elco VGL03 Operation and Maintenance Manual

elco
Brand
elco
Model
VGL03
Type
Operation and Maintenance Manual
08/2005 - Art. Nr. 13 018 073A
Betriebsanleitung
Für die autorisierte Fachkraft
Gasgebläsebrenner.............................2-27
Operating instructions
For the authorized specialist
Gas burners .......................................29-54
EN
DE
VECTRON GL 03.250 DUO
VECTRON GL 03.350 DUO
}
Elektro- und Hydraulikschema
Electric and hydraulic diagrams
Schémas électr. et hydraulique
Esquema eléctrico y hidráulico
Art. Nr.
13 018 316
}
Ersatzteilliste
Spare parts list
Pièces de rechange
Piezas de recambio
Art. Nr.
13 018 075
29
08/2005 - Art. Nr. 13 018 073A
Declaration of conformity for
dual fuel burners
We, CEB
18, Rue des Bûchillons
Ville-La-Grand
F-74106 ANNEMASSE Cedex
Declare upon our sole responsibility
that the products
VECTRON GL 03.250 DUO
VECTRON GL 03.350 DUO
conform to the following standards:
EN 60335
EN 50081
EN 50082
EN 676
EN 267
These products are EC identified in
accordance with the provisions of the
directives:
90 / 396 / EWG Appliances burning
gaseous fuels
89 / 392 / EWG Machine directive
89 / 336 / EWG EMC directive
73 / 23 / EWG LV directive
92 / 42 / EWG Energy efficiency
directive
Annemasse, 1
st
July 2005
J. HAEP
EN
08/2005 - Art. Nr. 13 018 073A
30
General overview
Contents
Contents Page
General overview Declaration of conformity . . . . . . . . . . . . . . . . . . . 29
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical data, Areas of operation . . . . . . . . . . . . . . 31
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Combustion head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fuel-oil functions Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety function . . . . . . . . . . . . . . . . . . . . . . . . 34
fuel-oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 35
Gas functions Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Safety function . . . . . . . . . . . . . . . . . . . . . . . . 36
Mode of operation of the compact gas unit . . . . . . . . . . 36
Assembly General instructions . . . . . . . . . . . . . . . . . . . . . 37
Place of installation . . . . . . . . . . . . . . . . . . . . . . 37
Attachment to the heat generator. . . . . . . . . . . . . . . 38
Compact gas unit connection. . . . . . . . . . . . . . . . . 39
Electrical connections . . . . . . . . . . . . . . . . . . . . 40
Gas connection. . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel-oil connection . . . . . . . . . . . . . . . . . . . . . . 41
Fuel-oil supply . . . . . . . . . . . . . . . . . . . . . . . . 42
Single-pipe installation, Two-pipe installation. . . . . . . . . 42
Burner-presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Start-up Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 45
Burner adjustment, fuel-oil-burning mode . . . . . . . . . . 45
Burner adjustment, gas-burning mode . . . . . . . . . . 46-47
Flame monitoring . . . . . . . . . . . . . . . . . . . . . . . 48
Automatic combustion unit . . . . . . . . . . . . . . . . . . 49
TC 106 leak controller (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-54
Description
VECTRON GL 03.250/350 DUO are
fully automatic forced draught burners
of compact design for fuel fuel-oil or
gas fuels.
They are economical and safe in
operation.
Their construction and mode of
operation are in conformity with the
latest directives.
Principal burner components
·
Burner housing with air intake box,
air flap and equipment base plate
·
Electric motor with fan turbine
·
Two-stage fuel-oil pump with built-in
filter, fuel-oil pressure regulator and
magnetic coupling
·
Electromagnetic cut-off valves
·
Burner tube with burner pot
·
Gas tube complete, comprising: gas
tube, nozzle rod, nozzle, ignition
electrodes, turbulator
·
Ignition transformer
·
Compact gas unit, two-stage
·
Air flap actuator
·
Automatic combustion controller
·
UV flame monitor
·
Pressure switch for control of air
pressure in fan housing
·
Numbered terminal block
·
Two flexible fuel-oil pressure hoses
·
Burner connection flange with
insulating gasket and fixing screws
·
Burner hood in impact resistant
plastic.
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08/2005 - Art. Nr. 13 018 073A
General overview
Technical data
Areas of operation
Burner type
GL 03.250 DUO GL 03.350 DUO
Burner output . . . . . . . . . . . . . . . . . . kW
Mode of operation . . . . . . . . . . . . . . .
Fuel. . . . . . . . . . . . . . . . . . . . . . .
Gas types. . . . . . . . . . . . . . . . . . . .
Gas flow pressure . . . . . . . . . . . . . . . mbar
Automatic combustion controller / flame monitor
Burner motor . . . . . . . . . . . . . . . . . .
Electrical power consumption. . . . . . . . . . W
Protection index . . . . . . . . . . . . . . . .
Ambient temperature . . . . . . . . . . . . . . max.
Ignition transformer . . . . . . . . . . . . . . .
Air flap actuator . . . . . . . . . . . . . . . . .
Air pressure monitor . . . . . . . . . . . . . .
Fuel-oil pump. . . . . . . . . . . . . . . . . .
Nozzle size . . . . . . . . . . . . . . . . . . . gal.
Hose pipe. . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . Kg
EC mark . . . . . . . . . . . . . . . . . . . .
100 - 250
two-stage
EL heating fuel-oil to DIN
51603
natural gas E, LL
20 - 50
LGB 22 / QRA2
230V 50Hz 450W
700
IP 21
40°
ZM20/10
SQN31.25/12.251 A27 30
LGW10-A1P
AT3 55
2.75 / 60° S
Rp 3/8i / M12 x 1i - 1500mm
33
0085 AQ 1117
118 - 350
two-stage
EL heating oil to DIN 51603
natural gas E, LL
20 -50
LGB 22 / QRA2
230V 50Hz 450W
700
IP 21
40°
ZM20/10
SQN31.25/12.251 A27 30
LGW10-A1P
AT3 55
4.0 / 60° S
Rp 3/8i / M12 x 1i - 1500mm
33
0085 AQ 1117
Areas of operation
The areas of operation correspond to
values authorized for the type test,
which were obtained on simple flame
tube boilers (in conformity with TÜV).
Back pressure values actually obtained
were 10 % higher than the values
given.
Establishing required burner
efficiency
Burner efficiency
Q
·
B
is calculated as
follows from boiler output
Q
·
k
and
bfuel-oiler efficiency h
k
:
*= assumed bfuel-oiler efficiency hK
of 90%
Q
·
k
Q
·
k
Q
·
B
==
hK 0.9
EN
V-GL 03.350 DUO
V-GL 03.250 DUO
08/2005 - Art. Nr. 13 018 073A
32
General overview
Dimensions
1 Fuel selector control
2 Burner hood
3 Compact gas unit
4 Gas connection
5 Electrical connection compact gas
unit
6 Burner pot
7 Burner tube
8 Insulating gasket
9 Burner connection flange
10 Air intake box
11 Burner housing
12 Automatic combustion controller
13 Ignition transformer
14 Air flap actuator
15 Equipment base plate
16 Gas tube, complete
17 Sight glass
18 UV flame monitor
19 Electric motor
20 Fuel-oil pump
21 Clip for fuel-oil pipes
22 Clip for electrical connection cables
Burner type Performance
band
kW
DIN
DVGW
Reg.no.
Design
type
No.
Approx.
weight kg
“DN” gas
connector
ABCDEF
GL 03.250 DUO
GL 03.350 DUO
100–250
118–350
86.01 bEO “K”
86.02 bEO “K”
19695/86K
19695/86K
42
42
1 ½”
1 ½”
490
490
335
335
440
440
380
380
150
150
225
225
Burner type G H J K L M N O P S T U
GL 03.250 DUO
GL 03.350 DUO
136
136
415
435
85-320
115-350
90
90
110
120
150-180
190-220
210
252
340
340
210
210
125
149
130
155
M 10
M 10
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08/2005 - Art. Nr. 13 018 073A
Combustion head
Construction of combustion
head/setting data
All parts of the ignition and mixing unit
are adjusted to optimum settings before
leaving the factory. Subsequent fine
adjustment may be necessary as a
function of the operating environment.
Should fine adjustment be required, the
gas tube must be removed complete
with the ignition and mixing unit. Setting
values should be taken from the table
opposite.
The basic setting distance A refers
to turbulator/gas nozzle setting.
Scale value = 0
Burner type Basic setting distances in mm
ABCDEF
GL 03. ... DUO 0 12 8 3 27 0
1 Burner tube
2 Gas tube
3 Turbulence plate
4 Electrode holder
5 Ignition electrodes
6 Turbulator
7 Burner pot
8 Gas nozzle
Separation distances:
A = Edge of burner pot/turbulator
B = Turbulator/fuel-oil nozzle
C = Ignition electrode/fuel-oil nozzle
D = Space between electrodes
E = Gas nozzle/turbulence plate
F = Gas nozzle/upper tube
EN
08/2005 - Art. Nr. 13 018 073A
34
Fuel-oil functions
Starting
Operation
Safety function
Starting in fuel-oil-burning mode
The fuel selector control located on the
burner unit is set to fuel-oil operation. If
heat is required of the installation, the
heat generator regulator switches the
burner on automatically. The electric
motor with fan turbine and fuel-oil pump
starts up. The combustion chamber and
exhaust gas flue are preventilated in
accordance with regulations. The air
deficiency safety device must switch
over to operating mode within the preset
time. When the initial blower time has
elapsed, the ignition switches in. The
fuel-oil pump draws in fuel-oil and feeds
it through the electrovalve pos. 3.
The electrovalve opens and releases
fuel-oil under pressure to the fuel-oil
nozzle. The fuel-oil is atomized, mixed
with the combustion air and ignited.
When the safety interval has elapsed,
the ignition switches off.
fuel-oil pressure is adjusted by the
pressure regulator valve incorporated in
the pump.
Fuel-oil in excess of the nozzle’s flow
capacity or fuel-oil circulating before
fuel-oil release by the electrovalve is
diverted to the fuel-oil return by the
pressure regulator valves.
Hydraulic diagram
1 Electric motor
2 fuel-oil pump
3 “fuel-oil release” electrovalve
4 fuel-oil nozzle
5 Turbulator
6 Air flap
7 Air flap actuator
8 Pressure regulator valve - partial load
9 Electrovalve - full load
10 Pressure regulator valve - full load
Operation in fuel-oil-burning mode
If the burner programme, preventilation,
fuel-oil release, fuel ignition and ignition
switch-off have functioned properly, a
correct operation signal must be
communicated to the automatic
combustion controller by the UV flame
monitor. The burner has then reached
operating mode.
Switching over to full load operation
After partial load operating state has
been reached, the air flap actuator pos. 7
receives current from the regulator and
moves the air flap pos. 6 to full load
position.
The electrovalve pos. 9 closes and puts
the “Partial load” pos. 8 electrovalve out
of operation. The “Full load” pressure
regulator valve pos. 10 takes over
regulation of pressure. The burner has
now reached full load stage.
Two-stage burner operation
Two-stage burners operate on the
principal of one nozzle and two fuel-oil
pressures. The two fuel-oil pressures
are regulated by two independent
pressure regulation valves in the fuel-oil
pump.
The electric motor, fan turbine and
fuel-oil pump are in operation. The air
flap pos. 3 opens; the burner has gone into
partial load mode. Ignition is switched off.
The partial load fuel-oil pressure is
regulated by the “Partial load” pressure
valve pos. 8. The pump is now running
on the set pressure of the partial load
stage; as the partial load stage is set to
a lower pressure than at the full load
stage.
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08/2005 - Art. Nr. 13 018 073A
Fuel-oil functions
Fuel-oil pump
Safety functions, fuel-oil-burning mode
Should a flame fail to ignite when the
burner is started (on fuel-oil release),
the burner will be switched off as soon
as the safety interval of max. 3 seconds
has elapsed (safety shutdown). In the
case of safety shutdown, the fuel-oil
electrovalve closes and the electric
motor stops.
In the event of flame extinction or air
deficiency, safety shutdown will always
kick in.
In the event of air deficiency during the
initial blower time, the burner will not come
into operation. If the power supply is
interrupted, the fuel-oil feed is turned off
immediately. When the power returns, the
burner starts up automatically.
If light deficiency is detected by the UV
flame monitor, a safety shutdown takes
place. If flame presence is signalled during
initial blower operation, the program
sequence is broken off and the automatic
combustion controller locks out.
Burner failure is signalled by a red
indicator light in the release button of
the automatic combustion controller.
Pressing the release button unlocks the
system and initiates a fresh start-up
procedure.
fuel-oil pump
1 Electrovalve for switching between
stages 1 & 2
2 Pressure measurement connection
- 1-stage : no pressure
- 2-stage : nozzle pressure
3 Pressure regulator valve adjusting
screw
(low pressure setting - 1
st
stage)
4 Pump cover
5 Pressure regulator valve adjusting
screw
(high pressure setting- 2
nd
stage)
6 Electrovalve (fuel-oil release)
7 Retaining screw (4x) for pump
cover with filter
8 Pressure connection (to nozzle)
9 Vacuum measurement connection
10 Pressure measurement connection
11 Plug
R fuel-oil return connection (two-pipe
installation only) and by-pass plug
S Suction connection
EN
08/2005 - Art. Nr. 13 018 073A
36
Starting in gas-burning mode
The fuel selector control located on the
burner unit is set to gas operation. If
heat is required of the installation, the
heat generator regulator switches the
burner on automatically. The
subsequent operation of the burner
depends on the way the automatic
combustion controller is programmed.
The electric motor with fan turbine
starts up on initial blower operation with
prescribed air flow rate and time.
Immediately after initial blower
operation starts, the air deficiency
safety device must switch within a
specific time limit to operating
mode, i.e. the set air pressure must be
reached and must be maintained until
the switch over. Pre-ignition then starts,
followed by gas release. Proper flame
quality must be signalled to the
automatic combustion controller by the
UV cell within the specified safety
period.
The burner is in operation.
Operating functions in gas-burning
mode
Once the sequence of initial blower
operation, high voltage ignition, gas
release and ignition switch-off has been
correctly performed, a flame must be
signalled by the UV cell.
The burner is then in operating mode.
Two-stage burner operation
The air flap actuator receives current
from the stage 2 thermostat of the heat
generator. The air flap and compact
gas unit open and release full load
quantities of gas and air. The burner is
in full-load mode.
Safety functions, gas-burning mode
Should a flame fail to ignite when the
burner is started (on gas release), the
burner will be switched off as soon as
the safety interval t2 of max. 3 seconds
has elapsed (safety shutdown). In
safety shutdown the gas valve
invariably closes and the electric motor
stops. In the event of flame extinction
during operation, the gas supply is
interrupted immediately and the
automatic combustion controller
switches over to fault within 1 second.
In the event of air deficiency during the
initial blower time, the burner does not
come into operation.
A safety shutdown follows. Air
deficiency during operation also triggers
a safety shutdown.
In the event of gas deficiency, the
burner does not come into operation.
No initial blower operation takes place.
In the event of gas deficiency during
operation, the gas valve closes and the
burner switches off. However, safety
shutdown does not take place. After
re-establishment of gas pressure, the
burner starts up again automatically.
If the power supply is interrupted, the
gas supply is immediately cut off. After
re-establishment of the power supply,
the burner starts up again
automatically.
If light deficiency is detected by the UV
flame monitor, safety shutdown takes
place. If flame presence is signalled
during initial blower operation, the
program sequence is broken off and
the automatic combustion controller
locks out. Burner failure is signalled by
a red indicator light in the release
button of the automatic combustion
controller. The installation can be
started up again by pressing the
release button.
Mode of operation of compact gas
unit type CG... V
When current is applied to the
windings, valve 1 and valve 2 open.
The incoming gas is cleaned by a filter
pos. 5. The integral pressure regulator
pos. 3 regulates the desired output
pressure. Burner gas pressure p
G
(internal pressure take-off line) of the
relative pressure regulator is
determined by combustion air pressure
p
L
(external pressure take-off line) as
reference variable.
Combustion chamber pressure pF can be
taken into account with it as a correction.
The required values for:
·
pressure monitor set pressure p
W
·
transfer ratio V and
·
zero point displacement N can be
adjusted with the adjusting screws pos. 4
provided on both sides.
Threaded connection points for combustion
chamber pressure p
F
and combustion air
pressure p
L
are provided on the front.
Inlet and outlet gas pressure can be
measured at sampling points pos. A
and pos. B.
1 Valve 1
2 Valve 2
3 Pressure regulator
4 Adjusting screw p
W
, V, N
5 Adjusting screw V
6 Adjusting screw N
7 Filter
8 Measurement point, inlet pressure
9 Measurement point, outlet pressure
10 Connection point p
L
“Combustion Air Pressure”
11 Connection point p
F
“Combustion
Chamber Pressure”
Gas functions
Starting
Operation
Safety function
Mode of operation of the compact gas unit
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08/2005 - Art. Nr. 13 018 073A
Assembly
General instructions
Place of installation
Leak controller TC 106 (accessory)
The TC 106 leak controller pos. 1 which
can be built onto the compact gas unit
is designed to detect prohibited leakage
from any of the valves of the compact
gas unit and to inhibit burner start-up
immediately.
General instructions
Installation and start-up of the burner
must be carried out by a specialist. He
bears the responsibility for proper
execution of the procedure.
For safe operation, environmentally
friendly and economical of energy, the
following standards must be respected:
DIN 4755 Fuel-oil-burning installations
DIN 4756 Gas combustion in heating
installations
DIN 4787 Atomized fuel-oil burners
DIN 4788 Blown gas burners
DIN 4789 Connection of blown
atomized fuel-oil and gas
burners to heat generators
VDE 0116 Electrical equipment of
combustion installations
CAUTION
Use only burners for natural gas and
Extra Light heating fuel-oil.
Place of installation
The burner may not be used in
environments where aggressive
vapours are present (e. g. hair spray,
perchloroethylene, carbon tetrachloride)
or in dust-laden or high humidity
atmospheres (e. g. laundries).
In the event of damage resulting from
the following causes, we decline all
responsibility:
·
improper use
·
improper assembly or repair by the
buyer or a third party, including use of
non-original spare parts.
Permissible environmental
conditions
·
Temperature 0 - 40° C
·
Rel. humidity 40 - 80 %
·
Air pressure 990-1100mbar
Instruction to users
The installation must undergo
maintenance by a specialist at least
once a year. In order to guarantee
regular maintenance to schedule, it is
advisable to take out a service contract.
EN
08/2005 - Art. Nr. 13 018 073A
38
Assembly
Attachment to the heat generator
Attachment to the heat generator
Most heat generators have a burner
flange mounting plate provided with an
opening to DIN 4789. If this standard
opening is not present, the fixing plate
on the heat generator must be
prepared to the dimensions given on
page 29.
The burner connection flange can be
used as a template to drill the tapped
holes.
·
Fix the connecting flange to the heat
generator with an insulating gasket.
Do not tighten the screws.
·
On the VECTRON GL 03.250/350
DUO, the burner pot pos. 1 is greater
in diameter than the burner tube.
Where the diameter of the burner pot
is greater than that of the burner
connecting flange or the boiler
opening, the burner pot must be
dismantled. To do this, remove the
burner hood, withdraw the UV flame
monitor pos. 3, slacken fuel-oil
connection pos. 4 on the nozzle rod,
unscrew the 4 screws pos. 5 and
take out the whole gas tube.
·
Slacken bolt pos. 2 on burner tube
and remove together with nut.
·
Pull burner pot out of burner tube,
push burner tube into connection
flange of heat generator, replace
burner pot and secure with bolt and
nut.
·
Insert burner tube again and tighten
screws, connect fuel-oil pressure
pipe to nozzle line and push in UV
flame monitor on gas tube.
·
Adjust burner pot according to table
on page 33.
·
Burner pipe installation depth
depends on the heat generator
involved. It should be determined
from the dimensions given on page
32.
·
Lifting the burner slightly, clamp
firmly with clamping screw pos. 6.
·
Tighten down the four securing
screws pos. 7.
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08/2005 - Art. Nr. 13 018 073A
Assembly
Compact gas unit connection
Compact gas unit connection
·
Place leakproof gasket pos. 1 in
position and secure compact gas unit
with four screws on the gas tube.
·
Connect plugs “A” and “B” pos. 2 to
the labelled equipment sockets on
the compact gas unit and secure with
screws.
NOTE
If desired, a TC 106 leak controller
(accessory) can be fitted.
For connections see page 50.
·
Remove burner hood.
·
Connect the ends of the two pressure
sampling lines pos. 3 to connection
nipples p
F
and p
L
on the compact gas
unit and tighten firmly.
p
F
- “black” pressure sampling line for
combustion
p
L
- “blue” pressure sampling line for
blower pressure
·
Match the lengths of the pressure
sampling lines.
·
Connect free end of p
F
pressure
sampling line to threaded socket pos. 4
of pressure sampling tube on burner
connection flange and tighten firmly.
·
Connect free end of p
L
pressure
sampling line to threaded socket pos. 5
of gas tube and tighten firmly.
EN
08/2005 - Art. Nr. 13 018 073A
40
Assembly
Electrical connections
Electrical connections
Electrical connections are made via two
plug connectors whose socket
elements pos. 1 (7-pin) and pos. 2
(4-pin) are built into the component
panel of the burner.
·
Connect plugs of heat generator pos. 3
and 4 to socket elements on burner.
NOTE
If the cables of the heat generator are
not fitted with plugs, the socket
elements on the burner can also be
used as terminal clamps pos. 5.
To do this, unscrew lid of socket
elements.
Choose the length of the cables so that
the burner can be swung out with ease.
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08/2005 - Art. Nr. 13 018 073A
Assembly
Gas connection
Fuel-oil connection
fuel-oil connection
The flexible fuel-oil pipes supplied with
the burner are connected to the
screwed sockets pos. 1 and 2 of the
fuel-oil pump and fixed with the clamp.
The shut-off and filter units must be
positioned in such a way that the pipes
run properly, i.e. that there should be
no kinking in the pipes.
The suction pipe should be positioned
up to 5cm above the bottom of the tank.
The return pipe should be led up to
about 5cm below the top of the tank.
Pipe dimensions for inflow and return of
the shut-off and tank filter units should
be as specified on page 42.
If the burner is being installed on the
single pipe system, the same
instructions apply as for two-pipe
installation, except that there is no
return pipe and only one flexible pipe
and one shut-off valve are required.
Conversion single/two-pipe
installation
The installation is converted by
unscrewing or inserting the by-pass
plug in the return connection pos. 1 on
the fuel-oil pump (see diagram of pump
cover and fuel-oil pump, page 35).
Plug
screwed in = two-pipe installation
(as delivered)
Plug
screwed out = single-pipe installation
(hexagon socket, 4mm key)
Gas connection
Gas pressure at the connection point
must be at least 18 mbar. For
pressures > 50mbar, an admission
pressure regulator must be fitted.
Screw a threaded connector into the
gas supply point on the compact gas
unit and connect the gas supply pipe.
NOTE
Bring the gas supply line to the burner
by the shortest route with the least
possible pressure loss.
Remove all dirt and foreign matter from
connectors before assembly.
Seal connections only with
DVGW-tested sealing materials.
Conduct leakage tests on unions under
full pressure after opening the manual
shut-off valve and main supply valve,
using a non-corrosive, DVGW-tested
foaming agent.
EN
08/2005 - Art. Nr. 13 018 073A
42
Assembly
Fuel-oil supply
Single-pipe installation
Two-pipe installation
fuel-oil supply
Connect flexible hoses and fuel-oil
pipes to the corresponding units.
Seal-screw connections with
fuel-oil-resistant materials only.
The values given in the table and
diagram are based on practical tests,
during which appropriate safety factors
were calculated and incorporated.
Should the limit values of 4m suction
height H or max. 60m effective length
of suction channel L be exceeded, an
auxiliary pump must be installed.
In this connection, see also technical
worksheets
TI-20.10.00 (section No. 121345) or
TI-20.10.02 (section No. 121347)
The values in square brackets refer to DN 6 H [m]
l/h
22 1.0 [4.0] [3.9] [3.6] [3.0] [2.5] [1.8] [1.4] [0 ] [0 ]
20 1.4 [4.0] [4.0] [3.7] [3.2] [2.7] [2.2] [1.7] [1.1] [0.6] [0 ] [0 ]
18 1.8 [4.0] 0 [4.0] [3.8] [3.4] [2.9] [2.6] [2.0] [1.5] [1.1] [0.7] [0.5] [0 ]
16 2.2 [4.0] 0.6 [4.0] [3.9] [3.6] [3.1] [2.9] [2.3] [1.9] [1.5] [1.3] [1.0] [0.5]
14 2.5 [4.0] 1.1 [4.0] [4.0] [3.8] [3.3] [3.1] [2.6] [2.3] [1.9] [1.7] [1.5] [1.0]
12 2.8 [4.0] 1.6 [4.0] 0 [4.0] [3.9] [3.5] [3.3] [2.9] [2.6] [2.3] [2.1] [1.9] [1.5]
10 3.1 [4.0] 2.2 [4.0] 0.8 [4.0] 0 [4.0] [3.7] [3.5] [3.2] [2.9] [2.7] [2.5] [2.3] [2.0]
8 3.4 [4.0] 2.7 [4.0] 1.5 [4.0] 0.3 [4.0] 0 [3.9] [3.7] [3.5] [3.3] [3.1] [2.9] [2.7] [2.5]
6 3.6 [4.0] 3.1 [4.0] 2.1 [4.0] 1.1 [4.0] 0.1 [4.0] 0 [3.9] [3.8] [3.6] [3.5] [3.3] [3.1] [2.9]
5 3.8 [4.0] 3.5 [4.0] 2.8 [4.0] 1.9 [4.0] 1.2 [4.0] 0.4 [4.0] 0 [4.0] 0 [3.9] [3.8] [3.7] [3.5] [3.3]
4 4.0 3.7 [4.0] 3.3 [4.0] 2.7 [4.0] 2.1 [4.0] 1.5 [4.0] 0.9 [4.0] 0.3 [4.0] 0 [4.0] 0 [4.0] [3.9] [3.7]
3 4.0 4.0 3.6 [4.0] 3.1 [4.0] 2.7 [4.0] 2.2 [4.0] 1.7 [4.0] 1.2 [4.0] 0.7 [4.0] 0.3 [4.0] 0 [4.0] 0 [4.0]
2 4.0 4.0 3.9 [4.0] 3.5 [4.0] 3.1 [4.0] 2.8 [4.0] 2.4 [4.0] 2.0 [4.0] 1.6 [4.0] 1.3 [4.0] 0.9 [4.0] 0.5 [4.0]
5 1015202530354045505560
L [m]
Single-pipe installation DN 4 [4x6] / DN 6 [6x8]
H = Suction height
L=Total length of suction pipework
l/h = Nozzle through flow
Two-pipe installation
Piping dimensions corresponding to:
Zone A Zone B Zone C
DN 6
8 x 1
DN 8
10 x 1
Auxiliary
pump
H = Suction height
H1 = Supply head when tank is
located higher
L=Total length of suction pipework
43
08/2005 - Art. Nr. 13 018 073A
Burner presetting
In order to achieve optimum
combustion efficiency, the burner must
be adjusted as a function of conditions
of installation.
For this, the following adjustments can
be made:
1) Air flap setting
2) Turbulator/gas nozzle setting
3) Compact gas unit setting
4) fuel-oil pressure setting
Air flap setting
The air flap regulates air flow by means
of the air flap actuator.
The regulation range is limited by
adjustable trip cams acting on limit
switches.
Trip cam I: Full load
Trip cam II: Air Flap “CLOSED”
Trip cam III: Partial load
Trip cam V: Stage 2 “fuel-oil”
Preset the air flap for desired
performance in accordance with the
values shown in the table on page 44.
For adjustment of trip points, the trip
cams pos. 1 are easily accessible and
can be adjusted during start-up with the
cam key pos. 2. The cam drum can be
uncoupled from the reduction drive
manually (see detail pos. 4).
End and auxiliary switch cam
adjustments to air flap actuator
To check correct end and auxiliary
switch function, the cam drum must first
be uncoupled from the drive by means
of the locking pin pos. 4.
Cam drum and air flap can then be
moved freely by means of the setting
wheel pos. 6. The air flap is closed
manually. The scale disc pos. 3 should
then be positioned on zero.
The air flap is preset by reference to
the table “Burner presetting” and limited
with the appropriate trip cam pos. 1
(see table page 44, column “Air flap
setting”). After adjusting the trip cams,
lock the cam drum and drive together
again.
It is essential that the trip points of the
trip cams should be adjusted after
installation as a function of the
environment and after analysis of the
flue gases (burner fine-adjustment).
Detail of pos. 4
Push locking pin in direction of arrow
The current air flap setting can be seen
through the sight glass pos. 5 with
scale.
EN
08/2005 - Art. Nr. 13 018 073A
44
Burner presetting
Turbulator/gas nozzle setting
The data given in the table for
turbulator/gas nozzle setting are
applicable for the combustion chamber
pressure p
F
shown and with natural gas
are equivalent to a lower heating value
in normal state Hu
n
= 9.942kWh/m
3
and
gas inlet pressure p
E
= 20mbar.
Carry out the required turbulator/gas
nozzle setting using the adjusting screw
pos. 2 and read it off the scale pos. 1.
Compact gas unit setting
Set the required values for:
·
pressure monitor: set pressure p
W
·
transfer ratio V and
·
zero point displacement N
in reference to the table below and
make the settings on the compact gas
unit using the adjusting screws.
The setting data in the table are basic
setting values with which the burner
can be brought into service. The
settings must be optimized as a
function of installation and flue gas
analysis.
Burner type Output range in
kW
Air flap setting
(scale value)
Combustion-
chamber
pressure pF
Turbulator-/
gas nozzle-
Setting
(scale value)
Compact gas unit setting data
Type CG... V
1
st
stage
2
d
stage
1
st
stage
2
d
stage
1
st
stage
2
d
stage
p
W
mbar
V N Adjusting
ratio
GL 03.250
DUO
102
139
182
143
205
256
1.4
2.4
3.0
2.3
3.5
5.5
+ 0.1
+ 0.8
± 0
+ 0.2
+ 2.0
+ 0.2
5
10
15
c. 10
c. 10
c. 10
+ 3.5
+ 2.0
+ 1.1
- 0.5
- 0.5
- 0.2
1 : 1.40
1 : 1.47
1 : 1.40
GL 03.350
DUO
118
174
255
180
279
350
1.9
3.0
3.5
2.8
4.4
5.5
± 0
+ 0.6
+ 0.2
± 0
+ 2.0
+ 0.4
9
12
21
ca. 10
ca. 10
ca. 10
+ 2.2
+ 2.7
+ 2.0
- 0.5
- 0.8
- 0.5
1 : 1.52
1 : 1.60
1 : 1.37
Burner type Setting data fuel-oil
Pump pressure
in bar
Nozzle
Gal
Flow rate
kg/h
1
st
stage
2
d
stage
60° S
or *SS
1
st
stage
2
d
stage
GL 03.250
DUO
12.0
9.5
10.0
25.0
25.0
22.0
2.0
2.75
4.0
8.3
12.0
15.3
12.0
17.0
21.2
GL 03.350
DUO
10.0
9.0
11.5
25.0
25.0
23.0
2.5
4.0
5.5*
10.0
14.8
21.5
15.0
23.4
29.5
Factory settings printed in bold script
45
08/2005 - Art. Nr. 13 018 073A
Start-up
Preparations
Burner adjustment, fuel-oil burning mode
Preparations before first start-up
·
Respect the operating instructions of
the heat generator manufacturer.
·
Check correct settings of :
–
temperature regulator
–
pressure regulator
–
limiter
–
safety monitor
·
Set correct gas inlet pressure p
e
–
p
e
min = 18mbar
–
p
e
max = 100mbar
·
Check leak tightness of gas and
fuel-oil supply elements
·
Bleed air out of fuel supply lines
·
Verify that flues are unobstructed and
that fresh air supply is adequate
Checking burner program sequence,
fuel-oil-burning mode
·
Remove gas tube, fit the appropriate
fuel-oil nozzle for the output required
(two-stage operation).
·
Verify conformity with setting data in
table on page 33 for
turbulator/fuel-oil nozzle adjustment
and refit gas tube.
·
Open manual fuel-oil shut-off valve.
·
Set fuel selector on burner to fuel-oil,
switch on heat generator to start and
check proper operation of program as
follows:
–
Blower operates with a delay,
depending on the settings to the
automatic combustion controller:
– Initial blower time t
1
= 30s
– Pre-ignition time t
3
=3s
– Electrovalve opens
– Safety interval t
2
=3s
NOTE
To check safety interval, pull out UV
flame monitor and shade it with the
hand.
– Safety shutdown after the safety
interval has elapsed with locking
out of the automatic combustion
controller (fault indicator light in
release button pos. 1 goes on).
Burner adjustment, fuel-oil-burning
mode
· Unlock automatic combustion
controller and start burner by
pressing release button pos. 1.
·
Bleed air from fuel-oil lines through
bleed screw on filter.
·
Switch off burner.
·
Remove screw plug pos. 2 and
connect vacuum meter.
·
Remove screw plug pos. 3 and
connect pressure gauge (R1/8”).
·
Connect ammeter according to
measurement instructions on page 48.
·
Switch on burner.
·
Check vacuum (max. 0.45bar).
·
Set stage 1 fuel-oil pressure for
desired output according to the table
on page 44 using adjusting screw
pos. 4.
Turn to right = increase pressure
Turn to left = reduce pressure
and adjust air flap setting until
prescribed flue gas values are
obtained.
·
Switch on stage 2 regulator on heat
generator.
·
Adjust trip cam pos. 6 for switch
over of stage 2 fuel-oil valve to
obtain reliable switch-over to stage 2
with low generation of pollutants.
Check for a stable flame signal on
the ammeter.
·
Set stage 2 fuel-oil pressure
corresponding to desired output
according to the table on page 44
using adjusting screw pos. 5:
Turn to right = increase pressure
Turn to left = reduce pressure
and adjust air flap setting until
prescribed flue gas values are
obtained.
EN
08/2005 - Art. Nr. 13 018 073A
46
Start-up
Burner adjustment, gas-burning mode
Checking burner program sequence
before first gas release
·
Close manual GAS shut-off valve.
·
Ensure absence of all current at the
burner by disconnecting electricity
supply.
·
Shunt out gas pressure monitor
across terminals 48 and 49 on
terminal block pos. 1 (see attached
wiring diagram).
·
Restore electricity supply.
·
Set fuel selector on burner to GAS,
then start by switching on heat
generator and check proper
functioning of program sequence as
follows:
–
Blower operates with a delay,
depending on the settings to the
automatic combustion controller:
– Initial blower operation t
1
= 30s
– Pre-ignition time t
3
=3s
– Electrovalve opens
– Safety interval t
2
=3s
– Safety shutdown after safety
interval has elapsed with lock-out
of automatic combustion controller
(fault indicator lamp in release
button pos. 2 goes on).
·
Ensure absence of all current at the
burner by disconnecting electricity
supply.
·
Remove shunt across terminals 48
and 49 on terminal block pos. 1.
·
Restore electricity supply.
Burner adjustment gas-burning
mode
·
Connect ammeter (see flame
monitoring, page 48).
·
At measurement point B on compact
gas unit, remove screw plug and
connect pressure measurement
instrument.
·
Preset in accordance with table
page 44, transfer ratio V for
compact gas unit, or for “reliable
operating zone”.
·
Open manual gas shut-off valve,
switch on heat generator. Burner
starts.
·
Check presence of flame signal.
This must read at least 200µA.
·
Set zero displacement N:
–
For air deficiency towards -
–
For excess air towards + and
carry out CO measurement check.
Permissible operating zones:
p
L
= 0.4 to 30mbar
p
L
- p
F
> 0.4mbar if p
F
is connected
p
G
= 0.4 to 50mbar
p
F
= - 2 to + 20mbar
V=p
G
:p
L
= 0.7 : 1 to 7 : 1
N = - 1.5mbar to + 1.5mbar
NOTE
For gas, adjust the burner only for N
and V on the compact gas unit, as
the air flap setting has already been
carried out for fuel-oil.
47
08/2005 - Art. Nr. 13 018 073A
Start-up
Burner adjustment, gas-burning mode
·
Proceed to 2
nd
stage on the
thermostat of the heat generator.
·
Set transfer ratio on compact gas
unit as a function of flue gas values.
In case of air deficiency = reduce V
In case of excess air = increase V
Set flue gas values in accordance
with regulations.
·
Go back from 2
nd
stage to 1
st
stage
and measure flue gas values.
In case of air deficiency = reduce N
In case of excess air = increase N
Set flue gas values in accordance
with regulations.
·
Bring burner to 2
nd
stage, measure
flue gas values and volumetric gas
flow
V
·
G
. Adjust transfer ratio V as
necessary.
·
Go back from 2
nd
stage to 1
st
stage
and measure volumetric gas flow
V
·
G
.
Air regulation in the burner head
influences not only air quantity, but also
air velocity in the mixing zone, as well as
air pressure in the burner tube.
Optimum adjustment of the turbulator
should be obtained by turning the
adjusting screw pos. 1. This also
influences the length of the flame in the
combustion chamber.
Turn adjusting screw
to the right = larger cross-section
(longer flame)
Turn adjusting screw
to the left = smaller cross-section
(shorter flame)
NB !
In this case, volumetric gas flow
V
·
G
must be matched by means of the
transfer ratio V.
EN
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elco VGL03 Operation and Maintenance Manual

elco
Brand
elco
Model
VGL03
Type
Operation and Maintenance Manual
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