Ecoflam Multicalor 300.1 Manuel utilisateur

techniques for energy saving

GASTEC

GAS / LIGHT-OIL DUAL BURNERS

LB1203

24.10.2003

Multicalor 300.1

Multicalor 400.1

Light oil / Natural gas 40÷300 mbar

MODEL

pag.2

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

TECHNICAL FEATURES : Multicalor 300.1 Multicalor 400.1

Max. thermal output kcal/h 2.586.000 3.362.000

kW 3.000 3.900

Min. thermal output kcal/h 543.100 754.300

kW 630 875

Max flow rate Nm3/h 301 392

Min flow rate Nm3//h 63 170

Natural gas supply pressure mbar 40÷300 40÷300

Max. light oil flow rate kg/h 253 329

Min. light oil flow rate kg/h 68 143

Voltage, 3phase + neutral, at 50 Hz V 230/400 230/400

Motor kW 5,5 7,5

Motor’s RPM N° 2800 2800

Fuels: Nat. Gas LHV = 35,9 Mj/Nm3 = 8.570 kcal/Nm3; Light Oil LHV = 10.200 kcal/kg max. 1,5° at 20 °C

mbar

1500 2000 2500 3000 3500 4000

1000

-2 kW

500

Multicalor

300.1 Multicalor

400.1

Multicalor

300.1 Multicalor

400.1

WORKING FIELDS

OVERALL DIMENSIONS

SUNTEC

ED - D1

0- STOP

1- GASOLIO

2- GAS

AUTO

MODEL A B C D D1 E F G H I L M

MULTICALOR 300.1 1351 453 898 328 528 755 290 466 280 315 315 M16

MULTICALOR 400.1 1351 453 898 363 563 755 320 466 280 315 315 M16

D = short head D1 = long head

Burner output

Backpressure in combustion chamber

pag.3

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

GAS TRAIN ASSEMBLY

1 . Main gas pipe

2 . Cut-off valve

3 . Antivibrating coupling

4 . gas rfilter

5 . Gas governor

6 . Safety gas valve

7 . Leakage control device

8 . Working gas valve

9 . Min. gas pressure switch

MODULAIR P 3000

MODULAIR P 4000

5312 478

To be supplied

by the installer

12 3 4 5

To be supplied by the installer 1 - main gas pipe

2 - ball valve

3 - antivibration coupling

4 - gas filter

5 - working gas valve

6 - actuator

7 - actuator

8 - leakage control

9 - gas pressure switch

12 34

5 - gas pressure switch

6 - safety gas valve

7 - leakage control

8 - working gas valve

1 - main gas pipe

2 - ball valve

3 - antivibration coupling

4 - governor

ELECTRICAL CONNECTIONS

All burner motors are tested at 400 V 3phase at 50 Hz, whilst auxiliaries are tested at 230V 1phase at 50 Hz.

Should it be necessary to power the burners at 230V/50Hz 3phase without neutral, carry out the necessary modifications accor-

ding to the burner’s wiring diagram, and check that the thermal relay is within the absorption field of the motor.

CONNECTION TO GAS PIPE

Once the burner has been connected to the gas supply, check that this last is perfectly sealed. Also verify that the chimney is not

clogged. Open the on-off valve and carefully bleed the piping through the pressure port, then check the pressure value through

a suitable pressure gauge. Turn on the system and adjust the thermostats to the needed temperature. When the thermostats

close, the leakage control device runs a valves leakage test, then enables the burner to start the ignition cycle.

OPERATION OF BURNER WITH GAS MULTICALOR 300.1-400.1

Before starting the burner, make sure it is mounted correctly. Then check connections are correct according to the diagram and

piping is appropriate to the system. Before connecting the burner to the electricity supply, make sure voltage corresponds to

burner plate data. The connection diagram and start-up cycle are shown separately. For wiring from control box to burner, see

the enclosed connection diagram. Pay particular attention to neutral and phase connections : never exchange them!. Vent air

and impurities of gas pipe. Check gas pressure conforms to the limits stated on the burner plate when connecting a master

gauge to the test port provided on the burner. Blower motor starts and pre-purging begins. Since pre-purging has to be carried

out with the max. air delivery, the burner control circuit turns the air damper to the max. delivery

position by the air servocontrol in approximately 30 seconds time. When the servocontrol is fully

open, a signal to the electronic control unit starts the 66 seconds pre-purge cycle. At the end of the

prepurging time, the air servocontrol gets to the Low Flame position so that burner ignition is ensu-

red at min. output. Simultaneously the ignition transformer receives voltage and after 3 seconds (pre-

ignition) opens the gas valve. Fuel flows to the combustion head and ignites, being governed by the

gas firing butterfly valve. Two seconds after gas valves have opened, the ignition transformer is excluded from the circuit. In

0 - STOP

1 - GASOLIO

2 - GAS

LIGHT-OIL

The control box starts the burner

fan, to carry out the prepurging of

the combustion chamber, and

cheks the vent air pressure through

the air pressure switch. At the end

of prepurging, the ignition tran-

sformer cuts-in and generates a

spark between the electrodes. At

the same time the two gas valves

open (Vs safety valve and Vl working valve). The total safety, in case of missed ignition or casual burner's flame-out,

is granted by a ionisation probe which cuts-in and sets the burner shutdown within the safety time. In case of gas

lack or a major pressure drop, the minimum air pressure switch shuts down the burner.

LANDIS & STAEFA, Model LFL1.622 OPERATING CYCLE

–

AIR EXCESS (%)

AIR FACTOR

THERMAL POWER (kW)

10 10 20 30 40 50 60

100 200 300 400

500

600

700

800

900

1000

1,1

1,15

1,2 1,2 1,2

1,25

1,3

2000 3000

5000

4000

6000

Natural Gas

CO29,6%

CO <100 ppm

Ref. Description

t1 Duration Waiting time for confirmation

t2 of air pressure

t3 Preventilation time

t4 Safety time

t5 Pressurizing time

Time for enabling operation of the

main gas valve on minimum capacity

t6 Time for enabling operation of the

main gas valve on maximum capacity

Duration

8”

66”

2”

4”

10”

Rivelazione

di fiamma

Spia di blocco

Valvola gas

Serranda aria

Serranda gas

Trasformatore

di accensione

Pressostato aria

Motore ventilatore

Pressostato gas

min

100%

t1 t2

t6t5

Ciclo di funzionamento normale Ciclo di funzionamento

in mancanza di fiamma all'accensione

t1 t2

Consenso

min./max. potenza

Gas manostat

Fan motor

Air Switch

Ignition transformer

Gas valve

Min/max capacity

enabling device

Air damper

Gas damper

Flame detector

Cut-out pilot lamp

Normal operating cycle Operating cycle in the event of

ignition failureNormal operating cycle

ADJUSTING THE PRESSURE REGULATOR

The pressure regulator, complete with its incorporated filter, must be installed to avoid contaminants

reaching the gas valve. It is important to ensure certain conditions: The pressure of the gas must not

exceed the established maximum pressure. To increase the pressure of the gas supply, tighten screw

C; to reduce the pressure, loosen screw C. After making any adjustments, put the cap back in place.

CALCULATING THE BURNER CAPACITY

To calculate the burner's capacity in kW, proceed as follows: Check the gas flow rate (in liters)

on the counter and the time of the reading in seconds.

Proceed with the calculation using the following formula: x f = kW

sec

e=Litres gas

sec = Time in second

G20 = 34,02

G30 = 116

G31 = 88

pag.4

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

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 suitable and that they com-

ply 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.

case of no ignition the burner goes to lock-out within two seconds. Now the burner is operating at the min. firing rate (about

30% of the max. firing rate). The air servocontrol runs at the Low Flame position and in case the temperature control has to be

set at the max. output it goes to a fully open position of air damper and butterfly valve. During the burner-off periods the air

dumper closes up fully.

pag.5

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

ADJUSTMENT OF GAS SOLENOID VALVES

The ignition flow rate is carefully adjusted. during test phase to 1/3 of the maximum flow rate (according to specifications).

Operations for eventual further adjustment must be carried out by skilled personnel authorized by ECOFLAM.

DUNGS MVDLE

To adjustment gas output, loo-

sen the screw R and turn the

knob P as required. To reduce

output, turn knob clockwise,

to increase it turn knob coun-

terclockwise. Tighten the

screw R. For fast opening adju-

stment, remove the cap T and

insert it in the pin Q with its

groove up. To reduce firing

output screw it up, to increase,

unscrew it.

DUNGS MVD

To adjustment gas output, take

out the cap L and loose the nut

F.Adjust the screw E with a

screwdriver. To reduce output

turn counter clockwise, to increa-

se it turn clockwise.

Tighten the nut F.

The pressure regulator is inside to gas solenoid

valve (actuator SKP20). For adjustment the pres-

sure proceed as follows:

Take out the cap (A) and turn the screw (B) with

a screwdriver. To increase pressure, turn screw-

driver clockwise, to reduce it turn screwdriver

counterclockwise. Take in the cap (A).

ADJUSTMENT THE PRESSURE OF GAS SOLENOID VALVE (Landis SKP20)

DUNGS SV-DLE

To adjustment gas output, loosen the screw R and turn the knob P as required. To reduce output, turn knob clockwise,

to increase it turn knob counterclockwise. Tighten the screw R. For fast opening adjustment, remove the cap T and

insert it in the pin Q with its groove up. To reduce firing output screw it up, to increase, unscrew it.

pag.6

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

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 combustion is cor-

rect. 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 1 mbar (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

gas pressure

switch

air pressure switch

LEAKAGE CONTROL DEVICE DUNGS VPS 504-VDK 200

When the thermostats are closed, the gas leakage control device checks the valve seals by pressurizing the circuit between the

two gas valves. When test pressure is reached the device remains in stand-by for about 25 seconds. At the end of the test the yel-

low pilot light on the control device lights up and the burner is enabled to carry out the start-up cycle. If the seal on one of the

valves is faulty and this causes a drop in test pressure, the device puts the system into the safety condition and the red pilot right

on the device lights up. The flame control device starts the burner fan to carry out prewashing of the

combustion chamber,checking fan air pressure via the air pressure switch. After preventilation the igni-

tion transformer starts operating, generating a spark between the electrodes and simultaneously the gas

valves open (safety gas valve VS and first stage operating valve VL). If the flame does not ignite or goes

out, total safety is ensured by an ionization detection probe. The safety time limit in the event of no

flame is less than 2 seconds at start-up and less than 1 during operation. In the event of no gas being

supplied or of a considerable drop in pressure the minimum gas pressure switch interrupts burner operation. About 20/30

seconds after ignition the flame control device commands operation of the second stage via the gas valve and air servocontrol,

thus taking the burner to maximum power.

VLVS

DISPOSITIVO

CONTROLLO

TENUTA

LANDIS & STAEFA SQM 50.381A2 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-High flame operating opening position adjusting cam (Light-Oil /Gas)

II -Ignition flame opening position adjusting cam (Gas).

III -Low flame operating opening position adjusting cam (Gas)

IV -Low flame operating opening position adjusting cam ( Light-Oil)

V-2nd flame solenoid valve opening On/Off cam (Light-Oil)

VI -Not used cam

VII -Not used cam

VIII -Not used cam

Multicalor 300.1

Cam VIII

is never used

LEAKAGE

CONTROL

DEVICE

I - High flame operating opening position adjusting air cam

II - Ignition flame opening position adjusting air cam (Gas/Light-Oil)

III - Low flame operating opening position adjusting cam (Gas)

IV - Low flame operating opening position adjusting cam (Light-Oil)

(always 3° lesser than Low flame adjusting V cam)

V - Low flame operating opening position adjusting air cam (Light-Oil)

VI - Low flame solenoid valve opening On/Off cam (Light-Oil)

VII - High flame solenoid valve opening On/Off cam (Light-Oil)

VIII -Not used cam

Multicalor 400.1

pag.7

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

AIR ADJUSTMENT

Part. 1

Part. 2

Part. 3

COMMUTATORE

AUTO

0 =

bloccaggio degli apparati per il

funzionamento in una posizione intermadia

funzionamento alla massima potenza

funzionamento alla minima potenza

AUTO =

funzionamento automatico

operating elements locked in an intermediate

position

operation on maximum capacity

operation on minimum capacity

automatic operation

SELECTOR

ADJUSTING THE MINIMUM CAPACITY OF THE BURNER – AIR and GAS

Position the selector placed on the control panel on position 2 and proceed as follows:

Adjust the minimum gas flow rate using a suitable wrench, turn the butterfly valve until you reach the correct gas

flow, as established by analyzing the combustion process.

ADJUSTING THE MAXIMUM CAPACITY OF THE GAS

Position the selector, situated on the control panel, on position 1 and proceed as follows:

Adjusting the maximum gas flow rate (see figure on solenoid valve adjustments) or adjust the gas pressure in the

governor.

ADJUSTING THE MAXIMUM AIR FLOW RATE

Adjusting the maximum air flow rate (see figure, detail 2). Loosen the nut holding the air damper transmission rod;

The correct air flow as established by analyzing the combustion process.

ADJUSTING THE INTERMEDIATE BURNER CAPACITY

Using the selector, start the servomotor (closing or opening) and position on 0 to stop the stroke; the adjustment is

made as outlined below. Repeat the operation for the other cam points.

Adjustment the intermediate gas flow rates (see figure, detail 3): - using a suitable Allen wrench, change the position

of the cam guide blade; if you screw it down, the flow rate is reduced; if you unscrew it, the flow rate increases.

22 23

LANDIS

LFL 1.622

Fotocellula

min 70 µA

croamperometro

fondo scala 1000 µA

FLAME DETECTION SYSTEM CHECK

PHOTORESISTOR

Microamperometer

full scale 1000 µA

pag.8

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

REMOVING THE BLAST TUBE REMOVING THE FIRING HEAD

FIRING HEAD SETTING

pag.9

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

HYDRAULIC CIRCUIT

1- HOSE

2- OIL FILTER

3- OIL COCK

4- SUCTION

5- RETURN

OPERATION OF BURNER WITH LIGHT-OIL FUEL MULTICALOR 300.1-400.1

Once 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. 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. At the end of prepurging, the control box powers up the ignition transformer and opens the light-oil

valve, so the burner start . the servomotor will set up to the light-oil ignition position, whilst the control box powers up the

ignition transformer and the “Safety” and “Low flame” solenoid valves. After a safety interval of 2 seconds and a correct igni-

tion, 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 (Multicalor 300.1) and 3rd stage solenoid valve (Multicalor 400.1). In case of

faulty ignition,the control box will shut down the burner in 2 sec.

In order to obtain a correct combustion, it shall be necessary to adjust the Low and High flame by following the instructions of

the Air servomotor and firing head adjustment.

During such a phase, it will be possible to manually switch between HIGH and LOW flame and viceversa, through the

High/Low flame switch. At the end of the adjusting phase, leave the switch in position “AUTO”. The fuel pump feeding pres-

sure, must remain around 12 bar.

0 - STOP

1 - GASOLIO

2 - GAS

Multicalor 300.1

Multicalor 400.1

LIGHT-OIL

pag.10

techniques for energy saving

LB1203 MULTICALOR 300.1÷400.1

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 fee-

ding 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 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.

PRIMING AND ADJUSTMENT OF OIL PUMP

1- INLET

2- RETURN

3- BLEED AND PRESSURE GAUGE PORT

4- VACUUM GAUGE PORT

5- PRESSURE ADJUSTMENT

6- TO NOZZLE

SUNTEC TA3C40105

SUNTEC

SUNTEC J7CCC10014P

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

28,00 106,40 111,60 116,60 121,30 125,90 130,30 134,60

30,00 114,00 119,60 124,90 130,00 134,90 139,60 144,20

GPH OUTPUT kg/h

NOZZLE FLOW RATE (DELAVAN B - MONARCH PLP)

Ce manuel convient aux modèles suivants

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