elco ES08.5200 G/F-VT Operating Instructions Manual
05/2009 - Art. Nr. 4200 1017 4400A
Operating instructions
For the authorized specialist
Gas burners ........................................... 2-20
Betriebsanleitung
Für die autorisierte Fachkraft
Gasgebläsebrenner............................. 21-39
Инструкция по эксплутации
Для авторизованного специалиста
газовые горелки................................. 40-58
ES08.5200 G/F-VT
fr, it, es................................. 4200 1017 4300
en
de
ru
............................................. 4200 1017 4200
05/2009 - Art. Nr. 4200 1017 4400A2
General information
Contents
Guarantee/safety
Main statutory instruments
Contents
General information
Guarantee, safety............................... 2
Main statutory instruments................. 2
Overview, key.....................................3
Packaging...........................................4
Technical data
See technical data
No. 4200 1017 4200
Installation
Assembly............................................5
Gas connection ..................................6
Electrical connection .......................... 6
Commissioning
Preliminary checks 7
Settings .....................................7 to 13
Programming the control
and safety unit.........................14 to 15
TC control panel...............................16
Firing ................................................17
Setting and checking of safety
devices .............................................17
Maintenance....................................18
Troubleshooting ............................. 19
Guarantee
Installation and start-up must be carried
out in accordance with correct practice
by a qualified specialist.
Current regulations, as well as the
following instructions, must be complied
with. Any failure, however minor, to
observe these provisions shall absolve
the manufacturer from any liability. Also
see:
- guarantee certificate enclosed with
burner,
- general terms of sale.
Safety
The burner is designed to be installed on
a generator connected to exhaust pipes
used for combustion products in working
conditions.
It should be used in an area where there
is an adequate supply of combustion air
and where polluted products can be
properly evacuated.
Flue size and design must be
appropriate to the fuel, in accordance
with current regulations and standards.
The control and safety unit and cut-off
devices used require a 230 VAC % 50
Hz
±1%
power supply.
In addition, the neutral conductor
must have the same electrical
potential as the earth conductor.
Should this not be possible, the burner
should be electrically supplied with an
isolating transformer with the necessary
safety devices (fuses and differential
circuit breaker 30 mA).
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 via an all pole switch
complying with the standards in force.
Operating staff should always act with
extreme caution and especially avoid
direct contact with areas that are not
heat-insulated and electrical circuits.
Avoid splashing water on the electrical
components of the burner.
In the event of flood, fire, fuel leakage or
abnormal operation (strange smells,
noises, etc.), switch off the burner, turn
off the power and fuel supplies and call
in a qualified specialist.
It is essential that all furnaces and
accessories, waste gas ducts and
connection pipes are serviced, cleaned
and swept once a year and before
burner start-up. See the applicable
regulations in force.
Main statutory instruments “FR”
Residential building:
- 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 no. 61-1
- Gas installations - April 1982
plus subsequent additions.
- DTU Standard 65.4 Technical
requirements for boiler rooms.
- 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”
Conform to the local regulations and
practices.
+
10
- 15
05/2009 - Art. Nr. 4200 1017 4400A 3
General information
Overview
Key
Key
B Gas train connecting flange
C Fixation screw nut for gas supply
line
E-F-D Mobile and fixed spindles and
safety screw
F6 Air pressure switch
M1 Blower motor
T2 Ignition transformer
V1 Fan motor variable speed
controller
Y10 Servomotor
1Blast tube
2 Spacer flange
5 Combustion head
identification plate
8 Housing (burner body)
9 Burner body identification plate
11 Electric control cabinet with TC
control panel
14 Air pressure tap for ventilation,
boiler window
119.2 Furnace pressure connector pF
119.3 Air pressure tap pL
en
05/2009 - Art. Nr. 4200 1017 4400A4
General information
Packaging
Packaging
This is made up of three packages
delivered on two pallets with a total
average weight of 316 to 381 kg
depending on the model.
The burner body with:
- The electric control cabinet, integrated
or separate. In this case, a connection
box is placed on the burner which
contains:
- the operating instructions,
- the burner wiring diagram and
hydraulic diagram,
- the boiler room plate,
- the certificate of guarantee.
- The frequency variator mounted
against the electric control cabinet
The combustion head with:
- the boiler front gasket, a bag of nuts
and bolts, and two hinge spindles.
The gas train with:
- a set of flange valves,
- a bag of nuts and bolts, a PG21
support, rubber sheet gaskets, two pF
tubes, a pL pipe, a diagram,
- and a pre-assembled external filter.
05/2009 - Art. Nr. 4200 1017 4400A 5
Installation
Assembly
Boiler front
• Prepare the burner front as shown in
the annexed diagram of space
required.
• If necessary set up a backing plate for
the burner front (option).
• Pack the space 1 with a fire-resistant
material recommended or provided by
the boiler manufacturer.
Do not block the burner pressure tap
pF.
Combustion head
• Position the combustion head so that
the gas train is connected horizontally,
from the right.
• No other assembly positions are
authorised.
• Assemble and affix the combustion
head with its gasket to the boiler front.
• Check subsequently for leaks
Gas train
• Check the seal is fitted and correctly
positioned on the collector flange B.
• Position the support PG 21 (diagram).
• When fitting the gas train, the valve
coils must be in the vertical top
position.
Important
When using a VGD gas train fitted on the
left, the SKP75 regulator must be
pivoted 180°. In order to do this:
• Remove the SKP75 regulator.
• Remove the connector (3P+T) on the
side of the regulator, and refit it on the
opposite side.
Block the old connector housing.
• Refit the regulator after pivoting it by
half a turn (180°).
en
Burner body
• Attach the burner body to the burner
head using the fixed spindle F
opposite the gas train.
• Connect:
- The two ignition cables to the
transformer.
- The wire marked by a yellow tag, on
the ionisation probe cable.
• Close the burner body with the mobile
spindle E.
• Insert the safety screw D.
Connection of gas pressure connectors
• Link the valve connection pF to the
identified connection pF on the
combustion head with two pre-formed
reversible pipes (right - left) which are
coupled by a connection (see
diagram).
• Crimp the rings on the pipes.
• Link the pipe marked pL to the pL
connection on the valve.
• Tighten the nut by hand.
• Check subsequently for leaks.
Fitting the leak testing device
VPS 504 S02
Gas valve VGD20
• Remove the two caps 3 and 4 on the
VGD20 valve.
• Assemble the elements provided
according to illustrations opposite.
When fitting the hydraulic block, take
care of the flow direction.
• Fit the VPS504 on the connection
adapter D using the four delivered
self-tapping screws.
• Check presence of the O'Rings on the
leak controller.
• Connect the 7P connector to the VPS.
• Check tightness.
Gas valve VGD40
• Remove the two caps 1 and 2 on the
VGD40 valve.
• Check presence of the O'Rings on the
VPS.
• Fit the VPS using the four delivered
self-tapping screws.
• Connect the 7P connector to the VPS.
• Check tightness.
VGD 20 VGD 40
VGD 20
VGD20
05/2009 - Art. Nr. 4200 1017 4400A6
Installation
Gas/electrical connections
Gas connection
The gas distribution system must be
connected to the gas train by a
technician.
The diameter of the piping must be
calculated so that load loss does not
exceed 5% of distribution pressure.
The external filter should be installed on
the valve with a clean connection piece,
in the horizontal position, with the cover
in the vertical position to ensure
maintenance access.
No other setup is authorised.
The quarter-turn hand-operated valve
(not supplied) should be assembled
upstream and as close as possible to the
external filter or to the valve (bag filter).
The threaded fittings used must comply
with current standards (tapered external
thread, parallel internal thread) and all
threads rendered leak-proof.
Allow enough space for access to set
the gas pressure switch.
Pipes must be drained upstream of the
quarter-turn hand-operated valve.
Connections performed in situ must be
tested for leaks using foam designed for
this purpose.
No leakage should be detected.
Electrical connection
The electrical setup and connections
must be performed in accordance with
the standards in force.
The earth wire must be connected
and tested.
See the diagram of electrics for
connecting the burner and its regulation.
The burner is delivered to be operated
with a 400 V- 50 Hz three-phase power
supply with neutral conductor and earth.
The blower motor is a direct start-up
motor.
A frequency variator can be installed as
an option.
Running on three phase
230 V - 50 Hz requires: the motor
couplings and switch thermal relays to
be replaced and a 630 VA isolating
transformer to be used on the control
circuit (not supplied).
For other voltages and frequencies,
please contact us.
Electrical connections
1) burner
- Integrated electric control cabinet.
• Use cable glands to guarantee the
degree of protection.
All the power and control connections
are connected to the control cabinet
terminal.
Ensure that you have sufficient cable
length to guarantee the rotation of the
burner body following setup.
• Check and adjust the rating of the
protection devices, the thermal relays
and the diameter of the wiring
according to the specifications of the
motor and the voltage available.
Wiring is not supplied.
- Separate electric control cabinet.
The control cabinet should be setup:
- either against a wall,
- or on a frame anchored to the
ground.
All the power and control connections
are connected between the control
cabinet and the connection box terminal
block on the burner body.
The other installation conditions are
identical to those for the integrated
control cabinet.
2) gas train
• Connect the standby points to the
valve:
- on the control cabinet,
- or on the connection box on the
burner body.
05/2009 - Art. Nr. 4200 1017 4400A 7
Commissioning
Preliminary checks/leakage test
Setting the air pressure switch
Commissioning the burner also involves
simultaneous installation by the fitter or
his representative; only they can
guarantee the boiler room complies with
currently accepted practices and
regulations in force.
The fitter must first be in possession of a
“certificate of gas fuel conformity” issued
either by the approved body or
distributor and also have tested the
pipes upstream of the quarter-turn handoperated valve for leaks and drained it.
Preliminary checks
• Check the following:
- nominal available voltage and
electrical frequency and compare
them with values found on
identification plate,
- polarity between phase and neutral
- the previously tested earth wire
connection,
- lack of potential between neutral and
earth,
- the direction of rotation of the
motors.
- the thermal relays, in manual
position (H) only and the current
strength setting.
• Turn off the power supply.
• Check absence of voltage.
• Close the fuel valve.
• Read the service instructions provided
by the generator and regulator
manufacturers.
• Check the following:
- that the boiler is full of pressurised
water,
- that the circulator or circulators
work,
- that the mixer valve or valves are
open,
- that the combustion air supply and
combustion product exhaust duct
are operational and compatible with
the nominal output of the burner and
the fuels,
- that the draught regulator on the
smoke exhaust duct is in place and
working properly,
- that the electrical protection
equipment outside the burner is
present, calibrated and set,
- the boiler regulator circuit setting.
Setting the air pressure switch
• Remove the transparent cover.
The unit includes a index and
graduated mobile disc.
• Provisionally set the pressure
controller to the minimum value shown
on the graduated disc.
Leak check
• Connect a pressure gauge to the
pressure tap upstream of the gas
train.
• Open the quarter-turn hand-operated
valve.
• Check the supply pressure and its
stability over time.
• Check for the absence of leaks in the
gas train connections and the exterior
filter using foam designed for this
purpose.
No leakage should be detected.
• If necessary, vent the piping
downstream of the quarter-turn handoperated valve.
• Stop venting, remove the pressure
gauge, and close the pressure tap.
en
05/2009 - Art. Nr. 4200 1017 4400A8
Commissioning
Settings check
Combustion components
Secondary air
Secondary air (Y dimension)
It is the air flow admitted between the
different diameters of the baffle and the
blast tube.
On delivery, dimension Y is set to 453
for KN and 753 for KL.
However depending on:
- firing quality
(shock, vibration, judder, delay),
- the cleanliness of the gas flow
combustion,
this value can be changed.
Setting
This is done when the burner is stopped
by disassembling the combustion
elements following the process
described in the previous chapter.
By increasing dimension Y, the
secondary air is reduced and the CO
2
increases and vice versa.
• Unscrew the two screws from the
baffle support.
• Slide the baffle support in the desired
direction.
• Measure the dimension Y; tighten the
two screws again.
• Adjust the diffusers according to the
type of head and the gas used as per
the plan opposite.
• Reassemble.
• Check to ensure the presence and the
correct positioning of the sheet gasket
on the gas supply line.
Natural gases (low NOx)
Secondary
air (max)
Secondary
air (min)
T1 Y=453 Y=478
T2 Y=753 Y=778
Factory settings in bold type
Secondary
air (max)
Secondary
air (min)
KN Y=453 Y=478
KL Y=753 Y=778
Checking and setting combustion
head
On delivery the burner is set to natural
gases.
• 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 ionisation
probe cable.
• Unscrew the nut and the lateral screw
C which immobilises the gas supply
line.
• Remove the combustion components.
• Adjust the settings of the ignition
electrodes, the ionisation probe and
the diffusors according to the gas
available and the diagrams included.
• Check to ensure the presence and the
correct positioning of the sheet gasket
on the gas supply line.
• Reassemble.
• Check the following:
- the tightness of the screw and the
nut C,
- the leak tightness afterwards.
05/2009 - Art. Nr. 4200 1017 4400A 9
Commissioning
Setting
Diffusors, injectors
Factory setting for head - low NOx
natural gases
Diffusors A:
- Exterior slots completely closed.
- Downstream injector patch P1: screw
in position 5.
Diffusors C:
- Upstream slot closed,
- Downstream injector: screw in position
G2.
Ignition diffusor D:
- Slot open inside,
- Downstream injector screw in position
G2.
Natural gases (low NOx)
G/F-VT
en
05/2009 - Art. Nr. 4200 1017 4400A10
Commissioning
Description of settings
Combustion air
Servomotor Y10
1 Connection terminal board
2 Cam setting key
3 Seven adjustable graduated cams
4 Lever to operate the motor release
mechanism
5 Non adjustable graduated cylinder
for servomotor position
6 Graduated cylinder indicator
SQM 10 16
Cam functions
CamFunction
I Nominal air flow
II Air closure on shutdown 0
III Firing air flow
IV Free 0°
VCam V provides the minimum
control flow information (to be set
between the values of cam I and
VI)
VI Minimum control air flow
VII Simultaneously powering up of the
large flame indicator and lower
hour meter at nominal flow rate
only
• Set this a few degrees lower than
the value read on cam I.
Cam
VI
determines the automatic minimum
control flow after the ignition phase. In the
electric control cabinet, the timer
K6
sets
itself at
≅
15s.
Setting
• Remove the cover.
• Check the cam drum reset.
• Pre-set the cams according to the boiler
capacity and to the values read on the
table enclosed.
In order to do this:
• Adjust the cams manually or with the
key. The angular position can be read
from the indicators located on each
cam.
Type
Burner
power
kW
700 25 - 30 3100 - 70 - 51
5200 - 80 - 57
Air setting in °
i gnition n om ina l
c a m III cam I
ES08.
5200
Frequency in Hz
Ignition N om ina l
05/2009 - Art. Nr. 4200 1017 4400A 11
Commissioning
Description and settings
VGD gas valve
SKP75 regulator
1 Gas pressure switch connection
(DIN 43650)
2 Electric supply of the magnetic
valves (DIN 43650)
3 Pressure switch
4 Inlet flange
5 Pressure tap G 1/8 before the filter
6 DN65 external filter
7 Identification plate
8 Gas connection G 1/8 for air
pressure pL
9 Ratio adjustment screw R
12 Adjusting screw D for correcting
point 0.
13 Connection G 1/8 for the furnace
pressure pF
14 Connection G 1/8 for the gas
pressure pBr
15 Outlet flange
16 Pressure tap tubes pBr - pL - pF
Gas pressure switch setting
• Remove the transparent cover.
The unit includes an index |
and a mobile graduated disc.
• Set the pressure switch provisionally at
the minimum value indicated on the
graduated disc.
Gas valve
opening
indicator
Setting
index of the
ratio R
Setting
indicator D
The VGD valve connected to a SKP75
regulator is used to obtain a constant
gas/air flow ratio. The regulator also
takes account of the pressure pF in the
combustion chamber or the atmospheric
pressure.
On delivery, the regulator is pre-set
according to the table included.
en
ES08.5200 G/F-VT
Gas P 20.050 40.065
(Scr.
R
)
3
(Scr.
D
)
0
(Scr.
R
)
2.8
(Scr.
D
)
-0.1
VGD
Burner
G20
150
300
05/2009 - Art. Nr. 4200 1017 4400A12
Commissioning
Description and settings
Gas valve/leak testing device
Leak testing device
VPS 504 S02
How it works:
Before each activation of the burner the
test device is used to test the leak
tightness between the safety valves and
the principle valves by raising the
distribution pressure.
Electrically the leak tightness test device
is connected in series between the
thermostatic circuit and the burner’s
control and safety unit.
Setup:
Directly onto the valve.
Program cycle:
When the burner is switched off the
safety valves and principle valves are
closed.
When the thermostat is closed, the leak
tightness test device is switched on and
the booster increases the distribution
pressure by 20 mbar.
After running for a maximum of 30
seconds:
- The leak test is validated; the yellow
light comes on, a voltage is released
to power the burner control and safety
unit, which begins its program.
- The leak test is not validated; the red
light comes on, power is not supplied
to the control and safety unit.
- Manual intervention is required to
relaunch a test cycle. If the problem
persists the valve must be changed.
Settings:
The leak tightness test device does not
need any on-site adjustments to its
setting.
Operating test:
While the leak testing device is in
operation.
• Open the pressure connector pa. The
leak generated prevents boosting and
after 30 secs the device will go into
safety mode.
• Reclose the pressure tap pa.
• Reset the leak tightness test device’s
safety catch by pressing the red
indicator.
The leak testing device restarts itself
and after 30 seconds the yellow light
comes on and the control and safety unit
is powered up and will start its program.
1 Wieland 7P connector. Female
3 Filter element
4 O-ring Ø 10.5 x 2.25
5 Fuse T6.3 250V Ø 5 x 20
6 Yellow light illuminated:
Leak test validated
7 Red light illuminated :
Leak test not validated Manual
unlocking
8 Spare fuse storage area
9 Pressure tap pa (p2) Ø 9
Test pressure: pe + 20 mbar
10 Pressure tap pe (p1) Ø 9 Inlet
pressure (distribution)
05/2009 - Art. Nr. 4200 1017 4400A 13
Commissioning
Diagram of operation of the LFL 1.333 control unit
Required input signals
Output signals
Fault Air pressure switch Limiter Burner motor Transformer Fuel valve Regulation Servomotor Flame check Reset
t1 Preventilation time with air flap open
t2 Safety time
t2’ Safety time or 1st safety time for burner with pilot
t3 Short pre-ignition time (transformer terminal 16)
t3’ Long pre-ignition time (transformer terminal 15)
t4 Gap between voltage on terminal 18 (start t2) and 19 (BV1-BV2)
t4’ Gap between start of t2’ and 19 (BV2)
t5 Gap between voltage on terminal 19 and 20 (BV-Regul.)
t6 Postventilation time (with M2)
t7 Gap between start-up order and voltage on 7
t10 Interval between starting and air pressure check without the
Flap travel time
t11 Air flap travel time OPEN position
t12 Air flap travel time MIN position
t13 Accepted postcombustion time
t16 Gap to air flap opening order
en
05/2009 - Art. Nr. 4200 1017 4400A14
Commissioning
Program of the LFL 1.333 (VARIO) control unit
Program of LFL 1.333 (VARIO) control
unit
t1:preventilation time 30s
t2:1st safety time 3s
t3:pre-ignition 6s
- :safety time on
flame extinguishing< 1s
Electrical operation
The LFL... control and safety unit is
designed for intermittent service, limited
to twenty-four hours of continued use.
For reasons of clarity, not all electrical
components are included in the
schematic diagram.
It is assumed that:
- the power supply is compliant.
- the servomotor pressure switches and
cams have been pre-set correctly.
Commands from control and safety unit.
Required input signals.
The terminal numbers
are those marked on
the base of the control
and safety unit.
Each phase of the control unit’s program
is identifiable by a symbol visible on a
rotating disc near to the reset button.
Program operating sequences:
Motor powered up (terminal 6) if
- mains voltage is supplied to
terminal 1,
- the air flap is closed: the voltage
on terminal 11 switches to
terminal 8,
- the air pressure regulator is at
rest: the voltage on terminal 12
switches to terminal 4,
- the thermostats (limiter and cutout) and the min gas pressure
switch are closed: the voltage on
terminal 4 switches to
terminal 5.
Servomotor control
(cam I) in wide open position
(terminal 9) with confirmation of
opening (terminal 8): start of
preventilation.
Start of permanent air pressure
check by the pressure switch and
confirmation at terminal 14: the
circuit between terminals 4 and 13
is broken.
Servomotor control
(cam III) in ignition position
(terminal 10) and confirmed of
position (terminal 8).
Start of pre-ignition (terminal 16).
Simultaneous opening of the safety
valve and main valve (terminal 18):
start of safety time.
Start of continuous monitoring of flame
presence.
Ignition transformer shutdown
shortly followed by
End of safety time.
Power control enabled (terminal
20).
Burner shut down by cut-off of the
limiter thermostat then servomotor
(cam II) closing position control.
During continuous operation, a
thermostatic cut-off is obligatory
after twenty-four hours.
05/2009 - Art. Nr. 4200 1017 4400A 15
Commissioning
Description, functions
TC control panel
TC
Description of functions of the TC
(Control Panel)
A2 Option: 48 x 48 or 48 x 96 mm
standard positions for installing
an output regulator
B10 Measuring bridge [µA DC]
ionisation current
F10 TC fuse
Green lights
H4 Ignition flow rate
H4.1 Safety valve
H4.2 Main valve
H5 Minimum control flow rate
H5.1 Nominal flow rate
H10 TC on
H15 Transformer
P4 Total hours counter
P5 Nominal flow rate hour meter
Three position switch:
S1 TC main switch
0 Off
1& Local mode
1> Remote control mode
S2 Power control selector
' Manual mode with S3
Auto Automatic mode
with S1&
S3 By pulse with S2'
+/- Power
increase/decrease
SA1 The control unit shows:
- the program,
- faults, red light lit and reset
pushbutton.
10 Two screws to be removed to
access the unit and the option
positions
11 Under the TC, remove two
screws 10 and swing open:
Access to DIN 35 mm rail and
terminals for options
21 Identification plate
23 Detachable plate for the cable
glands
Electric control cabinet on burner
The electric control cabinet contains all
the components needed to operate the
burner. The lockable access door has a
control panel TC viewer window,
indicators and an inside documentation
storage pocket.
There is a detachable plate with the
various cable glands in the lower part of
the cabinet.
This highly accessible cabinet can have
various options fitted:
- A built-in output regulator of a
standardised 48 x 48 or 48 x 96 mm
size.
- Data transmission relays to be placed
on a DIN 35 mm rail available under
the control panel (remove two screws
10 and swing open).
Connection box on burner
Option for separate control cabinet
B10 Measuring bridge [µA DC]
ionisation current
24 Linking terminals between the
burner and the electrical
cabinet
en
05/2009 - Art. Nr. 4200 1017 4400A16
Commissioning
Checking the operating sequence
Firing
Setting: safety checks
Checking the operating sequence
• Open the quarter-turn hand-operated
fuel valve, then immediately close it
again.
• Switch the burner on.
• On the control cabinet TC select the
manual operation mode
S1&- S2 '
• Close the thermostatic circuit.
The leak tightness test device VPS 504
S02 is switched on. After 30 seconds, if
the test is validated; the amber light
comes on. The control and safety unit is
powered on; the red light on the control
unit comes on
• Open the control unit and check that it
is working correctly.
The program should function in the
following way:
- complete opening of the air flap,
- preventilation for 30s,
- return to ignition position,
- 6-second electrode ignition,
- valves open,
- valves closed max 3 seconds after
opening,
- burner stops due lack of gas pressure
or control unit locks because flame
goes out.
If unsure, conduct the above test
again.
The unit can only be fired once this very
important operating sequence check
has been performed.
Firing
Warning:
The burner may be only fired when all
the requirements listed in previous
sections have been met.
• Connect a microammeter (scale 0 100 µA DC) in place of the measuring
bridge on the TC (check the polarity).
• Open the quarter-turn hand-operated
fuel valve.
• Close the thermostatic circuit.
The leak tightness test is switched on. At
the end of the test (30s), the unit is
switched on.
• Unlock the control and safety unit.
The burner is in service.
• Check the following:
- combustion as soon as flame
appears,
- any possible gas train leaks.
No leakage should be detected.
• Read the ionisation current (value
between 20 and 80µA inclusive).
• Measure the gas flow shown on the
counter.
• Raise the power to its nominal output
by activating the switch intermittently
S3+.
• Check combustion.
Comply with the smoke temperature
value recommended by the boiler
manufacturer in order to obtain the
required effective output.
According to the combustion tests, with
the burner operating at the nominal flow
rate turn screw V on the MB VEF valve,
or screw R on the SKP regulator.
• To increase the CO
2
rate, increase the
ratio and vice versa.
• Read the ionisation current (value
between 20 and 80µA inclusive).
• Measure the gas flow at the meter.
• Increase or reduce power by
increasing or reducing the value read
on the cam I graduated cylinder.
• Stop, then restart the burner.
• Check combustion as soon as the
flame appears.
According to the values measured, with
the burner operating, turn screw N on
the MB VEF valve, or screw D on the
SKP regulator.
• If necessary, adjust the cam III value
for ignition and the cam VI value for
minimum control.
Setting is performed in the same way
as for cam I.
• Return power to the nominal flow rate
and check the combustion
parameters.
If the value changes when screw N is
turned (screw D for the SKP), correct
the ratio V (R for the SKP) in the
desired direction.
• Obtain the best possible combustion
results by adjusting:
- the secondary air setting dimension
Y according to the procedure
described in the “Combustion
components and secondary air
head settings” section.
• Increase dimension Y: the CO
2
rate
increases and vice versa.
A modification made to the Y
dimension can necessitate a
correction of the air flow.
• Check combustion.
• Check operation during the following:
firing, increasing and decreasing
power.
• With the burner in operation check the
leak tightness of the gas train
connections using foam designed for
this purpose.
No leakage should be detected.
• Check the safety devices.
Setting and checking the safety
devices
Gas pressure switch.
• Set it to the minimum distribution
pressure.
The burner is in service at the firing flow
stage.
• Slowly close the quarter-turn handoperated fuel valve.
The burner must stop due to a lack of
gas pressure.
• Re-open the quarter-turn manual
valve.
The burner restarts automatically.
The pressure switch is set.
• Affix the cover and screw it on.
Air pressure switch.
The burner is operating at the firing flow
stage.
• Find the point where the air pressure
switch switches off (locking).
• Multiply the value read by 0.8 to obtain
the setting point.
• Restart the burner.
• Gradually block the air inlet.
• Check that the CO index is still below
10,000 ppm before resetting the
control unit.
If not, increase the air pressure switch
setting and repeat the test.
Leak testing device VPS :
• Open pa on the device.
• Restart the burner.
After 30s the device should enter safety
mode (red light on).
• Reclose pa.
• Unlock the tester safety catch by
pressing the red indicator.
The test cycle is relaunched.
The burner is in service.
• Check it is airtight.
• Disconnect the two wires on the
microammeter simultaneously.
The unit should reset itself immediately.
• Replace the measuring bridge and the
housings.
• Disconnect the measurement devices.
• Close the pressure taps.
• Unlock the unit.
The burner is in service.
• Check the following:
- the seal between the flange and the
boiler front,
- the opening of the control circuit
(limiter and safety),
- the current on the motor thermal
relays.
• Check the combustion under actual
operating conditions (doors closed,
etc.) and the circuit tightness.
• Record the results on the relevant
documents and give them to the
agent.
• Start-up automatic operation.
• Provide all the data required for proper
operation.
• Place the boiler room plate where it
can be easily seen.
05/2009 - Art. Nr. 4200 1017 4400A 17
Commissioning
Frequency variator ACH550
1) Parameters programmed via the "Assistant" mode:
Parameter no.
9905
9906
9907
9908
9909
9902
Adjustment
400V
21.7A
50 Hz
2880 rpm
11 kW
HVAC Standard
Hand-Off-Auto Switch: NO
Continue with external threshold setting: --> Continue
Continue
1103
1301
1302
1104
1105
1106
1107
1108
2007
2008
EA1
20%
100.0%
25 Hz
60 Hz
PID OUTPUT
0.0%
100.0%
0.0 Hz
60 Hz
Continue with On/off
setting: --> Continue
Continue
1001
2101
2102
2202
2203
EL1
Train
Free wheel
10s
10s
Continue with protection device settings: --> Continue
Continue
Continue with constant speed
settings? --> Continue
Continue
1201
1202
EL3
5 Hz
Continue with the PID regulator? Continue
--> Continue
Continue with the reduced noise setting? --> Continue
Continue
2606
2601
2501
4 kHz
YES
NO
Continue with console display setting? --> Continue
Continue
Config. Variable Process 1: YES
3401
3402
3403
3404
3405
3406
3407
OUTPUT FREQ.
0.0 Hz
500.0 Hz
DIRECT
%
0.0%
1000.0%
2003
2014
no. 21.8A
Max torque 1
Configure Start-up and
On validation controls? YES
Parameter no.
1601
1608
1609
Adjustment
NO Select
NO Select
NO Select
Configure Emergency
shutdown controls? YES
2109
2208
No Select
1.0s
Configure fault functions? YES
3001
3021
3022
3003
3004
NO Select
0.0%
0.0%
NO Select
NO Select
Configure Autoreset Functions? YES
3104
3105
3106
3107
3108
3101
3102
3103
INACTIVE
INACTIVE
INACTIVE
INACTIVE
INACTIVE
5
30.0s
6.0s
Config. Variable Process 3: YES
The variator is pre-set in the factory.
The settings indicated below are given as a guide.
For further information, please see the manufacturer's website: www.abb.com
en
05/2009 - Art. Nr. 4200 1017 4400A18
3415
3416
3417
3418
3419
3420
3421
EA1
0.0%
100.0%
DIRECT
V
0.0V
10.0V
Continue with timer function
settings? Continue
--> Continue
Continue with output settings? --> Continue
Continue
1401
1402
1403
READY
ON
FAULT (-1)
Use timer on relay outputs: NO
Configure analogue outputs: NO
Do you want to copy parameters to
console? NO
Config. Variable Process 2: YES
3408
3409
3410
3411
3412
3413
3414
CURRENT
no. 0.0A
no. 46.0A
DIRECT
A
no. 0.0A
no. 46.0A
2) Parameters programmed outside of
"Assistant" mode (in "Parameter" mode):
2001
2002
2007
2008
9901
1003
0 rpm
3440 rpm
0 Hz
60 Hz
Français
Rear
Commissioning
Frequency variator ACH550
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