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gho-tron 5.5000 r gho-tron 5.5800 r operating instructions for authorised specialists gas/heavy oil dual burners 1-30 en 31-45 ru 17/03/2010 art nr 420010264102

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420010264102 gho tron 5.5000 5.5800 r en technical data models thermal power max thermal power min natural gas pressure lpg pressure voltage 50 hz motor rpm fuel gho tron 5.5000 gho tron 5.5800 kw 5.000 5.800 kcal/h 4.310.000 5.000.000 kw 1.200 1.500 kcal/h 1.034.500 1.290.000 mbar 35÷700 50÷700 mbar 65÷600 90÷600 v 230/400 230/400 kw 11 15 n° 2800 2800 natural gas l.c.v 8.570 kcal/nm3 lpg l.c.v 22.260 kcal/nm3 heavy oil l.c.v 9.800 kcal/kg max visc 100°e at 50°c working fields mbar 22 20 18 pressure in the combustion chamber 16 o gh 14 12 10 8 6 4 2 0 500 500 40 1000 1000 80 1500 120 1500 2000 160 2000 2500 200 240 2500 3000 280 3000 3500 320 on tr 5.5 gho tron 5.5000 80 0 kcal/h x 1000 6000 kw 520 kg/h 3500 4000 360 4000 4500 400 4500 5000 440 5500 480 5000 burner output overall dimensions a e d d1 bclf 20 mm f i o 0 1 2 3 o i m 578 n suntec models gho tron 5.5000 gho tron 5.5800 abhc 633 633 d 350 350 g d1 600 600 e 1370 1370 2 f 320 320 g 778 778 h 400 400 i 330 330 l 330 330 m m16 m16 n 195 195 o 250 250 1322 689 1322 689

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420010264102 gho tron 5.5000 5.5800 r electrical connections all burners factory tested at 400 v 50 hz three-phase for motors and 230 v 50 hz monophase with neutral for auxiliary equipment if mains supply is 230 v 50 hz threephase withuot neutral change position of connectors on burner as in fig protect burner supply line with safety fuses and any other devices required by safety standards obtaining in the country in question en 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 connector 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 operation of burner with gas 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 gas oil turns the air damper to the max delivery position by the air servocontrol in approximately 30 seconds 2 0 1 time when the servocontrol is fully open a signal to the electronic control unit starts the 36 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 ensured at min output simultaneously the ignition transformer receives voltage and after 3 seconds pre-ignition opens the pilot gas valve fuel flows to the combustion head and ignites two seconds after pilot gas valves have opened the ignition transformer is excluded from the circuit in case of no ignition the burner goes to lock-out within two seconds after 6 sec open the working gas valve governed by the gas firing butterfly valve.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 damper closes up fully 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 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 30 air excess air factor 1,3 1,25 1,2 1,2 1,15 1,1 10 20 30 40 50 60 70 80 100 200 300 400 600 800 1000 90 500 700 900 thermal power kw 2000 1,2 natural g co2 9,6 co <100 ppm gpl 11,7 <50 ppm 25 20 15 10 co2 co combustion adjustment warning in order to have a correct combustion and thermal output adjustments these must be carried out together with a combustion analysis to be executed through suitable devices taking care that the values are the correct ones and are in accordance with the local safety regulations the adjustments must be carried out by qualified and skilled technicians authorised by elco 3

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420010264102 gho tron 5.5000 5.5800 r en landis staefa model lfl1.333 operating cycle ref description duration t1 duration waiting time for confirmation of air pressure 8 t2 preventilation time 36 t3 safety time 2 t4 pressurizing time 4 t5 time for enabling operation of the main gas valve on minimum capacity 10 t6 time for enabling operation of the main gas valve on maximum capacity ciclo di funzionamento normale normal operating cycle t1 t2 t3 t1 operating di funzionamento ciclo cycle in the event of in mancanza di fiamma all accensione ignition failurenormal operating cycle t2 t3 gas manostat pressostato gas motore fan motor ventilatore pressostato aria air switch 10 trasformatore ignition transformer di accensione t4 t4 valvola gas gas valve the control box starts the burner t5 t6 consenso min/max capacity fan to carry out the prepurging of min max potenza enabling device the combustion chamber and 100 serranda aria min cheks the vent air pressure throuair damper 0 gh the air pressure switch at the gas damper serranda gas end of prepurging the ignition rivelazione flame detector di fiamma transformer cuts-in and generates spia di blocco a spark between the electrodes at cut-out pilot lamp 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 sqm 50.481a2 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 manual change i ii iii iv v vi vii viii high flame operating opening position adjusting cam heavy-oil /gas limit switch for the air damper position at burner s shut down ignition flame opening position adjusting cam gas ignition flame opening position adjusting camheavy-oil low flame operating opening position adjusting cam gas low flame operating opening position adjusting cam heavy-oil not used cam not used cam 4

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420010264102 gho tron 5.5000 5.5800 r air and gas adjustment en part 1 part 3 -selector commutatore auto part 2 0 0 operating elements locked il an intermediate bloccaggio degli apparati per in position funzionamento in una posizione intermadia operation on maximum capacity funzionamento alla massima potenza operation on minimum capacity funzionamento alla minima potenza auto =automatic operation funzionamento automatico 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 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 e x f kw proceed with the calculation using the following sec f e sec g20 g30 g31 litres gas time in second 34,02 116 88 5

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420010264102 gho tron 5.5000 5.5800 r en 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 gas pressure switch 35 m n 2,5 5 30 10 15 2,1 d 0,4 1,8 0,6 0,9 1,2 1,5 g 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 illustration a wrong position could cause ignition troubles position of ignition electrodes 3 ÷ 4 mm 5 ÷ 6 mm detector current microamperometro full scala 1000 µa fondo scale 1000 µa uvfotocellula cell microamperometer the detector current is checked by inserting a microammelfl 1.622 ter scale 1000 µa d.c in series with the uv cell lfl 1.333 the flame detector current has to been 70 µa landis 22 23 min 70 µa 6 2,4 2,7 i unscrew screws a and b and remove cover c set the pressure switch to the minimum by turning regulator d to position 1 l start the burner and keep in low flame running while checking that combustion 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 air pressure switch 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 burc ner lockout remove the obstruction from the air intake screw on the cover c and start the burner by pressing the control box rearm button a 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 b turn the same clockwise to reduce the pressure counterclockwise to increase at the end tighten the locking nut adjustment of the air pressure switch 20 3,0 25 40 45 50 h e f

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420010264102 gho tron 5.5000 5.5800 r removing the firing head en warning 7

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420010264102 gho tron 5.5000 5.5800 r en pump s pressure oil temperature diagram pump inlet pressure:the vaporisation of light fraction of heated heavy oil causes premature pump wear to avoid this use the inlet pressures shown in the graph bar 6 5 4 pump inlet pressure 3 2 1 0 50 100 oil temperature 150 c° heavy oil feeding 1 2 3 4 5 6 inlet return bleed and pressure gauge port vacuum gauge port pressure adjustment nozzle outlet 230v 50hz warning for a correct working of the pump verify what follows pump suntec ta4c40105 oil temperature at the pump max 140 °c maximum allowable pressures max 5 bar on inlet 8

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420010264102 gho tron 5.5000 5.5800 r type of installation the burner must be supplied with oil heaving a min temperature at the pump 50°c drawing for heavy fuel oil up to 100°e at 50°c en hot water return section hot water pipe oil pipe heating cable hot water pipe oil pipe insulation 1 burner 2 tank 3 heater 4 safety/operation thermostat 5 level switch 6 self cleaning filter 7 heating coil 8 load pumps 9 ring pumps 10 regulator 11 heating cable 9

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420010264102 gho tron 5.5000 5.5800 r en before proceeding with the filling of the oil system check the following points motor s direction of rotation with 3phase version there must be fuel in the tank fuel cocks must be open fuel return piping must be free from obstructions after having checked all the above items proceed as follows connect a fuel pressure gauge set out1 out2 out3 out 4 to 0°c on gefran regulator disconnect the resistors power cable from the motor s remote control switch and insulate it temporarily unplug the safety box start the burner and manually operate the motor s remote control switch until the oil system is filled up note the oil system can be considered filled when pressure gauge will show a constant reading of 16÷18 bar when done shut off the burner switch off power and restore initial conditions as follows reconnect resistors power cable set out1 out2 out3 out 4 on gefran regulator to the initial value plug in the control box checks to be made to ensure a proper installation before proceeding with the filling of the fuel system and subsequent burner start up it is advisable to carry out the following checks power line must be adequate to system s adsorbed load fuses must be adequate to the system s load boiler s thermostats must have been properly connected voltage and frequency must be within the specified limits fuel type must be the one specified by the burner manufacturer feed piping section must be adequate to the requested fuel flow rate filters cocks as well as fittings must have been properly installed blast tube length must be the one specified by the boiler manufacturer nozzle s flow rate of the burner must be adequate to boiler s output 10

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420010264102 gho tron 5.5000 5.5800 r modulating operation with the bumer in the start position and the appliance thermostats enabled power is delivered to the resistances g of the preheater and heating cartridges for the pumps and the fuel sup2 1 ply line to the head o when the preheater thermostat reaches the set value 0 stop heavy-oil usually a minimum of about 90°c is necessary to guarantee a good level of circula 1 gasolio 2 gas 0 tion the pump start-up is enabled set point on out 1 if using the gefran 200 thermoregulating device if the preheating system of the tank is also equipped for a fluid exchanger hot water steam diathermic oil the thermostat may enable a contact in the terminal block for any stop-start of the fluid electrovalve this is not a standard solution as the heated fluid is normally always connected the pump starts to send oil the head has already been heated by its cartridge o and therefore has no residue of cold dense oil which flows from the tank to the head and then to the return line of the ring when the head thermostat reaches the set value usually about 70-30°c the cycle starts properly and the control programmer enables start-up the servomotor sets itself at minimum see chapter on regulation acting on the air and fùel via the pressure regulator on the return the electromagnet a opens the nozzle q in the followmg condition sparks from the ignition electrodes are generated by the transformer also governed by the burner control device if the cell fails to detect the flame the burner shuts down with the cyclic control programmer cutting in once ignition has taken place and after the flame stabilisation period the system starts operating in modulating mode before start-up make sure that the pump and delivery pipes are completely filled with hot fuel oil the absence of fuel oil can cause pump seizure if there is a block a specific waring light on the programmer and on the burner front control board lights up and this signal is usually sent to the main control board of the equipment using the burner setting off a buzzer and warning light a few blocks are normal on first starting up up to about 4 to release press the button on the programmer also found on the front of the bumer control board for repeating the start cycle should they continue to occur seek the help of a specialised technician n.b the position of the programmer at the time of the block is memorised to supply an indication of the cause of this block oil delivery adjustment the diagram illustrates the fuel feeding system of these types of burners which incorporates a by-pass nozzle with oil flow regulation on its return pipe the oil supply is varied by acting on the nozzle through the pressure in the return line max oil supply is therefore reached when the pressure in the pump line is about 22 bar and the return line is fully closed min oil supply when the return line is fully open relevant pressure readings in the return line are as follows pump pressure 22-25 bar max burner output return oil pressure fluidics nozzle 16 ÷19 bar bergonzo nozzle 20 ÷24 bar min burner output return oil pressure fluidics nozzle 6 ÷9 bar bergonzo nozzle 4 ÷8 bar en 11

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en pre purging phase a 420010264102 gho tron 5.5000 5.5800 rqofhpei 12 n d legend a solenoid valve n.c d regulator e tank f anti gas valve g resistance of the preheather h pipe filter i oil pump n manometr o resistance of combustion head p oil temperature sensor q oil nozzle g

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420010264102 gho tron 5.5000 5.5800 r en 13

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420010264102 gho tron 5.5000 5.5800 r en fluidics nozzle 25 50° 70° 90° spray angle return pressure supply 25 bar 20 15 60 kg/h 10 60 kg/h bar 5 20 40 60 80 100 output 14

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420010264102 gho tron 5.5000 5.5800 r adjustment of fuel temperature en display decrease key increase key function key 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 1113° out 2115° out 3120° out 4105° to modify factory temperature setting act as follows press key f the led out1 starts to flash 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 flashes please take care if key f is pressed for a too long time you enter in configuration level phase1 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 flashing on the display ­ wait 10 seconds untill the regulator automatically goes out from configuration level description of the control panel of the burner main switch i/0 lock-out lamp resistor lamp gefran regulator rwf 40 regulator selector 0-stop 1-hight flame 2-low flame 3-automatic heavy oil lamp selector gas 0 heavy oil gas lamp reset button 15

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