Installation, use and maintenance instructions Manuel d entretien Installatie-, gebruiks- en onderhoudsvoorschriften GB F NL Oil burners Brûleurs fioul Stookoliebranders One stage operation Fonctionnement à allure Eentrapsbranders CODE MODEL - MODELE TYPE 809900 SIME MACK SP 55 T 809900 SIME MACK 5SP 55 T5 90 (0)
INDEX. BURNER DESCRIPTION.............. Burner equipment................... TECNICAL DATA.................. Technical data...................... Overall dimensions.................. Working fields...................... INSTALLATION..................... Boiler fixing........................ ydraulic systems................... Electrical wiring.................... 5. WORKING....................... 6. Combustion adjustment.............. 6. Nozzles recommended.............. 6. Electrodes setting.................. 7. Air damper adjustment.............. 7.5 Pump pressure.................... 7.6 Burner start-up cycle................ 7 5. MAINTENANCE................... 8 6. FAULTS / SOLUTIONS.............. 9. BURNER DESCRIPTION One stage light oil burner suitable for working with fuel temperature higher than 0 C. The burner meets protection level of IP 0, EN 6059. Burner with CE marking in conformity with EEC directives: EMC 89/6/EEC, Low Voltage 7//EEC, Machines 98/7/EEC and Efficiency 9//EEC. Fig. 5 6 5 7 D67 Oil pump Control-box Reset button with lock-out lamp ydraulic jack with air-damper 5 Screws fixing air-damper 6 Flange with insulating gasket 7 Grommet. BURNER EQUIPMENT Flange with insulating gasket....no. Screws and nuts for flange to be fixed to boiler.. No. Screw and nuts for flange......no. Flexible oil pipes with nipples................ No. Grommet...................No. 7 pin plug............................... No. GB
. TECNICAL DATA. TECNICAL DATA Model MACK SP MACK 5SP Output kg/h.0..8.9 Thermal power kw.8 7.9. 6. ( i =.86 kwh/kg) Fuel Light oil, max. viscosity at 0 C: 6 mm /s Electrical supply Single phase, ~ 50z 0V ± 0% Motor Run current 0.7A 850 rpm 98 rad/s Capacitor µf Ignition transformer Secondary 8 kv 6 ma Pump Absorbed electrical power Pressure: 7 5 bar 0. kw. OVERALL DIMENSIONS Flange 80 9 = Burner 85 86 0 = 5 7 7 9 86 ø 89 5 D5908 0 50 6 D66. WORKING FIELDS (as EN 67) Pressure in the combustion chamber mbar,0 0,8 0,6 0, MACK SP MACK 5SP 0, 0,8,,,6,8,,,6,8 Light oil output kg/h D689 6 0 8 6 Thermal power kw GB
. INSTALLATION. BOILER FIXING Put on the flange () the screw and two nuts, (see fig. ). Widen, if necessary, the insulating gasket holes (5). Fix the flange () to the boiler door () using screws () and (if necessary) the nuts () interposing the insulating gasket (5), (see fig. ). Fig. Fig. 5 E9 E9 GB
. YDRAULIC SYSTEMS The burner is designed to allow entry of the flexible oil-lines on either side of the burner. WARNING: It is necessary to install a filter on the fuel supply line. The standard filter code 67600 and that one with recirculation code 6760 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 (), remove the by-pass screw () and then screw again the plug (), (see fig. ). 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. Fig. 7 6 5 max. m D68 SYSTEM NOT PERMITTED IN GERMANY Fig. 5 meters PRIMING PUMP: On the system in fig. 5 it is sufficient to loosen the suction gauge connection (6, fig. ) 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 0 seconds before repeating the operation. The pump suction should not exceed a maximum of 0. bar (0 cm g). 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 required. Should however the return line arrive over the fuel level, a non-return valve is required. This solution however is less safe than previous one, due to the possibility of leakage of the valve. 0.5.5 I. D. 8 mm 0 0 0 60 L meters I. D. 0 mm 0 0 80 00 8 D59 - Suction line - Return line - By-pass screw - Gauge connection 5 - Pressure adjuster 6 - Suction gauge connection 7 - Oil valve 8 - Auxiliary pressure test point meters 0 0.5.5.5 I. D. 8 mm 5 0 5 0 5 8 6 L meters I. D. 0 mm 00 00 00 90 70 0 0 max. m Fig. 6 Fig. 7 max. m D685 = difference of level; L = max. length of the suction line; I. D. = internal diameter of the oil pipes. GB
. ELECTRICAL WIRING WARNING DO NOT EXCANGE NEUTRAL WIT PASE ~ 50z 0V PE L N Main switch NOTES: Wires of mm section. The electrical wiring carried out by the installer must be in compliance with the rules in force in the Country. TESTING Check the shut-down of the burner by opening the thermostats. T6A Limit thermostat with manual resetting Regulating thermostat our counter (0V - 0.A max.) Remote lock-out lamp (0V - 0.5A max.) 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. 7 pin plug Fig. 8 7 pole socket CARRIED-OUT IN TE FACTORY CONTROL BOX 55SE Black White Blue Motor Oil valve Capacitor E957 A Ignition electrodes Photoresistance Burner-earth D86 Fig. 9 ACCESS TO TE POTORESISTANCE (See fig. 9) The photoresistance is fitted directly into the control-box (underneath the ignition-transformer) on a plug-in support. Ignition transformer Photoresistance E90 5 GB
. WORKING. COMBUSTION ADJUSTMENT In conformity with Efficiency Directive 9//EEC the application of the burner on the boiler, adjustment and testing must be carried out observing the instruction manual of the boiler, including verification of the CO and CO 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 damper 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 67). They refer to.5% CO at sea level and with light oil and room temperature of 0 C. Table B Pump pressure Burner output APPROXIMATE ADJUSTMENTS FOR INSTALLATION ON OTER BOILERS The values shown in the table are measured on a CEN boiler (as per EN 67). They refer to.5% CO at sea level and with light oil and room temperature of 0 C. Air damper adjustment BOILER BURNER Nozzle Code Model GP Angle bar kg/h ± % Set-point Rondò-Estelle 809900 MACK SP 0.75 60 W.5.9.9 Rondò-Estelle 5 809900 MACK 5SP 0.85 60 W.6 v8 Model Nozzle Pump pressure Burner output Air damper adjustment GP Angle bar kg/h ± % Set-point Fig. 0 MACK SP 0.50 70.0.7 0.55 60..9 0.60 60.. 0.65 60.6. 0.75 60.5.. 5 6 MACK 5SP 0.65 60.8. 0.75 60.0.5 0.85 60..0 0.85 60.5.9.7. NOZZLES RECOMMENDED: Monarch type R - NS ; Delavan type W-E Steinen type - Q ; Danfoss type - S. MAINTENANCE POSITION Access to the combustion head, electrodes and nozzle, (see fig. 0). Remove the burner out of the boiler, after loosing the fixing nut to the flange. ook the burner to the flange (), by removing the combustion head () after loosing the fixing screws (). Remove the electrodes assembly (5) from the nozzle-holder () after loosing its fixing screw (B, fig., page 7). Screw the nozzle (6). E955 6 GB
. ELECTRODES SETTING ATTENTION Fig. ± 0. mm IMPORTANT: TESE DIMENSIONS MUST BE OBSERVED Before removing or assembling the nozzle, loosen the screw (B, fig. ) and move the electrodes ahead. D50 B.5 mm. AIR DAMPER ADJUSTMENT, (see fig. ) The mobile air damper () operated by the jack () assures the complete opening of the air intake. The regulation of the air-rate is made by adjusting the fixed air damper (), after loosing the screws (). When the optimal regulation is reached, screw tight the screws () to assure a free movement of the mobile air damper (). The settings, indicated in the table (page 6), refer to the burner with its cover fitted and combustion chamber with depression zero. These Fig. regulations are purely indicative. Each installation however, has its own unpredictable working conditions: actual nozzle output; positive or negative pressure in the combustion-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 CO. 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. D686.5 PUMP PRESSURE: The pump is set in factory according to the value indicated in the table B at page 6. bar: Improves flame retention; it is therefore suitable for ignitions at low temperatures..6 BURNER START-UP CYCLE Thermostat Green led and motor Ignition transformer Oil valve Flame Lock-out lamp Normal Lock-out due to failure to light C ~ s ~ s 5s D509 C Lock out is indicated by a lamp on the control box (, fig., page ). 7 GB
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. TE BASIC CECKS 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. 0, page 6) and check the correct position of electrodes (fig., page 7). Clean the combustion head in the fuel exit area, on the diffuser disc. Leave the burner working without interruptions for 0 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 CO (%); Content of CO (ppm); Smoke value according to opacity smokes index according to Bacharach scale. 8 GB
6. FAULTS / SOLUTIONS ere below you can find some causes and the possible solutions for some problems that could cause a failure 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 (, fig., page ). 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. FAULTS POSSIBLE CAUSES SOLUTION Check presence of voltage in the L - N clamps of the 7 pin plug. The green led on the control box is off and the burner does not start. The green led on the control box is on and the burner remains in the prepurge phase. Burner runs normally in the prepurge and ignition cycle and locks out after 5 seconds ca. Burner starts with an ignition delay. Lack of electrical supply. The connections in the control box are wrongly inserted. The photoresistance sees false light. The photoresistance is dirty. The photoresistance is defective. Flame moves away or fails. The ignition electrodes are wrongly positioned. Air output is too high. Nozzle dirty or worn. Check the conditions of the fuses. Check that thermostat limit is not lock out. Check and connect completely all the plugs. Eliminate the light. Clear it. Change it. Check pressure and output of the fuel. Check air output. Change nozzle. Check the coil of solenoid valve. Adjust them according to the instructions of this manual. Set the air output according to the instructions of this manual. Replace it. 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. 9 GB