elco VG3 DUO Operation and Maintenance Manual

elco
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
en
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
2
per additional kW: : + 2.0 cm
2
CH: QF [kW] x 6= ...cm
2
; but at least
150 cm
2
.
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
en
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
en
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
en
02/2011 - Art. Nr. 4200 1028 2701B8
Earth
Flame check
Fault
display
Air pressure
switch
Igniter
Burner motor
Connector
Terminal
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
4
20 Minimum output thermostat live (T1)
19
2 Earth 21 Heating request signal (option T2)
3 Neutral 22 Flame monitoring signal
11
4 Solenoid valve live
2
23 Earth
5 Neutral 24 Live
6 Earth 25 Air pressure switch signal
10
7 Solenoid valve live 26 Live
8 Live 27 Live
20
9 Live L1
6
28 Remote unlocking signal
10 Earth 29 Neutral
21
11 Neutral 30 Signal fault live
12 Earth 31 Live
8
13 Earth 32 Live
14 Igniter live
5
33 Not used
34
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
Terminal
Connector
Terminal Description Connector Terminal Description Connector
1 not used
30
18 not used
14
2 not used 19 not used
3 not used 20 not used
4 not used
27
28
29
21 not used
5 not used 22 not used
6 not used 23 not used
7 not used 24 not used
33
8 not used 25 not used
9 not used 26 not used
32
10
Display or PC interface
16
/
17
27 not used
11 28
Air servomotor
15
12 29
13 30
14 31
15 32
16 33
17
Operation
Terminal allocation chart
Low voltage connections
en
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.
en
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
C.
• 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.
en
02/2011 - Art. Nr. 4200 1028 2701B14
Assembly
Gas connection
Electrical connection
Checks before commissioning
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.
en
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
DP
VG3.360
DP
Air flap setting
MB-VEF412 MB-VEF407
Burner
power
Dimension
Y
(mm)
Furnace
pressure
pF
(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
2
turn upwards on the
scale.
- For less CO
2
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
en
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
2
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
2
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.
en
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
2
, 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
Brand
elco
Model
VG3 DUO
Type
Operation and Maintenance Manual
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