Ferroli SUN Series Quick start guide

INSTALLATION, USE AND

MAINTENANCE

INSTRUCTIONS

INSTRUCTIONS POUR

L’INSTALLATION

L’UTILISATION ET

L’ENTRETIEN

S.p.A.

SUN

HEATING OIL

BURNER

BRULEUR À

FUEL

Index page

General information - Technical and dimensional features................................................................ 3

Main parts - Operative range of the burner ........................................................................................ 4

Electrical connections ........................................................................................................................ 5

Heating oil fuelling line ....................................................................................................................... 6

Boiler assembly - Pump pressure regulation ..................................................................................... 7

Choosing the injector ......................................................................................................................... 8

Head regulation and air flow rate adjustment - Example of combustion regulation

Position of electrodes-baffle............................................................................................................... 9

Setting at work - Work cycle...............................................................................................................10

Maintenance - Demounting and servicing the burner ........................................................................ 11

Troubleshooting ................................................................................................................................. 12

Components....................................................................................................................................... 13

List components ................................................................................................................................. 14

S.p.A.

SUN

Fig. 1

GENERAL INFORMATION

Ferroliisproudtopresentthisseriesofheatingoilburnersfordomesticboilers,withthermalpowerratings

of between 13,3 and 58,1 kW. A compact and attractive design make these burners fit for use with the

majority of the boilers currently available on the market.

Use of modern technologies has enabled Ferroli to produce these new appliances able to optmize the

air-fuel mixing function. This achieves high efficiency, low degrees of CO and NOx together with a very

silent flame.

Here are the more important technical features:

- Fine adjustment of the position of the combustion head in relation to the nozzle by means of a

micrometric screw.

- Accurate air adjustment on the intake.

- Airlockwithgravityclosingwhentheburnerstops.Thisnotablylimitsheatdispersionswhentheboiler

is on hold.

- Burneriscompletewithapreheateronthenozzleline.This improves combustion and ensures prompt

ignition after lengthy periods at a standstill during the colder season and when paraffinic heating oil is

used.

- The inspection and servicing operations are very convenient for all models.

TECHNICAL AND DIMENSIONAL FEATURES

Type SUN

IP40Prot. Class

220 WInput

220 - 240V 50HzEl. Power Supply

Heating oil max 20 °C 1.5 E

Fuel

70W 0.6A 2735 g/min

Motor

2x7 kV 40 mA

Ignition trasformer

Øe 64 - Øi 16 nr. 6 tagli

Fuel Nozzle

110 W

Preheater

146-48 rsx 40 pale

Fan

Thermal Power Rating kW

min.

max.

Fuel Flow Rate kg/h

min.

max.

G.6 R G.6

21,3

58,1

1,8

4,9

13,3

58,1

1,12

4,90

170 W

Ø91

Ø 170

Ø 140

250

286

Ø90

180

227

S.p.A.

SUN

MAIN PARTS

Fig. 2

Fig. 3 1

kg/h 1.5

0.6

0.5

0.4

0.3

0.2

0.1

∆p mbar

2.0 5.04.54.03.53.02.5

kg/h 1.5

0.6

0.5

0.4

0.3

0.2

0.1

∆p mbar

2.0 5.04.54.03.53.02.5

SUN G.6 R

SUN G.6

Pressure in combustion chamber ∆p mbar

Heating oil flow rate Kg/h

OPERATIVE RANGE OF THE BURNER

12 11 10 9

1Heating oil pump

2Motor

3Electromagnetic valve

4Burner unit

5Release button

6Mechanism

7Photoresistance

8Ignition transformer

9Burner coupling flange

10 Injector line with preheater

11 Ignition electrodes

12 Nozzle

13 Air lock adjuster screw

14 Spina allacciamento elettrico

15 Fan

16 Combustion head adjustment

17 Pump pressure adjustment

18 Pressure tap

Key

S.p.A.

SUN

ELECTRICAL CONNECTIONS

Fig. 4

Key

CO Hour counter

FFuse

FR Photoelectric resistance

IG Main switch

LS Safety light

MB Burner motor

PB Burner tap

PR Preheater (G6R only)

SC Plug

TA-TC Boiler - room thermostat

TR Ignition transformer

TS Safety thermostat

Tm Minimum rating thermostat

VE Electromagnetic valve

The following electrical connections are at the installer’s charge:

- power supply line

- thermostat line

- possible shutdown indicator light and/or hour meter

Attention

- do not switch the neutral and phase wires

- always install a good ground connection

Preheater cable

4321

Connection for without

preheater version

PREHEATER CONNECTION

12 34567891011122

Tm PR

PB SC

L1 NT1 T2 S3 B4

L1 N T1 T2 S3 B4

TA - TC

NNNPh

S.p.A.

SUN

HEATING OIL FUELLING LINE

Attention: Before starting the burner, check that the fuel return pipe is not clogged. Excessive over-

pressure would break the pump retaining component.

Install a filter on the fuel supply line.

(m)

0.5

1.0

2.0

1.5

L (m)

Øi 8 mm. Øi 10 mm.

100

HYDRAULIC CIRCUITS

AGravity supply

BSuction supply

CSiphoned supply

DRing supply

Nota: Add0.25meterstothepipelengthforeach

elbow or gate valve (load losses).

LTotal length of intake pipe including vertical

sections

HDifference in level

Øi Inner pipe diameter

(m)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

25 60

L (m)

Øi 8 mm. Øi 10 mm.

(m)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

25 60

L (m)

Øi 8 mm. Øi 10 mm.

Fig. 5a

Fig. 5b

Fig. 5c

Fig. 5d

S.p.A.

SUN

090

6030

SUNTEC AS

DELTA VM1 RL2

Fig. 6

-Insert screw 2 (m8x25) into flange 3

-Insert flange 3 into the boiler using the 5 screws (NR. 4 M8x30) with insulating seal 1 in between.

-Insert the burner into the boiler flange and fix it to screw 2 with nut 4.

PUMP PRESSURE REGULATION

DANFOSS BFP 11 R3

m h

Type BFP

NO.

MADE IN

DENMARK

230v. 50Hz.

VA. 11

Cod. M81

DELTA

Fig. 7

BOILER ASSEMBLY

S.p.A.

SUN

CHOOSING THE INJECTOR

The injector must be chosen according to the power rating of the boiler flue, remembering that heating

oil has a heat value (N.H.V.) of 10200 kcal/Kg. The chart gives the flow rate or consumption in Kg/h and

kW of heating oil according to the size of the injector (in GPH) and the pump pressure (in bar). When the

burner has a preheater, the effective capacity will be about 10% lower than the values in the chart.

Injector

G.P.H.

0,40

0,50

0,60

0,65

0,75

0,85

1,00

1,10

1,20

1,25

1,35

1,50

1,65

1,75

2,00

2,25

2,50

3,00

1,27

1,59

1,91

2,07

2,38

2,70

3,18

3,50

3,82

3,97

4,29

4,77

5,25

5,56

6,30

7,15

7,95

9,54

1,36

1,70

2,04

2,21

2,55

2,89

3,40

3,74

4,08

4,25

4,59

5,10

5,61

5,95

6,80

7,65

8,50

10,20

1,44

1,80

2,16

2,34

2,70

3,06

3,61

3,97

4,33

4,50

4,87

5,41

5,95

6,31

7,21

8,15

9,01

10,82

1,52

1 ,90

2,28

2,47

2,85

3,23

3,80

4,18

4,56

4,75

5,13

5,70

6,27

6,65

7,60

8,55

9,50

11,40

1,59

1,99

2,39

2,59

2,99

3,39

3,99

4,38

4,78

5,00

5,38

5,90

6,58

6,98

7,97

8,97

9,97

11,96

1,67

2,08

2,50

2,71

3,12

3,54

4,16

4,58

5,00

5,20

5,62

6,24

6,87

7,29

8,33

9,37

10,41

12,49

1,73

2,17

2,60

2,82

3,25

3,68

4,33

4,77

5,20

5,40

5,85

6,50

7,15

7,58

8,67

9,75

10,83

13,00

1,80

2,25

2,70

2,92

3,37

3,82

4,50

4,95

5,40

5,60

6,07

6,75

7,42

7,87

8,99

10,12

11,24

13,49

1,86

2,33

2,79

3,03

3,49

3,96

4,65

5,12

5,59

5,80

6,28

6,98

7,68

8,15

9,31

10,47

11,64

13,96

15 17

1,98

2,48

2,97

3,22

3,72

4,21

4,96

5,45

5,95

6,20

6,69

7,43

8,18

8,67

9,91

11,15

12,39

14,87

1,92

2,40

2,88

3,12

3,61

4,09

4,81

5,29

5,77

6,00

6,49

7,21

7,93

8,41

9,61

10,85

12,02

14,42

1,18

1,47

1,77

1,91

2,2

2,5

2,94

3,24

3,53

3,68

3,97

4,42

4,86

5,15

5,89

6,62

7,36

8,83

Pump pressure kg/cm

Flow rate at injector outlet kg/h

S.p.A.

SUN

POSITION OF ELECTRODES - BAFFLE (Fig. 9)

After having mounted the injector, check

thattheelectrodesandbafflearecorrectly

positioned according to the above listed

measurements.

Always check the measurements

whenever operations are carried out on

the head.

45.0°

6.5

3.5

Fig. 9

23,3

34,9

46,5

kcal/h

20.000

30.000

40.000

Burner

flow rate

Kg/h

2,176

3,25

4,35

Gall/h

0,6

0,85

1,1

1,0

Angle

60°

Code

3560154/0

3560134/0

3560128/0

3560127/0

Pump

pressure

Bar

Air

regulation

Tacca

kcal/h

22.200

33.200

44.400

25,8

38,7

51,6

Tacca

*** * ** *

Delivered heat

output Head

adjustment

MODEL

BOILER

GN1.02

GN1.03

GN1.04

Heat rate Injector

COMBUSTION HEAD AND AIR

DAMPER ADJUSTMENT (Fig. 8)

Thecombustionhead is adjusted accord-

ing to burner flow rate. To adjust, rotate

the adjustment screw (B) clockwise or

anticlockwise until the notch on the rod

“A” coincides with the indicator.

This modifies the position of the deflec-

torinrelationtothe draught tube and con-

sequently the passage of air.

Theairflowrate is adjusted via screw“C”.

When the burner shuts down, the air

damper closes automatically.

EXAMPLE OF COMBUSTION REGU-

LATION

Theinjector,pumppressure,combustion

headadjustmentandair flow rate regula-

tionmustbeestablishedaccording to the

flow rate required by the boiler, as indi-

cated in the following chart check com-

bustion. Fig. 8

* Regulations for without preheater burner version

S.p.A.

SUN

a) Oncethethermostaticlinehasbeenclosed,theburnermotorwillstartoperatingtogetherwiththepump

the intaken heating oil will be totally conveyed towards the return side. The burner fan and ignition

transformer will also be operating and the appliance will proceed with the following phases:

- flue pre-ventilation

- pre-flushing of part of the heating oil circuit

- pre-ignition, with discharge between the tips of the electrodes.

b) At the end of the pre-flushing phase, the electromagnetic valve will open and the heating oil will reach

the injector from which it will be finely atomized.

Contact with the spark between the electrode tips will form the flame. The safety time will now start.

WORK CYCLE

SETTING AT WORK

1) Preliminary operations

- mount the pressure gauge and vacuometer on the pump (remove after start-up)

- open the gate valves along the heating oil pipe

- power the equipment by means of the main switch

- close the thermostat line (boiler/room)

- release the appliance (by depressing the red button).

2) Start-up

Fig. 10

A' A B C D

tw t1

t3 t3 n

Preheater with TM

Motor

Transformer

Electromagnetic valve

Photoelectric resistance

Room-boiler thermostat

TA - TC

Signals required on input

Signals on output

TA-TC Room thermostat

FR Photoelectric resistance

MB Burner motor

TR Ignition transformer

VE Electromagnetic valve

Tm Heater Pr minimum

thermostat

AStart-up without preheater

BFlame on

CNormal operation

DAdjustment stop (TA-TC)

A' Start-up with preheater

t1 Pre-ventilation time: 13 sec.

t2 Safety time: 10 sec.

t3 Pre-ignition time: 13 sec.

t3n After-ignition time: 15 sec.

tw Preheating time: 60/90 sec.

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