elco Low-NOx N10.12000.37 G-EU2, Low-NOx N10.14000.37 G-EU2, Low-NOx N10.12000.30 G-EU2, Low-NOx N10.14000.45 G-EU2 FQ, Low-NOx N10.16000.45 G-EU2 FQ Operation Manual
Operation manual
for the authorized specialist
Gas forced draught burner Low-NO
x
N10... G-EU2
12/2011 14 072 205
2
Inhalt
Overview Contents ................................................................................................................ 2
Important information Warranty, safety instructions .............................................. 3
Safety instructions Installation, start-up, maintenance .......................................... 4
Technical data .............................................................................................................................. 5
Important components, burner description ............................................................ 6
Operation fields ..................................................................................................... 7
Operation fields ..................................................................................................... 8
Gas pressure loss burner head Gas pressure loss gas butterfly .......................... 9
Dimensional drawing ........................................................................................... 10
Installation conditions .......................................................................................... 11
Installation Mounting to boiler Electrical connection Presetting ............................................ 12
Burner head settings ........................................................................................... 13
Gas connection ................................................................................................... 14
Gas train description ........................................................................................... 15
Start-up Checking procedure ............................................................................................ 17
Disassembling firing head ................................................................................... 18
Gas start-up mode Gas operating mode General safety function ....................... 19
Fuel-air compound control .................................................................................. 20
Electronic burner controller ................................................................................. 21
Servo motor type SAD 15 ................................................................................... 22
Electrical actuator STM 40 .................................................................................. 22
Flame sensor ...................................................................................................... 23
Gas pressure switch Air pressure switch ............................................................ 24
Adjustment Combination controls CG 15 -30 ...................................................... 25
Exhaust gas test .................................................................................................. 27
Servicing instructions Burner maintenance ............................................................................................ 29
Fan impeller ........................................................................................................ 30
Trouble shooting instructions Cause and removal of disturbance ..................................................................... 31
Manufacturer’s declaration ............................................................................................................................ 33
Overview
Contents
12/2011 14 072 205
3
Overview
Important information
Warranty, safety instructions
General information
These operating instructions are a fixed
component of the system which should
be displayed in a prominent location at
the point of installation of the heat generator and should include the address
and telephone number of the nearest
customer service centre.
They are directed solely at authorised
expert personnel.
These operating instructions cont ain
the most important information for
installing, commissioning and maintaining the burner safely and must
be observed by any personnel who
work on the system.
Important information
The burners are designed in accordance with the specification in the Technical data section (alternative fuels on
request).
The burners should be installed and
taken into operation carefully by qualified personnel. The work should be
done in accordance with the applicable
regulations and guidelines.
Only a duly authorised specialist should
be entrusted with the installation of the
gas system, and all applicable directives and regulations must be observed.
Any repair work on monitors, limiters
and automatic furnace controllers and
on the other safety facilities are allowed
to be done on the single items only by
the manufacturers themselves or specialists authorized by them.
Original parts should only be exchanged by a duly qualified specialist.
Standards and regulations
The following standards should be
observed in the interest of a safe, easyon-the-environment and energy-saving
operation of the burner:
The operator must, in accordance with
country-specific standards and legislation, be given instruction on how the
heating installation operates.
National requirements and building regulations must be taken into consideration during installation of a gas-fired
system.
Screwed unions of metal used in gas
lines should be fitted with approved
sealing elements.
Prior to taking the burner into operation
make sure to vent the gas line, but this
should in no case be done through the
furnace chamber.
Place of installation
The burner must not be operated in
rooms containing corrosive vapours
(e.g. spray, perchloroethylene, hydrocarbon tetrachloride, solvent, etc.) or
tending to heavy dust formation or high
air humidity.
Adequate ventilation must be provided
at the place of installation of the furnace
system to ensure a reliable supply with
combustion air.
Maintenance
The furnace system should be serviced
at least once a year by an authorized
specialist. It is recommended to conclude a maintenance agreement to this
effect.
Guarantee
The guarantee does not cover damage resulting from:
- failure to commission and maintain the
burner in accordance with the operating instructions;
- damage or loss arising from incorrect
installation;
- damage or loss arising from incorrect
adjustment;
- damage or loss arising from unauthorised tampering and
- damage or loss arising from improper
operation (e.g. operating the system
at excessive pressure).
Subject to change without notice due to
ongoing technical developments.
EN 676 Gas burners with
blowers
Safety instructions
The burner has been built and tested to
applicable standards and directives and
recognised rules of technical safety
and, depending on the burner type, has
either been type tested (see declaration
of conformity in the Technical data
section) or must be tested individually
(see manufacturer's declaration in the
Technical data section). Risks to
persons or property may arise if the
burner is not operated correctly or used
for its intended purpose.
To eliminate these risks, the burner
may only be installed and operated
• in accordance with its intended
purpose
• in a technically safe condition
• in compliance with all guidelines and
information contained in these
operating instructions
• in compliance with all inspection and
maintenance guidelines, as specified
in the operating instructions or
components documentation, or as
defined by applicable national
legislation, standards or requirements.
Safety measures and rules of
conduct
1. Burner only to be operated in an
undamaged, defect-free and
technically safe condition.
2. Assembly, commissioning /
adjustments, repair and maintenance
carried out only by experts trained and
authorised for the work concerned.
This also applies to work on the
electrical system and the gas/oil
supply.
3. All safety devices of the system must
be checked on a regular basis as
specified by applicable regulations.
4. Protective clothing must be worn
while work is being carried out on the
system.
5. The information in the operating
instructions must be observed as well
as the applicable requirements or
regulations of accident prevention and
relevant national construction and
safety regulations, requirements,
standards and legislation.
6. The markings on the system must be
maintained in a clearly readable
condition and restored if necessary.
12/2011 14 072 205
4
Overview
Important information
Safety instructions
Installation, start-up, maintenance
7. Equipment to be operated only with
safety devices activated and in good
working order.
8. The system must be checked
annually – or more frequently if
necessary, depending on system
conditions - for externally visible
damage and for the correct operation
of safety devices.
9.Safety functions and safety times
must not be impaired, rendered
inoperational or modified by additional
external wiring.
Tasks carried out on the electrical system
• All tasks involving the electrical
system must be carried out by expert
electricians.
• Before any work is carried out, the
system must be disconnected from
the power supply and secured against
unexpected reconnection.
• Work on live systems may only be
carried out under the supervision of a
second person who would be able to
disconnect the power supply in the
event of danger.
• The electrical system must be
routinely checked as part of
maintenance. Damage of any kind
(e.g. loose connections, damaged
cable insulation) must be rectified
immediately.
Safety instructions for assembly
Always disconnect the system from
the power supply!
Before assembly work begins, switch
off the master and emergency switches
and secure them against the possibility
of being switched back on.
Danger! Failure to comply could result
in a harmful or fatal electrical shock.
Risk of severe injury and danger of
death.
Safety instructions for initial
commissioning
The initial commissioning of the heating
installation must only be carried out by
the constructor, manufacturer or
another of the experts described. All
regulating, control and safety devices
must be checked for correct operation
and – where adjustment is possible –
for correct adjustment.
Before initial commissioning, it is
necessary to check electrical circuits for
correct fusing, and the measures for
protection against accidental contact
with electrical equipment and wiring.
Safety instructions for
maintenance
• The operator must be informed of all
work to be carried out before it begins.
• Assembly, commissioning /
adjustments, repair and maintenance
carried out only by experts trained and
authorised for the work concerned.
This also applies in particular to work
on the electrical system and the gas/
oil supply.
• Protective clothing must be worn while
work is being carried out on the
system.
• Specified adjustment, maintenance
and inspection work must be carried
out at the specified intervals.
• Before any work is carried out on the
system, the system must be
disconnected from the power supply
and secured against unexpected
reconnection.
• The fuel supply must be closed before
work is carried out on the system.
• All safety devices of the system must
be checked on a regular basis as
specified by national requirements,
regulations, standards and legislation.
• Damaged system parts must be
replaced immediately. If parts are to
be replaced, it is only permitted to use
genuine parts, or replacement parts
that have been approved or
authorised by the manufacturer.
• The installation of additional
components that were not subjected
to model series or individual testing at
the same time as the system is not
permitted.
• Do not modify the system or fit
attachment or conversion parts
without the authorisation of the
manufacturer.
• Loose connections must be checked
for firm seating after they have been
reconnected.
• If seal connections are opened, the
sealing surfaces must be cleaned
thoroughly at the time of reassembly.
Ensure a perfect connection;
damaged seals must be replaced with
new ones. Check for leaks once
reassembly is complete.
• Repairs to limiting devices, automated
equipment, flame monitoring
equipment and other safety devices
must only be carried out by the
manufacturer or its appointed
representatives. The expert charged
with carrying out maintenance work
must replace complete components or
assemblies with those of the same
type.
• Safety devices must be checked for
correct operation following their
replacement or repair and after any
maintenance work has been
completed.
• Only use the burner with furnaces that
are suitable for the flame dimension
concerned, i.e. in which the flame may
burn out unhindered.
• Any change to the furnace pressure
(e.g. as a consequence of
modifications to the flue system), and
any modification that would result in a
change in the supply of air to the
burner (e.g. a retrofitted
soundproofing shroud), requires
reconfiguration of burner regulation.
• Persons present in the proximity
during burner operation must be
equipped with suitable measures for
protection against harmful noise
levels.
After all maintenance and repair
work:
1. Function test.
2. At all load points, check O
2
- (CO2-) /
CO -/ NOx- values, soot emissions
and exhaust gas losses.
3. Create a measurement report, leave
a copy with the system.
12/2011 14 072 205
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Technical data
Burner type
N10.12000.30
G-EU2
N10.12000.37
G-EU2
N10.14000.37
G-EU2
N10.14000.45
G-EU2 FQ
N10.16000.45
G-EU2 FQ
Combustion power
output
(*FQe=frequency converter
for motor externally)
1.500* - 12.000 kW
*(1.750 kW without
FQe or Natural gas
LL)
1.500* - 12.000 kW
*(1.750 kW without
FQe or Natural gas
LL)
1.750* - 14.000 kW
*(2.000 kW without
FQe or Natural gas
LL)
1.750 - 14.000 kW 2000 - 16.000 kW
Max. control ratio 1:8 for Natural gas E and with FQe
1:7 without FQe or Natural gas LL
Deviating values on request
(N.B.: the lower operating point must also be within the working field.)
Boiler furnace
pressure
Selection of the nominal burner capacity within the nominal capacity area marked in the working
field. Deviating nominal capacities on request. At burners with FQ higher furnace back pressure by
rise of the motor frequency to > 50 Hz up to the max. capacity limit.
Fuels Natural gas E, LL
Operation type Continuously modulating
Electronic air-fuel-
compound-control,
automatic firing
device
Etamatic OEM or BCS 300 on burner
Alternative electronic burner controls in separate cabinet
Electrotechnical
equipment
Attached to the burner is an IP54 control cabinet that contains the terminal block and, where applicable, the combustion manager and other components
Optional electrotechnical equipment
BCS or Etamatic OEM as burner controller
Power controller with protection, soft start or Y-D start externally in a separate control cabinet
Power regulation by external 4-20 mA nominal value input
Frequency converter externally in a separate control cabinet
Preparation for controller-specific O
2
regulation, probe fitted externally
Profibus DP, Modbus RT, Ethernet
Fan motor 400/690 V, 50/ 60 Hz / 2950 U/min, IP55
30 kW 37 kW 37 kW 45 kW 45 kW
Gas connection DN100, PN16, Natural gas E p
min
=250 mbar, Natural gas LL p
min
=300 mbar
Protection class IP40, IP54 as option
NOx-emissions Emission class 3 according EN 676, 70-150mg/kWh (0% O
2
acc. EN 676)
Precise values on request.
Flame length max. at
3% O
2
6,0 m 6,0 m 6,4 m 6,4 m 6,8 m
Flame diameter
min. 1,3 - 1,6 m
(depending on combustion output
and NOx requirements)
min. 1,4 - 1,75 m
(depending on combustion output and NOx requirements)
Acoustic
Emissions, Sound
Pressure
< 97 dB(A) (average value on enveloping surface at 1 m distance)
Site Closed rooms or weatherproof on site; non-aggressive atmosphere
Ambient temperature
(including impact of heat
radiation)
0°C - 60°C with BCS or Etamatic on burner,
-10°C - 60°C with alternative electronic burner controls in switch cabinet,
relative humidity max. 60% (special corrosion protection on request)
Burner weight Approx. 550 kg plus 100 kg for transport rack
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Technical data
Important components, burner description
important
components:
Flame monitor QRA 2, QRA 53 / FFS 06
Ignition transformer EBI
Servo motor SAD15 / STM 30/40
Air pressure switch DL 50 A
Burner type
N10.12000.30
G-EU2
N10.12000.37
G-EU2
N10.14000.37
G-EU2
N10.14000.45
G-EU2 FQ
N10.16000.45
G-EU2 FQ
Operating mode
The burner is designed as an automatic
controllable gas blast burner to EN 437
Gasfamily 2. It is tested according to
EN 676 and fitted with a delta burner
head, a system for the low NO
x
combu-
stion of fuel.
Application
The burners are applicable for the operation at heating boilers, steam boilers
and air heater with 3-pass, draft or
reverse furnace.
Design
The burner is supplied with connection
leads fixed to a terminal block ready for
connection to the boiler system.
BCS and Etamatic OEM design
The burner is equipped with an electronic burner control system (automatic
furnace controller, electronic compound
controller, gas valve leak detector).
Other electronic burner controller
Electronic burner control (automatic furnace controller, electronic compound
controller, gas valve leak detector) is
placed in the separated switch cabinet.
Combustion air
An overpressure fan impeller with a
steep characteristic is provided to
ensure a high pressure build-up. This
ensures a pulsation-free and steady
combustion behaviour also on boilers
with a high exhaust gas resistance.
Control
The fuel-air ratio is controlled by an
electronic compound controller with
actuators provided for positioning the
following control elements:
- air damper,
- gas damper.
- event. frequency inverter.
Sensors
A flame sensor and an approved automatic furnace controller are provided for
flame monitoring. An differential pressure switch is fitted for fan air monitoring. A speed monitor is installed if an
automatic speed control system is
used.
Ignition
Electrical high voltage ignition of the
enclosed ignition burner.
Heat capacity of the ignition flame
< 10% of the main flame.
Internal exhaust gas return
As a primary precaution to minimize the
generation of nitric oxides, the delta
burner head will internally extract combustion gases from the furnace chamber and feed them to the fuel mixture.
This concept does away with the equipment otherwise required for the external
return of the exhaust gases.
12/2011 14 072 205
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Technical data
Operation fields
0
4
8
12
16
20
24
28
32
36
40
012345678910111213
A rbei tsfel der N10.12000 G- EU2 nach EN 676
0
4
8
12
16
20
24
28
32
36
40
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Arbeitsfelder N10.14000 G-EU2 nach EN 676
Combustion power output [MW]
Limit full load range
Boiler furnace pressure [mbar]
Operation fields N10.12000 G-EU2 according EN 676
Operation fields N10.14000 G-EU2 according EN 676
Combustion power output [MW]
Boiler furnace pressure [mbar]
FQe=frequency converter for motor externally
FQe=frequency converter for motor externally
N10.14000.45
G-EU2 FQe
N10.14000.37
G-EU2 FQe
Limit full load range
N10.14000.37
G-EU2
N10.12000.30
G-EU2
N10.12000.30
G-EU2 FQe
N10.12000.37
G-EU2
N10.12000.37
G-EU2 FQe
12/2011 14 072 205
8
0
5
10
15
20
25
30
35
40
45
50
55
01234567891011121314151617
Arbeitsfeld N10.16000.45 G-E FQ
Operation fields N10.16000 G-EU2 FQe according EN 676
Technical data
Operation fields
Combustion power output [MW]
Boiler furnace pressure [mbar]
FQe=frequency converter for motor externally
12/2011 14 072 205
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Technical data
Gas pressure loss burner head
Gas pressure loss gas butterfly
Druckverluste G as Mischeinrichtung E10 G-EU 2
0
20
40
60
80
100
120
140
160
700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
Volumenstrom Erdgas [m³ /h], 15° C, 1013 mbar, dv 0,61
Druckverl u st [ m bar]
Operation volume flow natural gas [m3/h], t=15°C, 1013 mbar, dv=0,61
p p
diagr
T
288
----------
1013
p
-------------
dv
061,
-------------
=
Pressure loss [mbar]
Pressure loss gas mixed unit N10 ... G-EU2
1
10
100
100 1000 10000
D
r
u
c
k
v
e
r
l
u
s
t
[
m
b
a
r
]
Vol um enst r om V [m ³ /h ], Erdgas, 15 ° C, 1013 mbar, dv = 0,62
Druckverlust b ei voll geöffneter Gasklappe DN 100 Typ DKG / BVG
Ø 100 Ø 65
Ø 80
Pressure loss gas butterfly (full open) DN 100 type DKG/BVG
Operation volume flow natural gas [m3/h], t=15°C, 1013 mbar, dv=0,62
Pressure loss [mbar]
12/2011 14 072 205
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Technical data
Dimensional drawing
N 10... G-EU2
The cover of motor is
removable in case of opening boiler door for revision
Motor with disassembled protection grid
Drilling Template
Air intake box cover with
dismantled home
12/2011 14 072 205
11
Technical data
Installation conditions
ad 1) Boiler lining
D = 497
D
1
= 525
DF= combustion chamber
diameter
T
1
= 150-250
A = 620
(option: extensions
of 100 and 200 mm)
The burner lining must be installed at
right angles to the burner tube.
Possible trimming work (bevelling, rounding) as is required for reversing boilers, for example, should done at a
diameter not below 70 % of the combustion chamber diameter.
The space between the flame pipe of
the burner and the boiler lining should
be lined with heat resistant material,
such as Cerafelt.
This space is not allowed to be lined
with brickwork.
Minimum distance on double
flame tube boilers
ad 3)
Note:
In special cases, the air infake box can
be mounted in a way that the opening
shows to another direction. The dimensioned drawing will the differ slightly.
The air intake box can be rotated in
steps of 22,5 °..
3)
1)
2)
12/2011 14 072 205
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