as shown in point n.2).

7. If necessary repeat operations described on point n. 5 and n. 6 until You obtain the exact position of the gas flow

both in high and low flame.

8. Fix the nuts.

0 - STOP

1 - GASOLIO

2 - GAS

LIGHT-OIL

OPERATION OF BURNER WITH LIGHT-OIL FUEL

420010331102 Multica lor 45 ÷ 140 AB/AB

Bitubo dalla sommità del serbatoio

Bitubo in aspirazione

H (m)

Dall'asse

della

pompa

Lunghezza tubazioni

ø 10

ø 12

0,5

3,5

ø 12

ø 14

AS 67

AN 77

(m)

AJ 6

(m)

RSA 60

(m)

RSA 125

(m)

ø 10

ø 12

ø 10

ø 12

ø 15

100

H (m)

Dall'asse

della

pompa

Lunghezza tubazioni

ø 10

ø 12

0,5

3,5

ø 12

ø 14

AS 67

AN 77

(m)

AJ 6

(m)

RSA 60

(m)

RSA 125

(m)

ø 10

ø 12

ø 10

ø 12

ø 15

100

The correct length of pipes is calculated by summing up the length of all vertical and horizontal right sections and

bends. The static suction head will be the distance between the non-return valve and the burner’s pump axle.

The depression must not be greater than 0.45 bar; should it be higher, some damage could occur to the pump, with

consequent increase in mechanical noises and ,eventually, a failure.

MAXIMUM LENGTH OF SUCTION LINES FOR TWO-PIPE SYSTEM

Two-p i p e l ift sy s t e m

Two-p i p e s ipho n f e e d syst e m PIPE LENGTH

PIPE LENGTH

NOZZLE PUMP PRESSURE (bar)

GPH 10 11 12 13 14 15 16

2,50 9,50 9,97 10,41 10,83 11,24 11,64 12,02

3,00 11,40 11,96 12,49 13,00 13,49 13,96 14,42

3,50 13,30 13,95 14,57 15,17 15,74 16,29 16,83

4,00 15,20 15,94 16,65 17,33 17,99 18,62 19,23

4,50 17,10 17,94 18,73 19,50 20,24 20,95 21,63

5,00 19,00 19,93 20,82 21,67 22,48 23,27 24,04

5,50 20,90 21,92 22,90 23,83 24,73 25,60 26,44

6,00 22,80 23,92 24,98 26,00 26,98 27,93 28,84

6,50 23,70 25,91 27,06 28,17 29,23 30,26 31,25

7,00 26,60 27,90 29,14 30,33 31,48 32,58 33,65

7,50 28,50 29,90 31,22 32,50 33,73 34,91 36,05

8,30 31,54 33,08 34,55 35,97 37,32 38,63 39,90

9,50 36,10 37,87 39,55 41,17 42,72 44,22 45,67

10,50 40,06 41,73 43,74 45,41 47,20 48,90 50,50

12,00 45,60 47,80 50,00 52,00 54,00 55,90 57,70

13,80 52,40 55,00 57,50 59,80 62,10 64,20 66,30

15,30 58,10 61,00 63,70 66,30 68,80 71,10 73,60

17,50 66,50 69,80 72,90 75,80 78,70 81,50 84,10

19,50 74,10 77,70 81,20 84,50 87,70 90,80 93,70

21,50 81,70 85,70 89,50 93,20 96,70 100,10 103,40

24,00 91,20 95,70 99,90 104,00 107,90 111,70 115,40

GPH OUTPUT kg/h

NOZZLE FLOW RATE (DELAVAN B - MONARCH PLP)

420010331102 Multica lor 45 ÷ 140 AB/AB

The pump is adjusted during testing and inspection to

12 bar. VERIFY: - That piping system is perfectly sealed; - That the use of

hoses is avoided whenever is possible (use copper pipes preferably); - That

depression is not greater than 0,45 bar, to avoid pump’s cavitation; - That

check valve is suitably designed for the duty; The pump pressure is set at a

value of 12 bar during the testing of burners. Before starting the burner,

bleed the air in the pump through the gauge port. Fill the piping with light-oil to facilitate the pump priming. Start the

burner and check the pump feeding pressure. In case the pump priming does not take place during the first prepurging,

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 not allow the pump to work 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.

PRIMING AND ADJUSTMENT OF OIL PUMP

¡ STADIO GASOLIO

VgS

Vg2

Vg1

VG2

VG1

VGS

123

¡ STADIO GASOLIO

VgS

Vg2

Vg1

VG2

VG1

VGS

123

LIGHT-OIL CIRCUIT

A - HOSE

B - OIL FILTER

C - OIL COCK

1 - PUMP

2 - SAFETY OIL VALVE

3 - LOW FLAME OIL VALVE

4 - HIGH FLAME OIL VALVE

5 - LOW FLAME NOZZLE

6 - HIGH FLAME NOZZLE

7-GAS PRESSURE SWITCH

8-SAFETY GAS VALVE

9-LOW FLAME GAS VALVE

10 - HIGH FLAME GAS VALVE

SUCTION

RETURN

SUCTION

RETURN

SUNTEC AN 77

SUNTEC

SUNTEC D 67 A

SUNTEC

SUNTEC AS 67 B

SUNTEC AS 67 ...

SUNTEC

SUNTEC AS 67 B

SUNTEC AJ 6 C-C

1 - INLET

2- RETURN

3 - BLEED AND PRESSURE GAUGE PORT

4 - VACUUM GAUGE PORT

5 - PRESSURE ADJUSTMENT

6 - TO NOZZLE

420010331102 Multica lor 45 ÷ 140 AB/AB

Pull up the switch on the ter-

minal strip to keep burner in

first stage.

I- Manual low flame position

II -Manual operation : high flame position

Automatic operation : HI-LOW flame position by

the HI-LOW thermostat.

DESCRIPTION OF CONTROL PANEL

1 - Fuse

2 - Termal lock-out lamp

3 - Light-oil working lamp

4 - Gas working lamp

5 - High-low flame switch

6 - Main switch I / O

7 - Gas/Light-oil selector switch:

1- Light-oil operation

2- Gas operation

8 - Lockout disable push button

ADJUSTING THE FIRING HEAD

The adjustment of the com-

bustion head position is car-

ried out in order to

obtain the best combustion

efficiency. When installed for

small output operations,

the head shall be adjusted back.

For maximum operation the position is fully forward.

Steps: loosen the locking screw of A lever. Move the lever to

the needed position. Tighten back the locking screw.

min. max.

MULTICALOR

45-70-100

MULTICALOR

140

NOZZLE CLEANING AND REPLACEMENT

Use only the suitable box wrench provided for

this operation to remove the nozzle, taking

care to not damage the electrodes. Fit the new

nozzle with the same care.

Note: Always check the position of electrodes

after having replaced the nozzle (see illustra-

tion). A wrong position could cause ignition

troubles.

5÷6 mm

3÷4 mm

2 fiamme

REMOVING THE BLAST TUBE

The control of the detector current shall be carried out by plugging a microampe-

rometer with full scale at 1000 µA (D.C.) in series with the UV-cell. If the detec-

tor current is too low verify the connection between phase and neutral of the bur-

ner and the grounding of the burner itself. Minimum required detector current is

200 µA.

LGB 22

QRA

AGQ1.1A27

FLAME DETECTOR SYSTEM CHECK

SW = BLACK

BL = BLU

420010331102 Multica lor 45 ÷ 140 AB/AB

MAINTENANCE

YEARLY CHECKS

The burner’s periodical check (firing head, electrodes etc.) must be carried out by authorised personnel one or two

times per year, depending on the utilisation. Before going on with the maintenance controls of the burner, it should be

advisable to check its general conditions, according to the following steps:

Unplug the burner; close the fuel cock; shut down the gas supply; remove burner’s cover and clean the fan and air

intake; clean the firing head and check the electrode’s position; reassemble all the parts; check the connection’s sealing;

check the chimney; start the burner and check the combustion flue (CO2 = 9.5 ÷ 9.8; O = lower than 75 ppm).

BEFORE EVERY INTERVENTION CHECK:

The electric system is duly powered and the burner is plugged in.

The gas pressure must be the suitable one and the gas cock open.

The control devices must be properly connected.

When all the above conditions are met, start the burner by pressing the lockout enable pushbutton.

Check the burner’s cycle.

THE BURNER DOES NOT START:

Check the ON/OFF switch, the thermostats, the motor and the gas pressure.

The master switch is in position “0”. Fuses are blown out.

The control box is faulty.

THE BURNER RUNS THE PREPURGING AND SWITCHES TO LOCKOUT AT THE END OF CYCLE:

Check the fan and the air pressure.

Check the air pressure switch.

Control box faulty. Ignition transformer faulty.

Check the ignition cable. Electrodes are dirty or in wrong position.

Nozzles are clogged or worn. Filters are clogged. Light-oil pressure is too low.

Combustion air’s flow rate too high related to nozzle output.

THE BURNER RUNS THE PREPURGING BUT DOES NOT IGNITE:

Check the position of the electrodes; check the ignition cable;

Check the ignition transformer;

Check the control box.

THE BURNERS IGNITES BUT SWITCHES TO LOCKOUT AFTER THE SAFETY TIME:

Check phase and neutral for a correct connection.

Check gas solenoid valve.

Check the position of ionisation probe and its connection.

Check the control box.

Check nozzles (clogged or worn).

The photoresistor does not detect the flame.

The filters are clogged. Light-oil pressure too low.

Combustion air’s flow rate too high related to nozzle output.

THE BURNERS IGNITES BUT SWITCHES TO LOCKOUT AFTER FEW MOMENTS:

Check gas governor and gas filter.

Check gas pressure through a manometer.

Check ionization value (min. 200 µA).

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