elco VG3 DUO Operation and Maintenance Manual

Brand: elco

Model: VG3 DUO

Type: Operation and Maintenance Manual

02/2011 - Art. Nr. 4200 1028 2701B

VG3.290 DP

VG3.360 DP

Operating instructions

For specialist installation engineers

Gas burners ........................................... 2-28

de, fr..................................... 4200 1021 2401

it, nl ...................................... 4200 1021 2501

............................................. 4200 1021 2302

02/2011 - Art. Nr. 4200 1028 2701B2

Overview

Contents

We accept no responsibility for damage

arising from:

- inappropriate use.

- incorrect installation and/or repair on the

part of the buyer or any third party,

including the fitting of non-original parts.

Final delivery and instructions for use

The firing system fitter must supply the

operator of the system with operating and

maintenance instructions on or before final

delivery. These instructions should be

displayed in a prominent location at the

point of installation of the heat generator,

They should include the address and

telephone number of the nearest customer

service centre.

Notes for the operator

The system should be inspected by a

specialist at least once a year. Depending

on the type of installation, shorter

maintenance intervals may be necessary!

It is advisable to take out a maintenance

contract to guarantee regular servicing.

Overview Contents.................................................................... 2

Important information ................................................ 2

Burner description..................................................... 3

Operation Operation, safety operation....................................... 4

MB-VEFgas train....................................................... 5

Control and safety unit........................................... 6-8

Terminal allocation chart,

connection socket ................................................ 9-10

Assembly Burner assembly, gas train assembly................11-12

Checking the combustion components ................... 13

Electrical/gas connection ........................................ 14

Testing before commissioning ................................ 14

Commissioning Adjustment data ..................................................... 15

Air regulation........................................................... 16

Pre-adjustment without flame ............................17-18

Setting the flame ................................................ 19-21

Saving the adjustment values in the display .......... 22

Servicing Maintenance ..................................................... 23-24

Troubleshooting ................................................. 25-26

Fault diagnosis menu,

Operating statistics menu .................................. 27-28

Declaration of conformity

for gas burners

We, certified company No. AQF030,

F-74106 ANNEMASSE Cedex, declare

under our sole responsibility that the

products

VG3.290 DP

VG3.360 DP

conform to the following standards

EN 50165

EN 55014

EN 60335-1

EN 60335-2-102

EN 60555-2

EN 60555-3

EN 676

Belgian royal decree dated 08/01/2004

These products bear the CE mark in

accordance with the stipulations of the

following directives

2006/ 42/EC Machinery directive

2004/108/EC EMC directive

2006/ 95/EC Low voltage directive

92/ 42/EEC EEC Working

efficiency directive

Annemasse, 6th October 2009

M. SPONZA

Important information

VG3.290 DP and VG3.360 DP burners are

designed for the low-pollutant combustion

of natural gas and propane gas. The

design and function of the burners meet

standard EN 676. They are suitable for use

with all heat generators complying with

standard EN 303 or for use by hot air

generators complying with standard DIN

4794 or DIN 30697 within their respective

performance range. Any other type of

application requires the approval of ELCO.

Installation, start-up and maintenance

must only be carried out by authorised

specialists and all applicable guidelines

and regulations must be complied with.

Burner description

VG3.290 DP and VG3.360 DP burners are

two-stage fully automatic monoblock

devices. The special design of the

combustion head enables combustion with

low levels of nitrogen oxide and increased

output. Class 3 type-approval in

accordance with EN676 certifies that the

lowest emission values have been

achieved and means that the national

environmental regulations have been met

AT: KFA 1995, FAV 1997

CH: LRV 2005

DE: 1.BImSChV

Emissions values may differ, depending on

combustion chamber dimensions,

combustion chamber load and the firing

system (three-pass boilers, boilers with

reverse firing). For specifying warranty

values, the conditions for the measuring

equipment, tolerances and humidity must

be observed.

Packaging

The burner is supplied packaged in three

boxes on a pallet:

- Burner housing with operating

instructions, circuit diagram and spare

parts list.

- Burner head with flange seal and

securing screws.

- Compact gas train with integrated filter

The following standards should be

observed in order to ensure safe,

environmentally sound and energy-

efficient operation:

EN 226

Connection of fuel oil and forced-draught

gas burners to a heat generator

EN 60335-1, -2-102

Specification for safety of household and

similar electrical appliances, particular

requirements for gas burning appliances

Gas lines

When installing the gas lines and trains,

the general directives and guidelines, as

well as the following national regulations,

must be observed:

CH: - G1 instruction text from SSIGE

- EKAS form no. 1942,

liquefied gas directive, part 2

- Cantonal authority guidelines

(e.g. directives for the pilot valve)

DE: - DVGW-TVR/TRGI

Installation location

The burner must not be used in rooms with

aggressive vapours (e.g. hair spray,

tetrachloroethylene, carbon tetrachloride),

high levels of dust or high air humidity (e.g.

laundry rooms).

If no connection to an air exhaust system is

provided for the air supply, there must be a

supply air inlet measuring:

DE: up to 50 kW: 150 cm

per additional kW: : + 2.0 cm

CH: QF [kW] x 6= ...cm

; but at least

150 cm

Variations may arise as a result of local

regulations.

02/2011 - Art. Nr. 4200 1028 2701B 3

Overview

Burner description

A1 Control and safety unit

A4 Display

F6 Air pressure switch

M1 Blower motor

T1 Igniter

Y10 Air flap servomotor

3 Adjusting screw for dimension Y

5 Housing

6 Plate hanging device

(Maintenance)

7 Combustion chamber pressure

take-off pipe

8 Burner tube

10 7-pin connector

10.1 4 pin connector

18 Cover

19 Release knob

20 Hood securing screw

113 Air intake box

02/2011 - Art. Nr. 4200 1028 2701B4

Operation

Safety function

Description of the function

A pre-ventilation time of 24 seconds

begins when first powering up, after a

power cut or a lockout, after the gas

supply has been cut or after a shutdown

for 24 hours.

During the pre-ventilation time

- the air pressure is monitored

- a check is made for the presence of

any abnormal flame signals.

At the end of the pre-ventilation time

- the ignition is switched on

- the main and safety solenoid valves

are opened.

- burner start-up

Monitoring

The flame is monitored by an ionisation

probe. The probe is fitted with insulation

to the gas head and is routed through

the turbulator into the flame zone. The

probe must not have any electrical

contact with earthed parts. The burner

switches to malfunction if a short circuit

occurs between the probe and the

burner earth. During burner operation,

an ionised zone is produced in the gas

flame through which a rectified current

flows from the probe to the burner tip.

The ionisation current must be at least

8µA.

Safety functions

- If no flame is produced when the

burner is started (gas release), the

burner is switched off at the end of the

safety time which lasts no more than

3 seconds and the gas valve closes.

- If the flame is lost during operation, the

gas supply is cut within a second. A

new start-up sequence is activated. If

the burner starts, the operating cycle

starts running. Otherwise a lockout

occurs.

- If there is an air failure during pre-

ventilation or operation, a lockout

occurs.

- If there is a gas failure, the burner

either stops or will not start. As soon

as sufficient gas pressure is available

again, the burner restarts.

During the regulator shutdown

- The control thermostat interrupts the

heat request.

- The gas valves close

- The flame goes out

- The blower motor stops

- The burner is ready for operation

Compact train

CH note

In accordance with SSIGE instructions,

it is compulsory to install a gas safety

valve (mark 1) in the pipe

DE Note

In compliance with the reference layout

applicable to boiler rooms, sites with gas

furnaces must be fitted with a thermal

gas shut-off valve (1).

F4 Gas pressure switch

F6 Air pressure switch

Y12 Safety solenoid valve

Y13 Main solenoid valve

1 Thermal shut-off valve (to be

installed by the installer)

104 Gas pressure regulator

106 Screen

108 Gas cut-out valve (to be installed

by the installer)

119pBrGas pressure measuring point at

the valve outlet

119.1Gas pressure measuring point

upstream of the valves

119.2Air pressure measuring point

pF Furnace pressure

pG Gas pressure at the head

pL Air pressure

02/2011 - Art. Nr. 4200 1028 2701B 5

Operation

TCG 5xx control unit



The TCG 5xx control and safety unit

controls and monitors the forced draught

burner. The microprocessor-controlled

program sequence ensures maximum

stability of time periods, regardless of

fluctuations in the power supply voltage

or the ambient temperature. The

automatic combustion control unit is

designed to cope with brownouts.

Whenever the supply voltage drops

below its rated minimum level (< 185V),

the control unit shuts down - even in the

absence of a malfunction signal. The

control unit switches itself back on again

once the voltage has returned to normal

levels (> 195V).

Pressing the

unlocking button on

the unit for

… causes …

... 1 second ... the control unit to

unlock.

... 2 seconds ... the control unit to

lock.

... 9 seconds ... the statistics to

be deleted

Moves the cursor upwards.

Moves the cursor downwards.

Increases the marked value.

Reduces the marked value.

Modifies/Confirms the value

shown.

Unlocks the control unit.

Red LED (flashes if a fault is

present).

Locking and unlocking

The control unit can be locked (switched

to malfunction mode) by pressing the

unlocking button and unlocked (fault

deleted), provided the unit is connected

to the mains power supply.

Always switch off the power

supply before installing or

removing the control unit. Do not

attempt to open or carry out

repairs on the control unit.

Screen Description Screen Description

Awaiting the heat request from

the boiler

Opening the gas valve and

safety time

Air flap is forced open for pre-

ventilation.

Flame is present, awaiting

authorisation of regulation

Pre-ventilation

Burner in operation. The lower

cell shows the strength of the

signal and the operating time of

the burner.

Closing the air flap to the ignition

position, pre-ignition

02/2011 - Art. Nr. 4200 1028 2701B6

Operation

TCG 5xx control unit

• menu for setting the

servomotor,

• menu for storing the

servomotor setting

points in the display

• menu for consulting

faults

• menu for statistical data

In parallel with its control and safety

functions, the TCG5xx control unit

allows the following to be set:

(see illustration)

- the position of the air flap during

ignition

- the position of the air flap at minimum

pressure

- the position of the air flap at maximum

pressure

The parameters for the control unit are

set using the display and 5 keys.

Operating values are shown in real time

on the display.

Pressing the keys gives access to 7

menus:

(

The menu on the bottom right is not

activated in VG3.290 DP

and

VG3.360 DP burners

)

• menu for setting/

adjusting the standard

configurations.

• menu for setting

industrial applications

• menu for manual control

In these menus, it is

possible to adjust the

control unit's standard

configurations. These are

pre-set in the factory. No

modifications may be

carried out on-site without

prior consultation with

ELCO. The access code

and the setting setpoints

for this menu are available

on request.

02/2011 - Art. Nr. 4200 1028 2701B 7

Operation

TCG 5xx control unit

Operating cycle phases:

1: No voltage

2: Powering up, no heat request

3: Heating request

4: Opening an air flap, arrival in pre-

ventilation position

5: Checking the rest status of the air

pressure switch

6: Pre-ventilation: energizing of the

motor, checking the air pressure

7: Pre-ventilation

8: Air flap closes to the ignition position

9: Switching on the igniter, unauthorised

flame monitoring

10:Opening of the solenoid valve, flame

formation, safety time: max. 3 s.

11:Awaiting regulator release

12:Opening the air flap, until the

maximum output is reached

13:Closing of the air flap until the

minimum regulation position is

reached

14:Operation at intermediate regulation

power

15:Operation at minimum regulation

power

16:Regulator shutdown, closure of the

air flap

17:Awaiting a new heating request

02/2011 - Art. Nr. 4200 1028 2701B8

Earth

Flame check

Fault

display

Air pressure

switch

Igniter

Burner motor

Connector

Terminal

Connector

Remote

unlocking

L1 power

supply

Solenoid valve

Control

thermostat

Heating

request

Earth

Gas pressure

switch

Operation

Terminal allocation chart

230 Volt connection

Terminal Description Connector Terminal Description Connector

1 Burner motor live

20 Minimum output thermostat live (T1)

2 Earth 21 Heating request signal (option T2)

3 Neutral 22 Flame monitoring signal

4 Solenoid valve live

23 Earth

5 Neutral 24 Live

6 Earth 25 Air pressure switch signal

7 Solenoid valve live 26 Live

8 Live 27 Live

9 Live L1

28 Remote unlocking signal

10 Earth 29 Neutral

11 Neutral 30 Signal fault live

12 Earth 31 Live

13 Earth 32 Live

14 Igniter live

33 Not used

15 Earth 34 Not used

16 Neutral

17 Control thermostat live

T6/7/8

18 Signal T7

19 Signal T8

02/2011 - Art. Nr. 4200 1028 2701B 9

Display-PC interface

Air servomotor

Connector

Terminal

Connector

Terminal Description Connector Terminal Description Connector

1 not used

18 not used

2 not used 19 not used

3 not used 20 not used

4 not used

21 not used

5 not used 22 not used

6 not used 23 not used

7 not used 24 not used

8 not used 25 not used

9 not used 26 not used

Display or PC interface

27 not used

11 28

Air servomotor

12 29

13 30

14 31

15 32

16 33

Operation

Terminal allocation chart

Low voltage connections

02/2011 - Art. Nr. 4200 1028 2701B10

Operation

MB-VEF gas train

The MBVEF compact gas valve

assembly is a combination of filter, gas/

air ratio regulator, valves and a pressure

switch:

- Screen with 0.8mm mesh

- GWA5 pressure switch

- Servo-pressure control part with

adjustable ratio V, correction of the

zero point offset N and furnace

pressure connection.

- V1 and V2 fast-opening and closing

solenoid valves

Technical data

Input pressure 360 mbar max.

Ambient temperature -15 to +70°C

Voltage 230 V/ 50 Hz Max.

Absorbed output 50 VA

Protection rating IP 54

1 Electrical connection of solenoid

valves (DIN 43650)

2 Electrical connection of the

gas pressure switch (DIN 43650)

3 Gas pressure switch

4 Inlet flange

5 Pressure measuring nipple

R1/8, upstream of filter (option)

6 Filter (under the cover)

7 Connection for furnace pressure

release pipe pF, R1/8

8 Adjusting screw for V ratio

9 Adjusting screw for zero point

offset N

10 Connection for pressure pipe pL,

R1/8

11 Connection for pressure pipe pBr,

R1/8

12 Outlet flange

13 Pressure take-off pipe pBr

02/2011 - Art. Nr. 4200 1028 2701B 11

Assembly

Burner assembly

Ø a Ø b c d

155-190 175-220 M10 45°

Preparing the boiler front

• Prepare the burner mounting plate/

boiler door in accordance with the

diagram.

• Establish the internal diameter a of

155-190 mm.

• To mount the burner head bracket, drill

four M10 holes (drill diameter 175 to

220 mm) as shown in the diagram

opposite.

Burner head assembly

• Screw the bolts into the burner fixing

plate/boiler door and position the

insulation material. For a drill hole of

< 220 mm, elongated slots should be

cut to the required dimensions.

• Remove the combustion components

from the head

• Attach the burner head with 4 nuts

(ref. 4). At this point, check that the

gas connection flange is correctly

positioned (on the left or right).

Burner tube installation depth and

brickwork surround

Unless otherwise specified by the boiler

manufacturer, heat generators without a

cooled front wall require brickwork or

insulation 5 as shown in the illustration

opposite. The brickwork must not

protrude beyond the leading edge of the

flame tube, and should have a maximum

conical angle of 60°. Space 6 must be

filled with an elastic, non-flammable

insulation material.

The furnace pressure take-off pipe pF

must not be clogged.

Exhaust gas evacuation system

To avoid unpleasant noise emissions,

right-angled connectors should not be

used on the flue gas side of the boiler.

Fitting the burner body

• Remove the cover (2 screws W).

• Unscrew the two screws Z on the

burner body completely.

• Bring the burner body into contact after

having swivelled it at least 15° to the

left.

• Engage the two screws Z on the body

into the two lugs provided.

• Tighten the 2 screws.

For assembly in the position with

the volute facing upwards, unclip

the display, turn it over 180°, and

refit it.



On boilers with reverse firing, minimum

flame tube insertion depth A should be

observed as per the boiler

manufacturer's instructions.

02/2011 - Art. Nr. 4200 1028 2701B12

Assembly

Gas manifold

Pressure take-off pipes

Gas train assembly

• Check the correct position of the

O-ring B in the gas connecting flange

• Secure the gas train on the burner

head so that the gas train coils are in

the upper vertical position.

• Pay attention to the direction of

circulation.

• Connect the power cable to the gas

train.

Connecting pressure take-off pipes

pF and pL

• Connect the furnace pressure take-off

pL on the burner body and the union

pL on the gas train using the flexible

tube pL (blue), shorten the tube

depending on the assembly scenario.

• Connect the furnace pressure take-off

pF on the burner body and the union

pF on the gas train using the flexible

tube pF (grey), shorten the tube

depending on the assembly scenario.

• Manually screw in the unions (max.

5 Nm) and check tightness.

02/2011 - Art. Nr. 4200 1028 2701B 13

Assembly

Checking/adjusting the burner head

Checking the burner head

• Check the adjustment settings of the

ionisation probe and of the ignition

electrode as per the diagrams.

Check the radial position of the flame

tube

After untightening the three mounting

screws S, it is possible to change the

position of the flame tube using the lever

H. Nitrogen oxide emissions may be

affected by the radial position of the

flame tube

• To be set at the start to position 1.

Fitting the combustion components

• Check that the O-Ring J1 is in the

correct position in the gas elbow.

• Insert the combustion components

into the head, tighten the mounting

screw X using an Allen key, then

tighten the lock nut using an open-

ended spanner.

• Thread the ionisation cable IK and the

ignition cables ZK into the grommets

R and S.

• Remove the cover.

Setting to liquid gas operation

• Remove the gas diffuser 3 and the

turbulator 4.

• Fit adaptor 5 (supplied with the

housing).

• Refit the turbulator 4 and the gas

diffuser 3.

02/2011 - Art. Nr. 4200 1028 2701B14

Assembly

Gas connection

Electrical connection

Checks before commissioning

The following must be checked before

initial commissioning:

• That the burner is assembled in

accordance with the instructions given

here.

• That the burner is pre-set in

accordance with the values in the

adjustment table.

• Setting the combustion components.

• The heat generator must be ready for

operation, and the operating

regulations for the heat generator

must be observed.

• All electrical connections must be

correct.

• The heat generator and heating

system must be filled with water and

the circulating pumps must be in

operation.

• The temperature regulator, pressure

regulator, low water detectors and any

other safety or limiting devices that

might be fitted must be connected and

operational.

• The exhaust gas duct must be

unobstructed and the secondary air

system, if available, must be

operational.

• An adequate supply of fresh air must

be guaranteed.

• The heat request must be available.

• Sufficient gas pressure must be

available.

• The fuel supply lines must be

assembled correctly, checked for

leaks and bled.

• A standard-compliant measuring point

must be available, the exhaust gas

duct up to the measuring point must

be free of leaks to prevent anomalies

in the measurement results.

General regulations applying to the

gas connection

• The gas train must only be connected

to the gas mains by a recognised

specialist.

• The cross-section of the gas line

should be of a size designed to

guarantee that the gas flow pressure

does not drop below the specified

level.

• A manual shut-off valve (not supplied)

must be fitted upstream of the gas

train.

• In Germany, a thermally triggered

shut-off valve (to be installed by the

customer side) must be fitted as

specified by the draft combustion

ordinance.

It is the responsibility of the fitter or his

representative to obtain approval for the

system at the same time as the burner is

commissioned. Only the fitter or his

representative can guarantee that the

system meets applicable standards and

regulations. The fitter should be in

possession of the corresponding official

permit, and should carry out the

corresponding sealing tests and purge

the system of air.

All electrical installation and

connection work must only be carried

out by a suitably qualified electrician.

The applicable guidelines and

directives must be observed,

as well as the electrical circuit

diagram supplied with the

burner!

Electrical connection

• Check to ensure that the power supply

is as specified (230V, 50 Hz single

phase with neutral and earth)

Boiler fuse: 10 A

Electrical connection

It must be possible to disconnect the

burner from the mains using an

omnipolar shutdown device complying

with the standards in force. The burner

and heat generator (boiler) are

connected by a 7-pin connector 1 and a

4-pin connector 2 (not supplied). The

diameter of the cables connected to

these connectors must be between 8.3

and 11 mm.

Connecting the gas train

Connect the gas train to the plugs on the

burner (black to black, grey to grey).

Ionisation current measurement

To measure the ionisation current,

disconnect connector B10 and connect

a multimeter with a measuring range of

0-100 µA.

The ionisation current must be at least

8 µA. It is also possible to read the

ionisation current on the display.

02/2011 - Art. Nr. 4200 1028 2701B 15

Commissioning

Adjustment data

The adjustment values above are guide

values and facilitate commissioning.

The factory settings are in bold set

against a grey background The final

settings are essential in ensuring that

the burner functions as well as possible

Setting the gas pressure switch

• Remove the transparent cover.

• Provisionally set to 15 mbar.

Setting the air pressure switch

• Remove the transparent cover.

• Provisionally set to 1 mbar.

MB-VEF420

Mini. Maxi. Ignition Mini. Maxi. G25 G20 G25 G20 G25 G31

100 195 40 2,2

7,5 7,5 35 -

1,6 / 0,1 2 / -0,3 2 / -0,4 2,25 / -0,6 1,2 / -0,1

110 225 40 2,5 10 10 45 - 1,6 / 0,1

2 / -0,3

2 / -0,4

2,25 / -0,6 1,2 / -0,1

125 250 40 2,8 15 15 55 - 1,6 / 0,1 2 / -0,3 2 / -0,4 2,25 /-0,6 1,2 / -0,1

120 240 40 2,7 10 10 40 2,1 / -0,6

1,7/-0,4

2/-0,8

2/-0,4 2,4/-0,8 1,3/0,1

135 270 40 2,9 12 12 50 2,1 /-0,6 1,6/0,1

2/-0,8

2/-0,4

2,2/-0,5 1,3/0,1

150 300 40 3,3

17 17 90 2,1 / -0,6 1,75/-0,8

2,3/-1,5

2/-0,7 2,4/-0,8 1,3/0

Gas valve setting

Screw V / Screw N

VG3.290

VG3.360

Air flap setting

MB-VEF412 MB-VEF407

Burner

power

Dimension

(mm)

Furnace

pressure

(mbar)

02/2011 - Art. Nr. 4200 1028 2701B16

Commissioning

Air regulation

Gas valve adjustment

Air regulation

Combustion air is regulated at two

points:

• on the pressure side, using the gap

between the turbulator and the burner

tube.

• on the vacuum side, by the air flap

driven by servomotor Y10.

The regulation of air in the burner head

affects not only the air flow but also the

mixing zone and the air pressure in the

burner tube. Turning screw A

- right: more air

- left: less air

• Adjust dimension Y in accordance with

the settings table.

Air regulation by air flap

Air is regulated on the vacuum side by

an air flap. This is driven by servomotor

Y10.

Gas valve adjustment

V Setting the maximum power

N Setting the minimum power

- For more CO

turn upwards on the

scale.

- For less CO

turn downwards on the

scale.

02/2011 - Art. Nr. 4200 1028 2701B 17

• For the next step, press any

button.

The overall view of the menus

is displayed, and the air flap

positions settings menu is

selected.

• Open the settings menu by

pressing the key.

You must now enter the

access code (see the label on

the back of the display)

• Increase or decrease the

value in increments by

repeatedly pressing or

• When the first figure has

been set, move the cursor to

the right by pressing .

• Repeat the operation until

you reach the last figure.

• Confirm the access code by

pressing

Commissioning

Pre-setting without flame

Setting is carried out in 2 phases:

- pre-adjustment without flame

- setting the flame, to fine tune the

settings based on the combustion

results

When the burner is switched on, the

control unit displays the screen below.

Important

At this point, no setting position for the

servomotor has been defined, therefore

the burner cannot be started under

these conditions.

Modifying a settings value for the servomotor position:

- To modify the value of a position, move the cursor to the

corresponding location with the or key.

- Select the value to be modified using the key, the

selected value will flash.

- Increase or decrease the value in increments of 0.1° by

repeatedly pressing or . For large modifications, press

and hold the or key the value will scroll quickly up or

down.

- Confirm the new value using the key. The value stops

flashing.

The control unit then opens the

settings mode. The screen

displays the factory pre-

settings for the different

positions of the air flap (here for

example: for a VG3.290 DP).

The following positions for the

air flap are presented:

- ignition position (when the

menu is opened, the curser

goes to this position)

- the position of the air flap at

minimum pressure

- the position of the air flap at

maximum pressure

02/2011 - Art. Nr. 4200 1028 2701B18

Commissioning

Pre-setting without flame

General advice before starting the burner

End of presetting menu without flame

When all the positions of the servomotor have been determined according to the required

settings, it is then possible to move on to the next section for commissioning - "Setting the flame".

To do this, place the cursor in the lower part of the screen on the symbol and confirm by

pressing the key.

If it is necessary to quit the menu without saving the pre-settings, position the cursor on the

symbol and confirm with the key.

Optimising combustion values

Optimum combustion values can be

achieved by adjusting the position of the

turbulator (dimension Y) if necessary.

Doing this can have an effect on starting

characteristics, pulsation and

combustion values. Any reduction in

dimension Y increases the CO

value.

However, starting characteristics

become harsher.

Compensate for the change in airflow if

necessary by adjusting the air flap

position.

Precautions: To avoid condensation,

observe the minimum required flue

gas temperature specified by the

boiler manufacturer and comply with

the requirements for flue gas ducts.

Risk of deflagration

Continuously check CO, CO

and soot emissions when

adjusting. Optimise

combustion values if CO is

present. The CO level must

not exceed 50 ppm.

Function check

Flame monitoring must be checked for

safety as part of initial commissioning

and also after servicing or if the system

has been out of operation for any

significant period of time.

- Starting attempt with gas valve closed:

once the safety time has elapsed, the

control and safety unit should indicate

a lack of gas or switch to malfunction

mode.

- Starting with the air pressure switch

closed:

after an 8-second test period, the

burner switches to malfunction mode.

- Starting attempt with air pressure

switch open:

after a 60-second waiting period, the

control and safety unit locks.

- Starting attempt with brief opening of

the air pressure switch during pre-

ventilation:

the control and safety unit restarts the

pre-ventilation programme (air

pressure detected again within

60 seconds) ; otherwise a lockout

occurs.



02/2011 - Art. Nr. 4200 1028 2701B 19

Commissioning

Setting the flame

- If the boiler heating request

is not present, the boiler

remains on standby.

In this case, it is still possible to

return to the previous setting

menu "Pre-setting without

flame". To do this, position the

cursor on the symbol and

confirm with the key.

- If a boiler heating request is

present (T1-T2 contact

closed), the burner starts.

The air flap is opened to move

to the pre-ventilation position.

Air pressure switch test

Pre-ventilation

The air flap switches to the

ignition/pre-ignition position.

The fuel valve opens.

Awaiting flame signal

If no flame is detected at the

end of the safety time, the

control unit switches to

malfunction mode.

If the flame is detected

Flame stabilisation

The control unit awaits the

regulation authorisation.

02/2011 - Art. Nr. 4200 1028 2701B20

Commissioning

Setting the flame

Setting the minimum pressure

If the flame has been detected and stabilised, the control unit sets the burner to minimum power

as soon as it receives the regulation authorisation.

- Check the combustion values (CO, CO

, soot test). If necessary, adjust screw N on the valve

(see page16).

- Read the ionisation current value.

- Read the gas flow rate on the gas counter.

Modification of the air flow via the "manual output control"

The "manual output control" function allows the burner output to be modified.

To do this, position the cursor on the corresponding line on the display and confirm with the

key. It is then possible to adjust the burner output upwards or downwards using the , keys.

 The servomotor reacts in real time. This is why the combustion values must be continuously

monitored.

Setting the maximum output

Slowly increase the burner to the maximum output using the "manual power control" function. At

this point, adjust the gas flow using the regulator V on the gas train.

The preset limit values for the minimum output and the maximum output cannot be exceeded. If

necessary, exit the "manual output control" function again using the key and modify the limit

value for the maximum or minimum output.

Definitive limitation of the maximum output position

Limit the maximum opening of the air flap according to the position determined for the maximum

output. In this example, the new position determined for the maximum output is below the value

set manually. Using the "manual output control" function, it is now possible to reduce the burner

output, but this cannot be set above the new maximum position, which here is 50°.

Definitive limitation of the minimum output position

Using the "manual output control" function, reduce the burner output to the minimum output. If

necessary, limit the minimum output position, in the same way as for the maximum output.

Specific function: ignition checking

If the ignition position has been modified, it is possible to carry out a new burner start-up to check

the new ignition position, without having to quit the settings menu.

To do this, after modifying the ignition position, position the cursor on the symbol, and initiate

the new start-up using the key.

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elco VG3 DUO Operation and Maintenance Manual

elco VG3 DUO Operation and Maintenance Manual

elco VG3 DUO Operation and Maintenance Manual

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