elco ES08.2800 G/F-VT, ES08.3700 G/F-VT, ES08.4000 G/F-VT, ES08.5000 G/F-VT Operating Instructions Manual

04/2009 - Art. Nr. 4200 1018 1100A

ES08.2800 G/F-VT
ES08.3700 G/F-VT
ES08.4000 G/F-VT
ES08.5000 G/F-VT

Operating instructions

For the authorized specialist

Gas burners ........................................... 2-19

Betriebsanleitung

Für die autorisierte Fachkraft

Gasbrenner .......................................... 20-37

Инструкция по эксплуатации

Предназначено для квалифицированных
специалистов по установке

Газовая горелка ................................. 38-55

fr, it, es ................................. 4200 1018 1000

............................................. 4200 1018 0900

en

de

ru

04/2009 - Art. Nr. 4200 1018 1100A2

General information

Table of contents
Guarantee, safety
Main statutory instruments

Contents

General information

Guarantee, safety .............................. 2

Main statutory instruments................. 2

Overview legend.................................3

Packaging...........................................4

Technical data

See technical data N° 420010180900

Installation

Assembly............................................5

Gas connection ..................................6

Electrical connection .......................... 6

Start-up

Preliminary check-up.......................... 7

Settings .....................................7 to 13

Program of the control

and safety unit.........................14 to 15

Control panel TC ..............................16

Settings, safety checks.....................17

Firing ................................................17

Maintenance....................................18

Troubleshooting ............................. 19

Guarantee

Installation and start up must be carried
out in accordance with currently
accepted practices by a qualified
technician; current regulations as well as
the instructions that follow must be
complied with.
The manufacturer will decline all
responsibility in the event of failure to
comply fully and in every respect with
any of the relevant requirements.
Refer also to:

- the certificate of guarantee attached to
the burner;

- the general terms of sales.

Safety

The burner is designed to be installed on
a generator connected to exhaust pipes
used for products of combustion in
serviceable condition.
It should be used in areas where an
adequate supply of fresh air is available
for correct combustion and where any
waste products can be properly
evacuated.
The size and design of the flue must be
appropriate to the fuel in accordance
with current regulations and standards.
Power supply 230 VAC % 50Hz

±1%

the control and safety unit as well as to
the cut-off devices used must include an
earthed neutral wire.
In addition, the neutral conductor

must have the same electrical
potential as the earth conductor.

Failing that, power supply to the burner
must include an isolating transformer
and the appropriate protection (30 mA
circuit breaker and fuse).
In order that the burner operates

correctly, please respect the polarity
of the conductors when connecting
the 7P connector.

The burner must be able to be isolated
from the system by means of
a multi pole switch complying with the
standards in force.
Operating personnel should act with
extreme caution in all cases and more
especially avoid any direct contact with
areas that are not heat-insulated and
electrical circuits.
Water should not be splashed on to the
burner's electrical components.
In the event of flooding, fire, fuel leakage
or any other dangerous situation
(smells, suspicious noises, etc.), stop
the burner, cut off the main power supply
and the fuel supply and call in an
approved specialist.
The use of chlorinated solvents to clean
the burner is prohibited.
It is compulsory for all furnaces and
accessories, flues and connection
pieces to be maintained, cleaned and
swept at least once a year and prior to
burner start up. Consult the applicable
regulations in force.

Use a purpose-designed foam to test the
external tightness of valve assembly
connections, including the filter.

Main statutory instruments “FR”

Dwellings :

- French Order dated 2nd August 1977
and later modifying / supplementary
orders: Technical and safety
regulations governing combustible
gas and liquified hydrocarbon
installations located inside dwellings
and their outbuildings.

- DTU Standard P 45-204 : Gas
installations (formerly DTU n° 61-1

- Gas installations - April 1982 + later
addendums).

- DTU Standard 65.4 - Boiler house
technical provisions.

- French NF Standard C15-100 + Low
voltage electrical installation
regulations.

- French Departmental health
regulations.

Public Buildings :

- Public building fire and panic
prevention safety regulations.

General provisions :

- GZ sections (combustible gas and
liquified hydrocarbons);

- CH sections (heating, ventilation,
cooling, air conditioning and steam
and domestic hot water production);

Provisions specific to each type of public
building.

Outside “FR”

Refer to local regulations.

+

10

- 15

04/2009 - Art. Nr. 4200 1018 1100A 3

General information

Overwiew
Legend

Legend

B Valve assembly connecting flange
C Gas supply line nut/bolt
E-F-D Mobile and fixed shafts and safety

screw
F6 Air pressure switch
M1 Fan motor
T Nozzle line
T2 Ignition transformer
Y10 Servomotor
1 Blast-tube
2 Space flange
5 Combustion head identification

plate
8 Case (burner body)
9 Burner body ID plate
11 Control unit

Control panel TC
14 Boiler sight glass ventilation air

pressure take-off

119.2 pF combustion chamber take-off

119.3 pL Pressure take-off L

en

04/2009 - Art. Nr. 4200 1018 1100A4

General information

Packaging

Packaging

The burner is delivered on two pallets, in
three parcels, weighing on average 305
to 370 kg, depending on the model.
The burner of the body with :

- the built-in or detached electrical
cabinet. In those circumstances, a
connecting case is fitted on the burner
with the following inside :

- the operating instructions,

- the wiring and hydraulic diagrams of

the burner,

- the boiler house plate,

- the guarantee document,

The combustion head with :

- the burner front face seal, one bag of
bolts, two hinge pins.

The gas train with :

- a collector valve set,

- a bag o bolts, a PG21 support, rubber
gaskets, two tubes pF, one pipe pL, a
drawing, and a preassembled outside
filter.

04/2009 - Art. Nr. 4200 1018 1100A 5

Installation

Assembly

Boiler face

• Prepare face following the enclosed
space requirement diagram.

• If required, insert face counter-plate
(optional)

• Fill in space 1 with recommended
heat-resistant material or material
supplied by the boiler manufacturer.

Chamber pressure take- off pF should

never be choked.

Combustion head

• Position combustion head, so that gas
train is horizontally connected on the
right.

• The other assembly positions are not
allowed.

• Fix and secure combustion head with
its gasket on boiler face.

• Check subsequently for leaks.

Gas train

• Check presence and position of gasket
on the flange of gas train B.

• Install support PG 21 (drawing)

• When fitting gas train, valve coils must
be in high vertical position.

Important

When using a left-mounted VGD gas
train, the SKP75 regulator should pivot
by 180°. To that end :

• Remove regulator SKP75.

• Remove connector (3P + T) on the
side of the regulator, and put it back
together on the opposite side.

Seal off the former position of the

connector.

• Reassemble the regulator after it has
pivoted by a half turn (180°).

Burner Body

• Hook burner body to combustion head
using fixed pin F located on the
opposite side of the gas train.

• Connect the ignition cables on both
transformers.

• Close the burner body with removable
pin E.

• Fix safety screw D.

Connecting the gas pressure take-offs

• Connect coupling pF of the valve to
the coupling labelled pF on the
combustion head with two reversible
preformed tubes (right - left) ,which
are connected up by a coupling (see
drawing).

• Crimp the rings on the tubes.

• Connect the coupling labelled pL to
the coupling pL of the valve.

• Tighten nut by hand.

• Check subsequently for leaks.

Fitting the leaks controller
VPS 504 S02

• Remove the two screws pa and pe on
valve MBVEF, and the two screws 1
and 2 on valve VGD.

• Make sure the two O-rings are
available on the VPS.



• Fasten the VPS with the 4 self-forming
screws

• Connect the cord of plug 7P according
to the electrical diagram.

• Connect plug 7P to the VPS.

• Check subsequently for leaks

 Case of valve VGD20 : proceed as
indicated at the beginning of the earlier
paragraph, then :

• Fit the tubes and the terminal block
supplied.

• Fasten the VPS on the terminal block
using the 4 self-forming screws
supplied.

• Proceed afterwards as in earlier
paragraph.

en

04/2009 - Art. Nr. 4200 1018 1100A6

Installation

Gas and electrical connections

Gas connection

Connecting the gas distribution system
to the gas train must be carried out by a
skilled technician.
The pipe section must be calculated, so
that load losses do not exceed 5% of
distribution pressure.
The external filter (ES08.2800) must be
fitted horizontally with a clean tube and
the cover placed in a vertical position to
allow for maintenance and to prevent
dust being carried along downstream of
the filter upon disassembly.

Any other type of assembly is
prohibited.

The ball valve (not supplied) must be
mounted upstream and as close as
possible to the external filter or to the
valve (pocket filter).
Threaded couplings used should comply
with current standards: tapered external
thread, parallel internal thread, with
tightness secured in the thread.
Enough space should be provided for
access to the setting of the gas pressure
switch.
Piping must be drained upstream of the
valve. Connections carried out in sit
must be tested for leaks using foam
designed for that purpose.

No leakage should be detected.

Electrical connection

Electrical fittings and connections
should comply with the current
standards.

Earth must be connected and tested.

See electrical diagram when connecting
the burner and the regulator.
The burner is supplied for a three-phase
electrical voltage 400V - 50Hz with
neutral and earth.
The ventilation motor starts up
automatically. A variable frequency
regulator can be fitted as an extra
option.
The three-phase operation 230V - 50Hz
requires : changing the coupling of the
motors and of the thermal relays of the
contactors (ES08.4000 and 5000), and
using a 630 VA insulation transformer on
the control circuit (not supplied).
For other voltages and frequencies,
please contact us.

Electrical connections

1) burner

- Built-in electrical cabinet

• Use stuffing boxes in order to secure
the required level of protection.

All the links, power and control, are
connected to the terminal block of the
cabinet.
Provide cables in sufficient length to
secure the gyration of the burner body
according to the assembly.

• Check and adjust the calibre of the
contractors and thermal relays and the
wires section according to the
characteristics of the motor and of the
available voltage.

Wiring is not supplied.

- Detached electrical cabinet:

That cabinet can be installed:

- either against a wall

- or on a floor-mounted sub-frame.

All the links, power and control are
connected between the cabinet terminal
block and the terminal block of the
coupling case on the burner body.
The other assembly conditions are
similar to those of the built-in cabinet

2) of the gas train

• Connect the plugs pending to the
valve:

- either on the control cabinet,

- or on the coupling case on the

burner body.

04/2009 - Art. Nr. 4200 1018 1100A 7

Start up

Preliminary check-up and leakage tests
Adjusting air pressure switch

Burner start up simultaneously involves
starting up the installation by the fitter or
his representative; only they can
guarantee compliance of the boiler
house with currently accepted practices
and the regulations in force.
The fitter must first be in possession of a
"certificate of gas conformity" (fuel)
issued by either the approved body or
the distributor and also have leak-tested
and drained the pipework upstream from
the quarter-turn hand-operated valve.

Preliminary check-up

• Check the following:

- rated available voltage and electric
frequency and compare them with
the value showing on the
identification plate,

- polarity between phase and neutral,

- connection of the previously tested
earth wire,

- lack of potential between neutral and
earth,

- motors direction of rotation,

- thermal relays only in manual (H)
position with intensity adjustment.

• Cut off the power supply

• Make sure power is off

• Close fuel valves

• Read service instructions from boiler
and regulator manufacturers

• Check that :

- boiler is full of pressurized water

- circulator(s) is (are) working

- mixing valve(s) is (are) open

- combustible air supply to the boiler

and combustion products exhaust
pipe are actually operating and are
compatible with the rated capacity
of burner and fuels

- draught regulator is working properly

on the exhaust pipe

- protective fuses outside burner are

available, calibrated and adjusted

- boiler regulator circuit is adjusted.

Gas pressure switch setting

• Remove the transparent cover.

The unit includes a  index and a
graduated mobile disk.

• Provisionally set the pressure switch at
the minimum value shown on the
graduated disk.

Leakage test

• Connect a manometer on the pressure
nipple upstream from the gas train.

• Open and close the ball valve

• Check supply pressure and its long­term stability

• Use a specially designed foam product
to check tightness of gas train
connections, including external filter.

No leakage should be detected.

• Drain when necessary pipework
downstream from the ball valve

• Close drain valve, remove the
manometer and close the pressure
take-off.

en

04/2009 - Art. Nr. 4200 1018 1100A8

Start-up

Checking and adjustments
Combustion implements and secondary air

Secondary air (dimension Y)

This is the amount of air flowing between
the tubulators diameter and blast-tube.
On delivery, dimension Y is set at 453 in
KN and 753 in KL.
However,

- this value can be adjusted according to
the following :

- gas firing quality (shock, vibration,
judder, time lag),

combustion quality for gas flows.

Setting
It is performed when burner is shutdown,
with removal of combustion implements,
following the procedure outlined in the
earlier section.
By increasing dimension Y, secondary
air reduces, the CO

2

increases and vice

versa.

• Loosen both screws from the
turbulator support.

• Slide the turbulator support into the
required direction.

• Measure dimension Y; tighten both
screws.

• Adjust the diffuser according to the
type of head and gas used following
the enclosed plan.

• Reassemble the whole unit.

• Make sure the flat gasket is available
and in position on the gas inlet line.

Natural gases -low NOx

Bold : factory settings

secondary
air
maxi

secondary
air
mini

KN Y=453 Y=478
KL Y=753 Y=778

Natural gases & propane

Bold : factory settings

secondary
air
maxi

secondary
air
mini

KN Y=453 Y=478
KL Y=753 Y=778

Checking and setting combustion

Burner is supplied already set for natural
gas.

• Remove the safety screw D.

• Remove the movable pin E.

• Open the body of the burner.

• Disconnect the two ignition cables on
the transformer and the ionization
sensor cable.

• Unscrew the nut and the lateral screw
C which immobilise the gas supply
line.

• Withdraw the combustion
components.

• Check the settings :
of the ignition electrodes, the
ionisation sensor, and of the diffusors
according to the gas available and the
accompanying diagrams.

• Check to ensure the presence and the
correct positioning of the sheet gasket
on the gas supply line.

• Re-assemble.

• Check :

- the tightness of the screw and the

nut C,

- subsequently for leaks.

04/2009 - Art. Nr. 4200 1018 1100A 9

Start-up

Adjustments
Diffusors and injectors

"G-VT-type" head adjustment for
Low NOx natural gas

Diffusors A:

- External slots fully closed

- Downstream injector pellet P1 with
screw in position 4 for ES08.2800 and
5 for ES08.3700 to 5000.

Diffusors C:

- Upstream slot closed

- Downstream injector with screw in
position G3 for ES08.2800 and G2 for
ES08.3700 to 5000.

Ignition diffusor D:

- Upstream slot open

- Downstream injector with screw in
position G2

Head F-VT adjustment for Low NOx
propane gas

Diffusors A:

- Upstream slots open

- Downstream injector pellet P1 with
screw in position 1

Diffusors C:

- Upstream slot closed

- Downstream injector with screw in
position G2

Ignition diffusor D:

- Upstream slot open

- Downstream injector with screw in
position G2

Natural gas Low NOx

G/F-VT

Propane gas Low NOx

G/F-VT

en

04/2009 - Art. Nr. 4200 1018 1100A10

Start up

Description, settings
Combustion air

Servomotor Y10

1 Connection terminal board
2 Cam setting key
3 Seven adjustable graduated cams
4 Motor disengaging lever
5 No adjustable graduated cylinder

for servomotor position

6 Graduated cylinder index

SQM 10 16

Cam functions

Cam Function
I Nominal flow-rate
II Stop/0°
III Firing air flow-rate
IV Free 0°
V Cam V gives minimum regulation

info; must be set between values

of cam I and VI
VI Set minimum air flow-rate
VII Simultaneous switch-on of

nominal flow indicator and hour

counter (only for operation hours

below nominal flow rate)

• Set a few degrees below the
regulation flow-rate value of Cam
I.

Cam VI controls minimum automatic
flow-rate following ignition. If not
requested, the flow remains unchanged.
The time-delay unit K6 in the control
cabinet must be set at ≅ 15s.

Setting

• Remove cover.

• Check cam drum reset.

• Preset the cams according to boiler
capacity and the values shown in the
table below.

To do this:

• Adjust the cam either by hand or with
the key going along with the
servomotor. The angular position is
obtained in relation to each cam index.

Burner

power

kW

2100 33
2850 55
2250 50

3800 80
2400 55
4100 80
2800 55
4600 80

Air setting in °

i gnition nominal

cam III cam I

ES08.

2800

15

ES08.

3700

ES08.

4000

ES08.

5000

04/2009 - Art. Nr. 4200 1018 1100A 11

Start up

Description and adjustment
MB-VEF gas valve

1 Pressure switch electrical

connection (DIN 43650)

2 Solenoid electrical connection

(DIN 43650)
3 Pressure switch
4 Intake flange
5 Pressure take-off G 1/8 before

possible filter on either side
6 Filter under the cover
7 Identification plate
8 Air pressure pL G 1/8 connection
9 V ratio adjusting screw
10 Pressure take-off pe G 1/8 both

sides
11 Gas pressure take-off pBr

M4 (V2)
12 Adjusting screw for correction of

zero point N
13 Connection G 1/8 for combustion

chamber pressure pF
14 Connection G 1/8 for gas pressure

pBr

15 Outlet flange
16 Pressure pa take-off after V1 both

side
17 On indicator V1, V2 (optional)
18 pBr - pL - pF pressure take-off

tubes

MB VEF valve

MB VEF valve…is a compact assembly
including the following :
A built-in or pocket filter, adjustable
pressure switch, non-adjustable quick­acting safety valve, proportional
regulator-controlled main valve which
can be adjusted on opening (V and N). It
ensures a constant gas flow/air flow ratio
and is quick-acting.
The regulator also takes into account
combustion chamber pF pressure or
atmospheric pressure.
The valve is delivered preset according
to table here below.

Air pressure switch setting

• Remove the transparent cover.

The unit includes a  index and a
graduated mobile disk.

• Provisionally set the pressure switch at

the minimum value shown on the
graduated disk.

Regulator setting

All settings are carried out with the
burner working:

• Use 2,5mm hex key to turn the 2

screws.

- Screw V gives the gas/air ratio,
graduated 0,75 to 3,0.

- Screw N is used to adjust air excess,
graduated - 2 to + 2.

ES08.2800 G/F-VT

Gas

P

VEF 412 42

0

V

3

N

0

V

3

N

0

V

3

N

0

ES08.3700 G/F-VT

Gas

P

VEF 412 42

0

V

3

N

0

V

3

N

0

V

3

N

0

ES08.4000/5000 G/F-VT

Gas

P

VEF 412 42

0

V

3

N

0

V

3

N

0

G20 1 50

G20 3 00

G25 3 00

G20 1 50

G20 3 00

G25 3 00

G20 3 00

G25 3 00

en

04/2009 - Art. Nr. 4200 1018 1100A12

Start-up

Description and settings
VGD gas valve
SKP75 regulator

1 Pressure switch electrical

connection (DIN 43650)

2 Solenoid electrical connection

(DIN 43650)
3 Pressure switch
4 Intake flange
5 Pressure take-off G 1/8 before the

filter
6 External filter DN65
7 Identification plate
8 Air pressure pL G 1/8 connection
9 Adjusting screw R of gas flow/air

flow ratio
12 Adjusting screw D for correcting

zero point
13 Connection G 1/8 for combustion

chamber pressure pF
14 Connection G 1/8 for gas

pressure pBr
15 Outlet flange
16 pBr - pL - pF pressure take-off

pipes

Setting gas pressure switch

• Remove transparent cover.

Unit includes a | index and a
movable graduated disk.

• Provisionally set the pressure

switch at the minimum value
shown on the graduated disk.

Gas valve
opening
indicator

R ratio
indicator

D value
indicator

The VGD valve associated with
SKP75 regulator ensures a constant
gas flow/air flow ratio and is quick­acting. The regulator also takes into
account combustion chamber pF
pressure.
The valve is delivered preset according
to table here below.

ES08.2800 G/F-VT

Gas P 40.06

5

40.08

0

(Scr. R)1 2
(Scr.

D

)2 1,4

ES08.3700 G/F-VT

Gas P 40.06

5

40.08

0

(Scr. R)2
(Scr.

D

)1,4

(Scr.

R

)1

(Scr.

D

)2

ES08.4000/5000 G/F-VT

Gas P 40.06

5

40.08

0

(Scr. R)1
(Scr.

D

)2

G20 150

G20

40

150

VGD

VGD

G20 20 - 40

VGD

04/2009 - Art. Nr. 4200 1018 1100A 13

Start-up

Description of adjustments
Gas valve / leakage controller

Leakage controller VPS 504 S02

Optional for ES08.2800
Operating principle :
Prior to each start-up of burner, the
control unit shall check subsequently for
leaks between safety and main valves
by increasing the distribution pressure.
Electrically, the leakage controller gets
connected serially between the
thermostatic circuit and the control and
safety unit of the burner.

Installation :
Directly on valve.

Program development :
At shutdown, safety and main valves are
closed.
At thermostatic shutdown, the leakage
controller is powered up and the booster
increases distribution pressure by
20mbar.
After no more than 30 seconds of
operation :

- If leakage test is validated, the yellow

light comes on and power is released
to feed the control and safety unit,
which starts its cycle.

- If leakage test is not validated, the red

light comes on and the control and
safety unit is not powered up.

- Control cycles need to be restarted

manually. If fault persists, valve
should be changed.

Adjustment :
The leakage controller requires no on­site adjustment.
Operating test :
While leakage controller is working :

• Open pressure take-off pa. The

leakage so generated prevents the
super pressure from building up, and
the safety unit locks on after
30 seconds.

• Close pressure take-off pa.

• Release controller safety by pressing

the red indicator light.
The leakage controller restarts and, after
30 seconds, the yellow indicator lights
up and powers up the control and safety
unit, which begins its cycle.

1 Wieland 7P socket
3 Filter element
4 O-ring Ø 10.5 x 2.25
5 Fuse Y 6.3 250V Ø 5 x 20
6 Yellow indicator On :

Leakage test validated

7 Red indicator On :

Leakage test not validated,

manual release
8 Spare fuses magazine
9 pa (p2) pressure take- off Ø 9.

Test pressure : pe + 20mbar
10 Pressure take- off : pe (p1) Ø 9.

Inlet pressure (distribution)

en

04/2009 - Art. Nr. 4200 1018 1100A14

Start up

LFL 1.333 Control and safety unit

Required input signals

Output signals

Reset Trouble Pressure switch Limiter Burner motor Ignition transfo. Oil valve Regulator Servo motor Flame Reset

t1 Pre ventilation time with open air flap

t2 Safety time

t2’ Safety time or 1st safety time for burner with driver

t3 Short pre-ignition time (transformer terminal 16)

t3’ Long pre-ignition time (transformer terminal 15)

t4 Interval between voltage at terminal 18 (t2 start) and 19 (BV1-BV2)

t4’ Interval between t2’ start and 19 (BV2)

t5 Interval between voltage at terminal 19 and 20 (BV-Regul.)

t6 Post-ventilation time (with M2)

t7 Interval between start order and voltage in 7

t10 Interval between start and air pressure monitoring without flap movement time

t11 OPEN position air flap movement time

t12 MINI position air flap movement time

t13 Accepted post combustion time

t16 Interval until air flap opening order.

04/2009 - Art. Nr. 4200 1018 1100A 15

Start-up

LFL 1.333 control unit program

LFL 1.333 control unit program

t1 : Pre ventilation time 30s
t2 : 1st safety time 3s
t3 : Pre-ignition time 6s

- Safety time following

flame disappearance < 1s

Safety unit operation

The control and safety unit LAL 2.25 is
designed for intermittent service,
(limiting it to twenty-four hours of
continued use).
For convenience sake, the function
diagram does not include all electrical
components.
It is assumed that :

- Power supply is compliant

- Pressure switches and servomotor

cams have been preset correctly.

Commands from
control and safety unit
Required input signals

Terminal numbers are those shown on
the control and safety unit base.
Each unit program sequence is shown
by a visible symbol on the rotating disk,
near reset button.

Program operating sequences :

 Motor switched on (terminal 6)

when :

- main voltage is applied to
terminal 1,

- air flap is closed : voltage at
terminal 11 is applied to
terminal 8,

- air pressure switch is off : voltage
at terminal 12 is applied to
terminal 4,

- limit and safety thermostats and
min. gas pressure switch are off:
voltage at terminal 4 is applied to
terminal 5.

 Servomotor control (cam I) is wide

open (terminal 9) and opening
confirmed (terminal 8) : start of
pre ventilation.

 Start of permanent air pressure

monitoring by air pressure switch
and confirmation at terminal 14.
Circuit broken between terminals 4
and 13.

 Servomotor control (cam III) in

ignition position (terminal 10) and
position confirmed (terminal 8).

 Start of pre-ignition (terminal 16)

 Simultaneous opening of safety

valve and main valve (terminal 18)
: start of safety time.

Start of continuous monitoring of flame
presence.

 Ignition transformer off, shortly

followed by end of safety time.

 Power regulation enable

(terminal 20) :

 Burner stoppage via limit

thermostat cutoff, then servomotor
control off (cam II).

Important :
in continual functioning, a
thermostatic cut-out is obligatory
after twenty-four hours.

en

04/2009 - Art. Nr. 4200 1018 1100A16

Start-up

Description of functions
Control panel TC

TC

Description of TC functions
(Control Panel)

A2 Standardized 48x48 or

48x96mm power regulator
positions (option)

B10 Measuring bridge [µA DC],

ionization current

F10 Control panel fuse TC

Green indicators

H4 Ignition load
H4.1 Safety valve
H4.2 Main valve
H5 Minimum control flow
H5.1 Nominal flow
H10 Control Panel (TC) energized
H15 Transformer
P4 Hourly totalizer counter
P5 Nominal flow hourly counter

Three position switch :

S1 General switch of TC

0 Off
1& Local mode
1> Remote control mode

S2 Choice of power setting

' Manual mode with S3
Auto Automatic mode with

S1&

S3 Pulse with S2'

+/- Power increase/decrease

SA1 The control unit displays :

- the program

- faults : red indicator illuminated
and reset button

10 Two screws to be removed for

access to the control unit and to
option positions

11 On the underside of the control

panel (TC), remove two screws
10 and switch to DIN 35mm rail
and terminals for options

21 Rating plate
23 Movable plate for the cable

glands

Electrical cabinet on burner

The electrical cabinet holds all the
required components for the operation
of the device. The access door, which
can be locked, is fitted with a window
displaying the control panel TC, signals
and, inside, a magazine containing the
literature.
In the lower part, there is a removable
plate with the various stuffing boxes.
Thanks to such cabinet with easy
access, it is possible to install various
options :

- A built-in power regulator in a
standardized space requirement of 48
x 48 or 48 x 96 mm.

- Relays for data transmission to be
fitted on a 35 mm DIN rail ,in
abeyance under the control panel
(remove two screws 10 and tip out).

Coupling case on burner

Option for cabinet outside burner
B10 Measuring bridge [µ A DC]

cell current

24 Link terminals between burner

and electrical control cabinet

04/2009 - Art. Nr. 4200 1018 1100A 17

Start up

Working cycle test
Firing
Safety unit settings and checks

Cycle functioning test

• Open and then shut the quarter-turn
manual fuel valve.

• Charge the burner.

• In the TC of the electric control box
select the manual operation mode

S1& - S2'.

• Close the thermostatic circuit.

The leak tightness test device VPS 504
S02 is charged. After 30s if the test is
validated ; the yellow light will shine. The
control and safety unit is supplied with a
voltage; the red light of the unit will
shine.

• Reset the control and safety unit and
check that it is working correctly.

The program should function in the
following way :

- air flap totally open,

- initial blower time 30s,

- return to ignition position,

- ignition of electrodes for 6s,

- opening of the valves,

- closing of the valves after a maximum
of 3s after they were opened,

- the burner will stop functioning due to
a lack of gas pressure or due to
resetting of the control and safety unit
due to the disappearance of the flame.

In case of doubt, perform the test
previously described.

It is only after this very important
program test phase that the burner can
be fired.

Firing

Warning :

Firing should only take place when all
the conditions set out in the previous
chapters have been adhered to.

• Connect a microammeter scale (0­100µA DC), instead of the measuring
bridge located on the TC.

• Open the quarter-turn manual valve of
the fuel.

• Close the thermostatic circuit.

The leak tester is charged. At the end of
the test (30s), the unit is charged.

• Reset the control and safety unit.

The burner will be working.

- Check :

- the combustion process once the

flame has appeared,

- the overall leak tightness of the gas

train.

There should not be any leakage.

• Read the current of ionization (a value
between 20 and 80µA).

• Measure the gas flow shown on the
counter.

• Raise the power to its nominal output
by activating the switch intermittently
S3+.

• Test the combustion.

Observe the waste gas temperature
recommended by the boiler
manufacturer to obtain the required
useful output.
According to the combustion tests,
adjust the burner while in operation to
the nominal output on the screw V of the
MB VEF valve (R for the Skp regulator).

• To increase the CO

2

rate, increase the
ratio (decreasing the ratio will have the
opposite effect).

• Read the current of ionization (a value
between 20 and 80µA).

• Measure the gas output on the
counter.

• Increase or reduce the power by
increasing or reducing the value read
from the graduated vessel of the
cam I.

• Stop and then start the burner up
again.

• Check the combustion process once
the flame has appeared.

According to the measured values,
adjust the burner while in operation on
the screw N of the MB VEF valve (D for
the SKP regulator).

• If necessary, adjust the cam value III
for ignition and the cam VI for
minimum control.
The adjusting procedure is identical to
that of the cam adjustment I.

• Increase the power back up to the
nominal output and check the
combustion.
If the value has been changed by the
action performed on the screw N (D
for the SKP regulator); adjust the ratio
V (R for the SKP regulator) as
required.

• Optimize combustion results by
adjusting :

- the setting of the secondary air (Y

dimension) following the procedure
described in the chapter : “Setting
combustion components and
secondary air ”;

• Increase the Y dimension, the CO

2

rate rises and this process can occur
inversely.

A modification made to the Y dimension
can necessitate a correction of the air
flow rate.

• Test the combustion.

Assess burner operation : on ignition,
and when power is increased and
decreased.

• Check, while the burner is functioning,
and by using a foaming liquid product
that is specially designed for this
purpose, the leak tightness of the gas
train connections.

There should not be any leakage.

• Test the safety devices.

Setting safety test devices

Gas pressure

• Set at the minimum distribution
pressure.

Burner is working with ignition flow.

• Close the quarter-turn manual valve of
the fuel slowly.

The burner should stop functioning
owing to a lack of gas pressure.

• Re-open the quarter-turn manual
valve.

The burner will start up again
automatically.
The pressure switch is set.

• Fix and screw on the housing.

Air pressure switch.
Burner is working with ignition flow.

• Locate the switch’s cut-off point (lock).

• Multiply the value by 0.8 to obtain the
setting point.

• Restart the burner.

• Progressively obstruct the aspirating
port on the motor-driven blower unit.

• Check that the CO rate is still inferior
to 10, 000ppm before resetting the
control unit.
If not, increase the air pressure switch
setting and repeat the test.

Leak testing device tester VPS :

• Open pa on the device.

• Restart the burner.

After 30s the device is safe (red light
illuminated).

• Close pa.

• Reset the leak tightness tester’s safety
device by pressing the red indicator.

The test cycle is relaunched.
The burner is operational.

• Check for leaks.

• Disconnect the two cables of the
microammeter simultaneously.

The unit should reset itself immediately.

• Replace the measuring bridge, the
housings.

• Disconnect the measurement devices.

• Re-close the pressure connectors.

• Reset the unit.

The burner will be working.

• Check :

- the absence of leaks between the

flange and the boiler front,

- opening of regulator (limiter and

safety) circuit,

- intensity of thermal relays of the

motor-driven blower unit according
to the manufacturer’s instructions.

• Check combustion under actual
operating conditions (doors closed,
etc) and absence of leaks in the
different systems.

• Note the results on the appropriate
documents and communicate them to
the dealer.

• Start-up automatic operation.

• Distribute the information required to
operate the boiler.

• Place the boiler-room plate where it
can be easily seen.

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