elco N6.2400 GL-RZ3/LFL, N6.2900 GL-RZ3/LFL, N7.3600 GL-RZ3/LFL, N7.4500 GL-RZ3/LFL Operating Instructions Manual

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Page 1

09/2011 - Art. Nr. 4200 1040 7900A

N6.2400 GL-RZ3/LFL N6.2900 GL-RZ3/LFL N7.3600 GL-RZ3/LFL N7.4500 GL-RZ3/LFL

............................................. 4200 1035 0600

Operating instructions

For specialist installation engineers

Dual fuel burners

de ......................................... 4200 1035 0500

fr ........................................... 4200 1040 8000

it ........................................... 4200 1041 4900

nl .......................................... 4200 1041 5000

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09/2011 - Art. Nr. 4200 1040 7900A2

General information

Contents

General information Contents ............................................................................................................................ 2

Important notes .................................................................................................................3

Burner description ............................................................................................................. 4

Installation General information regarding burner assembly ............................................................... 5

Boiler lining for GL-RZ3/LFL burner ..................................................................................6

Burner assembly................................................................................................................7

Burner head setting data GL-RZ3/LFL ..............................................................................8

Gas train

Gas train description .............................................................................................. 9

Basic design....................................................................................................... 10

Description of gas train with MBC... .....................................................................11

Description of Dungs MBC double gas valve... (gas multiblock)..........................12

Changing MBC-300-700-1200 filter ..................................................................... 13

Setting MBC-300-700-1200-SE pressure regulating component ....................... 13

Setting MBC-1900-5000-SE pressure regulating component .............................14

Description of double gas valve VGD... with servomotors SKP ........................... 15

Gas filters ............................................................................................................ 16

Gas/air pressure switch...................................................................................... 17

Leakage controller, test burner............................................................................ 18

Hydraulics

General information regarding fuel oil system, fuel oil hydraulics diagram ......... 19

Fuel oil pressure switch ....................................................................................... 20

General information regarding fuel oil system .....................................................21

Pump...............................................................................................................22-25

Nozzle line 3-stage..........................................................................................26-27

Commissioning Control and safety unit LFL 1.../LGK... ............................................................................ 28

Electrical servomotor..................................................................................................29-30

Flame monitor, probe current measurement .............................................................31-32

Connecting the gas train, electrical connection, checks before commissioning.............. 33

Gas connection................................................................................................................ 34

Fuel-air coupler control....................................................................................................35

Design of switch cabinet door.......................................................................................... 36

Dual fuel load regulator ..............................................................................................37-38

Control .............................................................................................................................39

Preventilation................................................................................................................... 40

Fuel oil start-up mode, fuel oil operating mode ............................................................... 41

General safety functions..................................................................................................41

Gas start-up mode, gas operating mode......................................................................... 42

General safety functions..................................................................................................42

Servicing Maintenance ..............................................................................................................43-45

Checking, assembling the combustion components ....................................................... 45

Setting for ignition electrodes .......................................................................................... 46

Exhaust gas analysis..................................................................................................47-48

Diagnosing and remedying faults ...............................................................................49-50

Faults .............................................................................................................................51

Declaration of conformity ...........................................................................................52-53

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09/2011 - Art. Nr. 4200 1040 7900A 3

Important information

Burners

N6 and N7 GL-RZ3/LFL

are designed for the combustion of natural gas and light oil. The design and function of the burners comply with EN676 and EN 267. They are designed for use with systems that are approved for the use of burners in accordance with EN 676 and EN 267.. To use the burner with heat generators in conformity with Pressure Equipment Directive 97/23/ EU, special burner components are required (not supplied with standard equipment). Before using the burner with equipment of this type, the equipment characteristics must be checked. Burners that comply with Pressure Equipment Directive 97/23/EU come with a declaration of conformity to this effect and are labelled on the identification plate. Any other type of application requires the approval of ELCO. The burner may only be used in accordance with the instructions set out in this documentation and the relevant technical data. If not used properly, it could cause damage to property and the environment and personal injury. Furthermore, the burner would no longer be CE compliant. Installation, commissioning and maintenance may only be carried out by authorised specialists and all applicable guidelines and regulations must be complied with.

Burner description

The burners

N6 and N7 GL-RZ3/LFL

are progressive, fully automatic mechanical monoblock-type burners for gas and 3stage for fuel oil. Emissions rates may differ, depending on combustion chamber dimensions, combustion chamber load and the furnace (threepass boilers, boilers with reverse firing). For specifying warranty values, the conditions for the measuring equipment, tolerances and humidity must be observed.

Scope of delivery

The burner is supplied packaged in three boxes on a pallet:

- Burner with:

- integrated switch cabinet

- flange seal and securing screws

- operating instructions, circuit diagram and spare parts list

- Burner head

- Compact gas train with gas filter Before commissioning, a check must be carried out to ensure that the product delivered complies with the scope of delivery.

The following standards should be observed in order to ensure safe, environmentally sound and energy-efficient operation:

EN 226

Connection of fuel oil and forceddraught gas burners with fan to a heat generator

EN 60335-1, -2-102

Specification for safety of household and similar electrical appliances, particular requirements for gas burning appliances

DIN EN 60204-1

Safety of machinery. Electrical equipment of machines

DIN EN 50156-1

Electrical equipment for furnaces

Gas lines

When installing the gas lines and trains, the general directives and guidelines, as well as the following national regulations, must be observed: CH: - SVGW-Gasleitsätze G1

- Vorschriften der kantonalen Instanzen (SVGW Gas Direc tives G1 - Cantonal specifi cations) (e.g. fire authority specifications)

DE: - DVGW-TVR/TRGI

Installation location

The burner must not be used in rooms with aggressive vapours (e.g. hair spray, tetrachloroethylene, carbon tetrachloride), high levels of dust or high air humidity (e.g. laundry rooms). The limitations of use set out in the technical data must be complied with. Adequate provision must be made for the supply of combustion air. Given standard conditions, the combustion air requirement may be calculated as follows: Vl [Nm³/h] = QF [kW] *1.25 [Nm³/(h*kW)]

We can accept no warranty liability whatsoever for loss, damage or injury caused by any of the following:

- inappropriate use

- incorrect installation and/or repair on the part of the buyer or any third party, including the fitting of non-original parts

Final delivery and instructions for use

The furnace fitter must supply the operator of the system with operating and maintenance instructions on or before final delivery. These instructions should be displayed in a prominent location at the point of installation of the heat generator. They should include the address and telephone number of the nearest customer service centre.

Notes for the operator

The system should be inspected by a specialist at least once a year. It is advisable to take out a maintenance contract to guarantee regular servicing.

Warning:

When in operation, the burner produces an electromagnetic field. In certain circumstances, this field could affect medical implants (e.g. pacemakers). Before working with the machine,

anyone who has a medical implant should consult their doctor and the manufacturer of the medical implant in order to reduce the risk of serious or fatal injury.

Transport \ packaging \ storage

Safety measures

The burner and accessories must be transported and stored using suitable lifting equipment, means of transport and tools. The safety instructions must be complied with.

Transport

Depending on the size and weight of packaging, burners and accessories must be transported manually or with the use of suitable aids. The transport instructions on the packaging must be complied with. The burner must be properly secured for transport. If measures to secure the burner have not been taken at the factory, suitable measures to secure it during transportation must be taken.

Packaging

The burner and accessories are placed on a wooden pallet and shrink-wrapped. When unpacking the product, suitable lifting equipment and tools must be used to remove the screw connections and clamping devices between the burner and the packaging. Suitable protective clothing must be worn (gloves, safety shoes).

Storage

In order to protect the burner from environmental influences, it must be placed in a dry, locked room when stored temporarily. For the maximum storage temperatures, please refer to the technical data sheet.

Disposal

The current local legislation must be complied with without fail.

General information

Important notes

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09/2011 - Art. Nr. 4200 1040 7900A4

General information

Burner description

2 Load regulator (option) 5 Body 6 Gas inlet flange 8 Burner tube 10 Integrated switch cabinet 11 Burner fixing flange 13 Air intake box 14 Mechanical coupler 19 Hoisting eyes 20 Connector for inspection glass

cooling F6 Air pressure switch M1 Fan motor Y10 Servomotor for air and gas flaps 102 Pump

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09/2011 - Art. Nr. 4200 1040 7900A 5

Installation

General information regarding burner assembly

Tightening torques

During installation, commissioning and maintenance, the following torques for unions must be complied with.

Recommended tightening torques

Standard unions

M4 M5 M6 M8 M10 M12 M16 M20

2 6 10 25 48 85 210 415 Nm

N.B.:

In general, the correct tightening torques have been applied when the unions are tightened hand-tight using a screwdriver (ISO 272) or angled Allen key.

Tightening torques for root connector for fan impeller

SM16 (Ø28)

No.: 1615

SM20 (Ø38 and 42)

No.: 2012

SM25 (Ø42 and 48)

No.: 2517

Bushing

20 30 50 Nm

N.B.:

For more information regarding installation/dismantling of the fan impeller, please refer to the relevant chapter in the operating instructions.

Tightening torque for gas train flange connector

M16 / DN 65 - DN 125

Max. 50 Nm

N.B.:

The unions must be tightened crosswise. The union must be checked to ensure it is tight. If it is not sufficiently tight, the fitting must be removed and checked (tightening surfaces).

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09/2011 - Art. Nr. 4200 1040 7900A6

Installation

Boiler lining for GL-RZ3/LFL burner

Boiler lining

The burner lining must be installed rightangled to the burner tube. Possible trimming work (bevelling, rounding) as required for reverse boilers, for example, should done at a diameter not below 70% of the combustion chamber diameter. The space between the flame tube 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

Sealed area must cover the entire circumference

Seal corners with sealing tape

Warning!

Owing to the fibre diameter, the mineral fibre tightness thermocord may cause reversible mechanical irritation to the eyes and skin. In the event of high dust concentrations, the upper respiratory tract may suffer mechanical irritation. When working with the tightness thermocord, the operator should wear loosefitting, long-sleeved clothing. In the event of high fibre dust concentrations, the operator should wear an FFP1 mask and well-sealed protective goggles (when carrying out overhead work too).

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09/2011 - Art. Nr. 4200 1040 7900A 7

Burner assembly

• Remove cover.

• Take the flame tube (delivered in a

separate box).

• Fit it on the burner body.

• Tighten the 2 fixing screws S1.

• Fit the boiler seal to the burner.

• Raise the burner with the aid of

hoisting eyes 19 and fix it to the boiler.*

• Tighten the 4 fastening screws S2

(comply with tightening torques).

• Place cover back on.

* Alternatively a forklift truck may be

used for fixing it if the burner is fixed to the transport pallet supplied with it. Provision must be made for adequate transport safety. It may be necessary to use suitable materials for transportation (lashing straps).

The burner boiler must be tested while in operation to ensure it is leak-proof. Every effort must be made to ensure that exhaust gases cannot leak in harmful amounts. Poorly sealed burner boiler connections may result in combustion problems

D = see dimensioned drawings D1 = see dimensioned drawings DF = combustion chamber diameter T1 = 70 to 200 mm T = standard muffle depth

(option : extensions: see technical

data)

Note for reverse flow boilers!

For reverse flow boilers, the dimension T1 is only a recommended value. Depending on type of boiler the burner head must stand at least 70 mm ahead the opening for exhaust gas turning back.

Installation

Burner assembly

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09/2011 - Art. Nr. 4200 1040 7900A8

Installation

Burner head setting data GL-RZ3/LFL

Ø a Ø b Ø c d e f g

min max

N6.2400 320 270 240 29 121 60.5 380 148 137

N6.2900 320 270 240 29 121 60,5 380 148 137

N7.3600 320 270 240 40 150 60 425 202 182

N7.4500 340 270 240 30 150 60 425 195 130

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09/2011 - Art. Nr. 4200 1040 7900A 9

Installation Gas train

Gas train description

Gas train installation

To install the gas train supplied in the burner, the unions and seals intended for this must be used (supplied with the product).

Warning: in order to prevent injury, heavy gas train components should only be fitted using suitable aids and lifting equipment (crane, cable slings, assembly supports). The max. tightening torques must be complied with (see chapter on Installation/ tightening torques). The unions must be tightened crosswise and evenly. The union must be checked to ensure that it is tight. For further information, please refer to the chapter on commissioning the gas connection.

Gas valve group selection

The gas trains must be dimensioned to suit the throughput required and the available gas pressure. The gas valve group is defined on a system-specific basis. The following must be taken into consideration:

• Burner output,

• Combustion chamber counterpressure,

• Gas pressure loss in the burner head,

• Gas pressure losses in the gas fittings.

The total drop in gas pressure must always be lower than the available gas flow pressure.

The burner's scope of delivery may include a gas train. In this case, the burner and the gas train are issued with a CE Declaration of Conformity. If the gas train is not delivered with the burner, the conformity of the burner is valid only if the gas fittings and the design of the gas train satisfy the burner test specified by EN 676 and meet the Pressure Equipment Directive. Individual testing will be necessary where this is not the case. The gas train delivered has its own documentation including operating instructions and a spare parts list. There follows a general description of the gas train.

Gas trains with a double gas valve are intended for the supply, main shut-off, gas filtration, gas pressure regulation and monitoring of the gas supply. They are compatible for use with gases conforming to the specifications of the gas fittings. The design complies with EN 676. All function parts have been individually tested and awarded the CE mark and number of the notified body. The prefitted gas train is subjected to a leak test at the manufacturer's works.

Low- and high-pressure gas trains

If the outlet side of the regulator, i.e. individual fittings and instruments downstream of the gas pressure regulator, has not been designed to be compatible with the maximum supply pressure that occurs in the event of a fault, the gas train must be equipped with a safety shut-off valve (SSOV) and a safety relief valve (SRV) in accordance with EN 676. This equipment is generally required for maximum supply pressures of >360 mbar and > 500 mbar respectively. These are known as high-pressure gas trains. If all fittings and instruments of the gas train have been designed/approved for the maximum supply pressure that occurs in the event of a fault, the gas train is known as a low-pressure gas train. This is the case, depending on component selection, for maximum supply pressures of 360 and 500 mbar.

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09/2011 - Art. Nr. 4200 1040 7900A10

Installation Gas train

Basic design

100 Burner 101 Gas pressure impulse pipe 120 Air flap 141 Ball valve 142 Gas filter 144 Gas pressure regulator 145 Safety gate valve (SGV) 148 Safety relief valve (SRV) 150 Gas control butterfly 151 Double gas valve or 2 single valves 155 Ignition unit 313 Min. gas pressure switch

314 Gas pressure switch for checking valve tightness 349 Servomotor

Options in accordance with country-specific requirements: 143 Pressure gauge with pushbutton valve 147 Test burner with pushbutton valve 148 Compensator 154 Gas safety valve (additional) 313a Max. gas pressure switch

High pressure

100 Burner 101 Gas pressure impulse pipe 120 Air flap 141 Ball valve 142 Gas filter 150 Gas control butterfly 151 Double gas valve with integrated regulation

(Siemens VGD system shown) 155 Ignition unit 313 Min. gas pressure switch

314 Gas pressure switch for checking valve seals or valve

tightness control device

349 Servomotor

Low pressure

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09/2011 - Art. Nr. 4200 1040 7900A 11

Description

The gas trains with Dungs MBC ... double gas valves MBC... are used for gas supply, as the main isolation valve, for gas filtering, gas pressure regulation and monitoring of the gas supply. They can be used for all gases in the 1, 2, 3 gas families in accordance with DVGW worksheet G 260/1 and/or EN 437. The design complies with EN 676. All the functional components have been tested individually and awarded the CE mark and number of the Notified Body. The premounted gas valve group is subjected to a leak test at the manufacturer's works.

Minimum scope of delivery for gas trains

in accordance with

EN 676:

- 1 Ball valve

- 1 Gas filter

- 1 Double gas valve with spring 580 mbar

- 1 Min. gas pressure switch

- 1 Leakage controller or 1 gas pressure switch for valve leak test

Options:

- Springs for other outlet pressures

- Test burner with pushbutton valve

- Pressure gauge with pushbutton valve

- Compensator

- Max. gas pressure switch

- Gas meter

- Pipe parts and connection parts

- Ignition gas device

- Installation support

- High-pressure regulator with safety shut-off valve (SSOV)

- Settling section with pulse lines for high-pressure regulator

- Safety relief valve (SRV)

- Additional gas safety valve

Low and high-pressure gas trains

If the outlet side of the regulator, i.e. individual fittings and instruments downstream of the gas pressure regulator, has not been designed to be compatible with the maximum supply pressure that occurs in the event of a fault, the gas train must be equipped with a safety shut-off valve (SSOV) and a safety relief valve (SRV) in accordance with EN 676. This equipment is generally required for maximum supply pressures of >360 mbar and > 500 mbar respectively. These are known as highpressure gas trains. If all gas train fittings and equipment have been designed and/or approved for the maximum supply pressure that occurs in the event of a fault, the gas train is known as a low-pressure gas train. This is the case, depending on component selection, for maximum supply pressures of 360 and 500 mbar.

Gas valve group

The gas valve group is defined on a system-specific basis.

The following must be taken into consideration:

• Burner output

• Furnace counterpressure

• Gas pressure loss in the burner head

• Gas pressure losses in the gas fittings

The total drop in gas pressure must always be lower than the available gas flow pressure.

The section of the pipings must be calculated so that the loss of load doesn’t exceed 5% of the supply pressure.

Warning!

With burners that have the CE mark, only the use of gas fittings that have been approved on the basis of burner type-testing is permitted. If alternative gas fittings are used, the burner must undergo individual testing by the relevant testing body.

Subject to change without notice due to ongoing technical developments.

Gas train with MBC Technical data:

Types of gas:

Gas types of gas families 1, 2 and 3 according to DVGW Worksheet G 260/1

Max. inlet pressure:

MBC700-1200 with CG15 ignition gas fittings: 360 mbar without ignition gas fittings: 360 mbar

MBC1900-5000 with CG15 ignition gas fittings: 360 mbar

MBC1900-5000 with FRS 505/ MVD 505 ignition gas fittings: 500 mbar without ignition gas fittings: 500 mbar

Elect. connection: AC 220-240 V, 50 Hz

Protection level: IP 54

Ambient temperature:

-15 °C to +60 °C

Installation Gas train

Description of gas train with MBC...

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09/2011 - Art. Nr. 4200 1040 7900A12

Technical data

Gas multiblock MBC-.../SE:

Type of gas: Gases in accordance with DVGW worksheet G 260/1, gas families 1, 2, 3

Electrical data: 230 V -15% + 10%, other voltages on request

50...60 Hz

Protection level: IP 54

Ambient temperature:

-15C to +60C

Installation position: MBC-300-1200: magnet vertically upright or magnet horizontal

MBC-1900-5000: magnet vertically upright

Max. operating pressure: MBC-300-1200: 360 mbar MBC-1900-5000: 500 mbar

The MBC...SE gasmultibloc integrates the filter, valves and servo pressure regulator into one compact unit:

- Dirt trap: fine filter (MBC-300-1200 only)

- 2 solenoid valves up to 360 mbar in accordance with DIN EN 161 Class A Group 2 fast-closing, fast-opening (MBC-300-1200)

- 2 solenoid valves up to 500 mbar in accordance with DIN EN 161 Class A Group 2 fast-closing, fast-opening (MBC-300-1200)

- Servo-pressure regulation component in accordance with DIN EN 88 Class A Group 2, EN 12067-1

- Outlet pressure: 0 - 300 mbar (MBC300-1200), 4 - 300 mbar (MBC-1900-

5000)

- Sensitive adjustment of the outlet pressure with the SE version for optimum outlet pressure sensitivity

- Sensitive adjustment of the gas and air pressure ratio with the VEF version

- Flanged connections with pipe threads in accordance with ISO 7/1 or NPT (MBC-300-1200)

- Flanged connections in accordance with EN 1097-1 / ISO 7005 (MBC1900-5000)

1, 2, 3

Seal plug G 1/8

4, 5, optional

Connection system accessories (optional)

6, 7

Seal plug G 1/4

8, 9, optional

Seal plug G 1/2 (optional)

Impulse line p

(integrated)

Breather plug G 1/8

Installation Gas train

Description of Dungs MBC double gas valve... (gas multiblock)

Pressure switches

MBC-300/

700...

MBC-1200...

1, 2, 3, 4, 5

Seal plug G 1/8

MBC-...-SE 1900-5100

Pressure switches

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09/2011 - Art. Nr. 4200 1040 7900A 13

Filter inspection must be carried out at least once a year

Replace filter if p between pressure

port 1 and 2 > 10 mbar.

Replace filter if p between pressure port 1 and 2 is twice as high as the last measurement.

1. Interrupt gas supply: close ball valve.

2. Unscrew screws 1-2.

3. Replace fine-filter element 3.

4. Screw in and gently tighten screws 1-

5. Carry out a function test

and a test to check the water tightness p

max.

= 360 mbar.

Space required for filter replacement: MBC-300-...: 150 mm MBC-700-...: 170 mm MBC-1200-...: 230 mm

Adjusting the MBC-300-700-1200-SE pressure regulating component

1. Open the slide.

2. Start the burner, correction of set values possible while burner in operation (fig. 1).

3. Check ignition safety of the burner.

4. If necessary repeat the setting steps. Check intermediate values.

5. Apply a security seal to the adjusting screw, see right.

Optimum combustion and ignition safety must be ensured.

Security seal

After you have set the desired nominal pressure value:

1. Close the slide.

2. Secure the slide in closed position using the screw (fig. 3).

Installation Gas train

Changing MBC-300-700-1200 filter Setting the MBC-300-700-1200-SE pressure regulating component

Allen key no. 2.5

Open2Closed

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09/2011 - Art. Nr. 4200 1040 7900A14

Installation Gas train

Setting the MBC-1900-5000-SE pressure regulating component

Allen key no. 2.5

Adjusting the MBC-1900-5000-SE pressure regulating component

1. Open the protective caps.

2. Start the burner, correction of set values possible while burner in operation (see figure).

3. Check ignition safety of the burner.

4. If necessary repeat the setting steps. Check intermediate values.

5. Apply a security seal to the adjusting

screw (see below).

Optimum combustion and ignition safety must be ensured.

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09/2011 - Art. Nr. 4200 1040 7900A 15

Installation Gas train

Description of double gas valves VGD... with servomotors SKP

VGD 20

VGD 40

SKP 15

SKP 25

SKP 75

Technical data

Double gas valves VGD with servomotors SKP:

Type of gas: Gases in accordance with DVGW worksheet G 260/1, gas families 1, 2, 3 and biogas (H

S-content 0.1 Vol.% max.),

Electrical data: 220 V -15%...240 V +10% 100 V -15%...110 V +10% 50 to 60 Hz

Protection level: IP 54

Media temperature :-15°C to +60°C

Ambient temp.: -10°C to +60°C

Installation position: Magnet vertically upright or on its side, magnet horizontal

Max. operating pressure: VGD20: 500 mbar VGD40: 700 mbar (DN 40 and DN 50 to 1000 mbar)

Double gas valve VGD with servomotors SKP

The combined servomotor and valve perform the following functions:

• safety shut-off valve Class A Group 2 in accordance with EN 161 (SKP15...)

• safety shut-off valve Class A Group 2 in accordance with EN 161 with gas pressure regulator (SKP25..., SKP55..., SKP75...)

The electrohydraulically operated servomotors with valve are designed for gases of families I to III and air, and are intended mainly for use in gas-fired furnaces. They are slow-opening and fast-closing. The servomotor can be combined as desired with any of the valves and nominal widths specified above. The servomotor can be supplied with a limit switch (closed position signalling). Valve dimension information is provided on the "Throughput diagram" in the relevant valve datasheet.

The SKP25... operates as a constantpressure regulator with setpoint spring. It is mainly intended for use with forced draught burners

- with mechanical coupler;

- with electronic coupler.

The SKP75... operates as a constantratio pressure regulator and regulates gas pressure in proportion to the pressure of the combustion air. This keeps the gas/air ratio constant across the entire load range. It is intended mainly for use with modulating forced draught gas burners with pneumatic coupler.

System accessories available for the double gas valve include the VPS 504 leak testing system and the GW...A5 pressure switch.

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09/2011 - Art. Nr. 4200 1040 7900A16

Installation Gas train

Gas filter

Installation and mounting of the gas filter

The gas filter may be installed in any desired position. Take care only to observe the direction of flow of the gas (arrow on filter housing). Make sure there is adequate clearance to facilitate the removal of the cover and replacement of the filter cartridge.

Filter replacement

The filter cartridge should be replaced with a new one as soon as a high pressure drop is noticed. If a new filter cartridge is not at hand it will be possible to wash the filter mat in 40°C water adding some light-duty detergent. Allow the mat to dry before reinstallation.

Warning: when installing the filter mat, comply with the marking or adhesive label.

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09/2011 - Art. Nr. 4200 1040 7900A 17

Installation Gas train

Gas/air pressure switch

Determining the differential preflushing pressure and adjusting the differential pressure switch

• Burner in the pre-aeration phase.

• Measure pressure on test connection (2).

• Measure vacuum on test connection (3).

• Add the measured pressures.

• Set the scale to 90% of the calculated value.

Switch function test

• Test buttons are provided to check the switch functions for proper operation (with safety cut-out and interlock). The burner is normally run in part-load condition when testing the safety functions. On pressing button (4) the vacuum will be removed which causes the differential pressure to drop below the required level. If it is necessary to test the pressure switch functions under full-load conditions this may be done by pressing button (1).

Technical data:

Type of gas: Gases according to DVGW Worksheet G 260/1, gas families 1, 2, 3

Protection level: IP 54

Ambient temp.: -15°C to +50°C

Installation position: any

Operating pressure up to: GW 50/150 A5A6 500 mbar GW 500/ A5/A6 600 mbar

Gas pressure switch GW...A5/A6

The gas pressure switch is designed to monitor the gas flow pressure. It can be used for monitoring either falling pressure (minimum) or rising pressure (maximum, specified for equipment according to TRD 604). The types GW...A5/A6 may be used as pressure switches of a specific construction according to VdTÜV leaflet "Pressure 100/1" for application in furnaces complying with TRD 604. The setpoint (switching point) may be selected by means of a setting disk with vessel.

Air pressure switch

The air pressure switch is provided for monitoring the pressure of the combustion air fan. Pressure switch LGW... is suitable for switching an electrical circuit or for switching it on or off if the actual pressure values are changing vis-a-vis the setpoint. The pressure switch LGW... can be used as overpressure, vacuum or differential pressure switch for air and non-aggressive gases but not for gases according to DVGW Worksheet G 260/l.

Certification

The pressure switch has been tested in accordance with EN1854 and is CE/DIN-

DVGW-registered. It has been registered in other important gas consumption countries.

N.B.(Gas and air pressure switches) The pressure switches must be set in accordance with the specifications. Furthermore, each time they are set, a function test must be carried out. Noncompliance could result in personal injury or damage to property! Once the pressure switches have been set, they must be protected to prevent settings from being altered. For example, this can be done by placing a spot of varnish on at least one of the screws on the equipment's protective cover.

Setting the min. gas pressure switch

Remove the protective cover. At the rated output, measure the gas flow pressure and calculate the switch-off pressure by reducing by approximately 20%. Adjust the graduated disc to the desired switch-off pressure opposite the arrow (the graduations are approximate values). Operate the burner at minimum power. Close the gas shut-off valve slowly to obtain the desired switch-off pressure. Turn the graduated disc until the burner switches off. Refit and screw down the protective cover.

Max. gas pressure switch

Remove the protective cover. At the rated output, measure the gas flow pressure and calculate the switch-off pressure by increasing by approximately 20% (no more than 30% under any circumstances). Adjust the graduated disc to the desired switch-off pressure opposite the arrow (the graduations are approximate values). Operate the burner at minimum power. If the max. gas pressure switch switches off the burner, increase the adjustment value but not to more than 130% of the flow pressure at the rated output.

Gas pressure switch A5

Gas pressure switch A6

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09/2011 - Art. Nr. 4200 1040 7900A18

Gas train

Leakage controller Test burner

1 Wieland 7P socket 3 Filter element 4 O-ring Ø10.5x2.25 5Fuse

T6.3 250V Ø 5x20

6 Yellow indicator On :

Leakage test OK

7 Red indicator On :

Leakage test NOK

Manual clear 8 Spare fuses 9 pa (p2) pressure switch Ø 9

pe + 20mbar 10 pe (p1) pressure switch Ø 9

inlet pressure (distribution)

Leakage controller VPS 504 S02 Working principle :

Prior to each burner start-up, the controller checks for possible leaks between safety and main valves by increasing supply pressure. Electrically, the leakage controller is serially connected between the thermostatic circuit and burner control and safety unit. Installation : Directly on valve.

Program stages :

On stoppage, safety and main valves are closed. On thermostat stoppage, the leakage controller is turned on and booster increases supply pressure by 20 mbar. After no more than 30 seconds operation :

- the leakage test has been passed; the

yellow light comes on and current is released to feed the burner’s control and safety unit, which then starts its program cycle.

- If the leakage test is not passed; the

red light comes on and the power supply to the control and safety unit for the burner is not released. Control cycles have to be restarted manually. Change valve if fault persists.

Setting :

The controller requires no on-site setting. Working test : While controller is working :

• Open pa pressure switch. The precip-

itated leak prevents superpressure from building up and safety unit locks.

• Reclose pa pressure switch.

• Release controller safety by pressing

red indicator light. The leakage test is restarted; after 30 seconds, yellow indicator lights up and powers up the burner's control and safety unit, which then starts its program cycle.

Test burner

Depending on the country-specific requirements, when installing steam boilers it may be necessary to fit a test burner to the gas train (e.g. in line with directive TRD 412). This is used to vent the gas pipes. The gas supply is switched on by pressing the button (1). The flow of gas brings in the required amount of combustion air via the hole in the burner tube (3). The gas/air mixture is routed towards the burner head (4) and ignited manually at its opening. Gas is supplied for as long as the button is pressed and cut off when it is released.

Technical data:

• Type of gas: gases in accordance with DVGW worksheet G 260/1, gas families 1, 2, 3

• Ambient temp.: -15°C to +70°C

• Installation position: vertical, facing upwards

• Operating pressure to: 500 mbar

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09/2011 - Art. Nr. 4200 1040 7900A 19

Installation Hydraulics

General information regarding fuel oil system Fuel oil hydraulics diagram

100 Burner 101 Fan 118 Nozzle 120 Air flap 143 Pressure gauge (optional) 175 Filter 176 Pump 178 Solenoid valve, supply line 349 Servomotor

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09/2011 - Art. Nr. 4200 1040 7900A20

Installation Hydraulics

Fuel oil pressure switch

Fuel oil pressure switches are used to monitor burners to ensure that they do not exceed or fall below specific fuel oil pressures. Depending on the burner variant, pressure switches may be specified for backflow only or for backflow and the supply line. The shut-off pressure in question is set depending on the system parameters (ring line pressure, fuel oil nozzle etc.).

Fuel oil pressure damping

To reduce fluctuations in fuel oil pressure, a throttle screw (2) or a capillary tube may be screwed into the connection nozzle.

Adjustment of switching pressure

To adjust the switching pressure, the adjustment button (1) can be pulled upward and reinserted the opposite way around.

Setting the fuel oil pressure switch min.:

The shut-off pressure is the fuel oil supply pressure at full load, minus approx. 20%.

Setting the fuel oil pressure switch max. (only for burners with a return nozzle):

The shut-off pressure is the ring line pressure with a full load plus approx.

2...3 bar. The set shut-off pressure should also take cognisance of the set switch difference. When the setting procedure is complete, the setting button must be returned to its original orientation for safety. A seal must be applied to the pressure switch to secure the setting (Item 4).

Switching difference

The switching difference may be set at the limits of the pressure switch in accordance with the values in the table. To do this, the set screw must be rotated in the adjusting screw (3) for the switching point. 1 turn modifies the switching difference by approx. 20% of the total switching difference range.

Model Adjustment

range

Switching difference

Application

DSB 158 F ... 0-25 bar 1.0... 7.5 bar

Standard EN 267 supply line and backflow

Page 21

09/2011 - Art. Nr. 4200 1040 7900A 21

Installation Hydraulics

General information regarding fuel oil system

Fuel oil connection

Hoses are used to make a connection to the fuel oil tubes or the gate valves. To prevent kinks and therefore any risk of rupture, the hoses must be fed correctly (no tension or distortion). When installing the fuel oil tubes or the gate valves, care must be taken to ensure that the lines terminate as close to the burner as possible and that they are positioned in such a way that the boiler door and the burner can be swivelled out without obstruction.

Gate valve

In the fuel supply feed line, manual gate valves must be fitted before the burner (supply line and backflow). These must be installed in such a way that they are easily accessible. The manual gate valves are not included in the scope of delivery.

Gas and air separators

Air or gas In the fuel supply line could cause noise and operational problems. In order to avoid this, a suitable gas air separator must be fitted in the fuel supply line.

Fuel oil filter

To protect the oil pressure pump and the hydraulic system, a filter must be installed before the pump. A filter with ≤ 200 µm is recommended.

Installation options

• Two-line installation (separate supply line and return line with no delivery pump)

• Ring line system (with delivery pump and gas-air separator)

Fuel oil pressure regulator (supply line)

The supply pressure is regulated by the pressure regulator fitted in the pump and, depending on the burner output and make of nozzle, it is set to 1015 bar. The pressure regulator is actuated by rotating screw 3. Before commissioning, the pump must be filled with fuel oil.

Venting

With the ring line, if any, in operation, open the supply line and return gate valves. Reduce the oil pressure on the pressure regulation valve. Switch on the pump by depressing the contactor. Check whether the direction of rotation is correct, the pump is supplying fuel oil and the fuel oil hydraulics system is leak-proof. Vent the pump, e.g. at the pressure gauge connector. When commissioning the burner, the oil pressure must be increased slowly until it reaches the operating value.

Pressure regulation (fuel oil intake pressure)

The maximum possible vacuum is

0.2 bar. If the vacuum pressure is greater than this, gas emissions are produced from the fuel oil and this could cause problems. In the case of ring line operation, the oil pressure at the pump must not exceed the maximum permissible pressure. For the maximum pressure, please refer to the technical data.

Connecting test devices

Before setting the burner, test pressure gauges must be fitted to determine supply pressure 1 and possibly intake pressure 2.

N.B.:

When commissioning is complete, the pressure gauges must be removed and the connections must be duly sealed. If the pressure gauges are left on the burner, they must all be shut off with shut-off valves.

Oil hoses for burner connection

Burner type DN Length [mm] Connection on

both sides

Minimum bending radii R

[mm] N6.2400 20 1500 R 1/2" 145 N6.2900 20 1500 R 1/2" 145 N7.3600 20 1500 R 3/4" 145 N7.4500 20 1500 R 3/4" 145

Connection to the test point

Burner Test point for

intake

pressure

Test point for

pump pressure

(at pump)

Test point for pump pressure (bef. 1st safety valve)

N6.2400 G1/2 G1/4 Ø10 pipe connector acc. to DIN EN ISO 8434-1* N6.2900 G1/2 G1/4 Ø10 pipe connector acc. to DIN EN ISO 8434-1* N7.3600 G1/4 G1/4 Ø10 pipe connector acc. to DIN EN ISO 8434-1*

N7.4500 G1/4c G1/4 Ø10 pipe connector acc. to DIN EN ISO 8434-1* *In order to be able to use the test components, a cutting ring in acc. with DIN EN ISO 8434-1 is required. If the pressure gauge is not left on the burner, a union nut in acc. with DIN EN ISO 8434-1 is also required.

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09/2011 - Art. Nr. 4200 1040 7900A22

Installation Hydraulics

Pump type J7

Areas of application

- Light, medium-grade oil

- Two-line system.

- Generally connected to the solenoid valve in the nozzle line

Description of Functions

The gearbox draws the fuel oil from the tank through the built-in filter and supplies it under pressure to the valve which controls the oil pressure for the nozzle line. In the case of two-line installations, fuel oil which exceeds the nozzle capacity flows back to the tank through the valve via the return opening. Description of how the integrated valve works: a flat section on the pressure regulation piston assists drainage of the fuel oil*. If rotation of the gearbox is increased when pumping commences, all the fuel oil flows to the backflow via the flat section and the hydraulic valve remains closed. It is only when a specific rotational gearbox speed is reached that the fuel oil can no longer be returned via the flat section. The pressure before the control piston increases rapidly and opens the valve as soon as it is higher than the force of the valve springs. When switched off, the valve closes as soon as the gearbox capacity is lower than the outflow via the flat section on the piston on account of the lower rotational speed. Opening and closing of the valve depends on the size of the gearbox and the set pump pressure.

Venting

In the two-line system, venting is carried out automatically. However, venting can be speeded up by opening the pressure connection.

*In the J 1002 models, the bypass hole in the nozzle plug prevents shut-off. For shut-off, a separate solenoid valve must be installed in the nozzle line.

Pumping capacity

Pump power requirements

Capacity (l/hr)

Power (W)

Pressure (bar)

Viscosity = 5 cSt - pump speed = 2850 rpm

Allowance has already been made for gearbox wear in the curves shown. In selecting the gearbox capacity, you should therefore ensure that the pump is not over-dimensioned.

Viscosity = 5 cSt - pump speed = 2850 rpm

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09/2011 - Art. Nr. 4200 1040 7900A 23

Installation Hydraulics

Pump type J7

General

Attachment Flange attachment as per EN 225.

Model 1000 Model 1001/1002 Connections Conical Cylindrical in acc. with ISO 228/1 Supply line and backflow 1/4" NPTF G 1/2 Nozzle outlet 1/8" NPTF G 1/4 Pressure test connection 1/8" NPSF G 1/8 Vacuum test connection 1/4" NPTF G 1/2 Valve function Pressure regulation and shut-off (apart from J 1002). Filter Filter area: 45 cm²

Mesh size: 170 µm Shaft Ø 11 mm in acc. with EN 225. Bypass-plug Installed in the return opening

For two-line installaiton Weight 4 kg

Hydraulic data

Pressure range C : 10 - 21 bar

E : 10 - 30 bar Pressure setting

when delivered

12 bar

Viscosity range 2 - 75 mm²/s (cSt) Fuel oil temperature 0 - 90°C in the pump Supply pressure 1.5 bar max. Return pressure 1.5 bar max. Intake height 0.45 bar max. vacuum in order to avoid air separation Rotational speed 3600 rpm max. Torque (at 45 rpm) 0.30 Nm

Fuel oil under vacuum

Fuel oil under pressure

Excess fuel oil returned to the tank or to the section side

Supply

Vacuum test connection

Gearbox

Pressure regulation

To the nozzle

Bypass

plug

screwed down

firmly

Pressure test connection

Backflow

TWO-LINE INSTALLATION

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09/2011 - Art. Nr. 4200 1040 7900A24

Installation Hydraulics

Pump type TA3

Areas of application

- Domestic oil and heavy-grade oil (for use with kerosene, please contact SUNTEC)

- Two-line system.

Description of Functions

The gearbox draws the fuel oil from the tank and supplies it under pressure to the valve which controls the oil pressure for the nozzle line. In the case of two-line installations, fuel oil which exceeds the nozzle capacity flows back to the tank through the valve via the return opening.

Venting

Pump venting is speeded up by opening a pressure connection.

Note:

All TA pumps supplied are for two-line installation (bypass plug screwed into the vacuum connection). To convert to single-line operation, the bypass plug must be removed and the return opening must be sealed off with a gasket and metal plug.

Pumping capacity

Pump power requirements

Capacity (l/hr)

Power (W)

Pressure (bar)

The values specified in the curves apply to new pumps (with no evidence of wear)

Viscosity

- Rotational pump speed = 2850 rpm

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09/2011 - Art. Nr. 4200 1040 7900A 25

Installation Hydraulics

Pump type TA3

General

Attachment Flange attachment Connections Cylindrical in acc. with ISO 228/1 Supply line and backflow G 1/2 Nozzle outlet G 1/2 Pressure test connection G 1/4 Vacuum test connection G 1/4 Shaft Ø 12 mm Bypass-plug Used in the vacuum connection

for two-line installaiton

Weight 45.4 kg (TA2) - 5.7 kg (TA3)

6 kg (TA4) - 6.4 kg (TA5)

Hydraulic data

Pressure range 30 : 7 - 30 bar

40 : 7 - 40 bar

Pressure setting when delivered

30 bar

Viscosity range 3 - 75 mm²/s (cSt)

(Fuel oil with a higher viscosity may be used if the fuel oil is supplied under pressure and is heated in such a way that the viscosity falls below 75 cSt. For use with kerosene, please contact SUNTEC)

Fuel oil temperature 0 - 150°C in the pump Supply pressure Light oil operation: vacuum 0.45 bar max.

in order to avoid air separation Heavy-grade oil operation: 5 bar max.

Return pressure Light oil operation : 5 bar max.

Heavy-grade oil operation: 5 bar max. Rotational speed 3600 rpm max. Torque (at 40 rpm) 0.30 Nm

Selecting the heating element

Heating cartridge Ø 12 mm Thread connection In acc. with EN 50262 Power 80-100 W

Fuel oil under vacuum

Fuel oil under pressure

Excess fuel oil returned to the tank or to the section side

Supply

Pressure control

To the nozzle

Bypass

plug

screwed down

firmly

Backflow

TWO-LINE INSTALLATION

Vacuum or boost pressure test connection

Pressure test connection

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09/2011 - Art. Nr. 4200 1040 7900A26

Installation Hydraulics

Nozzle line, 3-stage

3-stage nozzle line

The nozzle line consists of three pipes each of which carries the fuel oil to a nozzle. The flow of the fuel oil is controlled by the upstream fuel oil safety valves. These are normally closed. Each of the three valves controls a nozzle in the fuel line. When the valves are engaged, load stages 1, 2 and 3 are implemented. In load stage 3, i.e. at maximum burner output, all the valves are open and all the nozzles are operating simultaneously. To the front of the nozzle line there is a nozzle plate designed to hold the nozzles. The table (see below) lists the standard

fuel oil nozzles for the lowest and highest output range. Intermediate gradations are possible. The nozzle configuration selected must ensure that the burner output falls within the specified working field (see technical data). It must not fall below or exceed this. It is essential to have stable, hygienic and reliable combustion. The fuel oil pressure set must be taken into account when selecting the nozzle.

Valve block

The valve block collects the oil and distributes it to the three fuel oil valves fitted directly onto the block. The fuel oil is supplied through the fuel oil pump on the burner. Before it reaches the fuel oil block, the fuel oil first passes through the first fuel oil safety valve. The valve block is fixed to the rear of the nozzle line with two screws. In this way, the entire burner head can be dismounted along with the nozzle line and valve block.

The connections to be unscrewed have been kept to a minimum.

The nozzles for the 3-stage nozzle line are selected so as to meet the maximum performance requirements of the boiler with the best possible control range and high combustion quality overall. This means that in selecting the nozzles, not only is the nominal capacity of the relevant boiler crucial, so is the minimum performance and the quality of combustion during each load stage. The nozzle for the first stage must be selected in such a way that it is within the range of the permissible working field of the burner. For the working field and the minimum permissible outputs, please refer to the technical data.

All the Monarch and Steinen nozzles have permanent labels containing the following information (subject to change and based on CEN standards):

- Flow (in USGPH at 100 Psi = 6,895 bar)

- Manufacturer's code

- Spray angle

- Nozzle series ID

- Manufacturer's logo

Standard configuration for fuel oil nozzles for domestic fuel oil

Burner 1st stage 2

stage 3rd stage

Model Size Model Size Model Size Fuel oil

pressure

supply line

[basic load]

N6.2400 min. Steinen SS60° 15.0 GPH Monarch PLP 60° 15.5 GPH Monarch PLP 60° 19.5 GPH 11.5 bar

N6.2400 max. Steinen SS60° 18.0 GPH Monarch PLP 60° 21.5 GPH Monarch PLP 60° 24.0 GPH 11 bar

N6.2900 min. Steinen SS60° 18.0 GPH Monarch PLP 60° 19.5 GPH Monarch PLP 60° 21.5 GPH 10 bar

N6.2900 max. Steinen SS60° 18.0 GPH Monarch PLP 60° 19.5 GPH Monarch PLP 60° 24.0 GPH 12 bar

N7.3600 min. Steinen SS60° 22 GPH Monarch PLP 60° 30 GPH Monarch PLP 60° 30 GPH 12 bar

N7.3600 max. Steinen SS60° 24 GPH Monarch PLP 60° 30 GPH Monarch PLP 60° 30 GPH 13.5 bar

N7.4500 min. Steinen SS60° 22 GPH Monarch PLP 60° 30 GPH Monarch PLP 60° 30 GPH 14 bar

N7.4500 max. Steinen SS60° 26 GPH Monarch PLP 60° 35 GPH Monarch PLP 60° 40 GPH 16 bar

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09/2011 - Art. Nr. 4200 1040 7900A 27

Installation Hydraulics

Nozzle line, 3-stage

Oil throughput with pump pressure in bar

STEINEN

Oil through-

put at 7 bar

Kg/hr

Pressure in bar

GPH1012141820

10.00 38.28 41.93 45.29 51.36 54.14

11.00 42.11 46.13 49.82 56.50 59.56

12.00 45.94 50.32 54.36 61.64 64.98

13.00 49.77 54.52 58.89 66.77 70.40

14.00 53.6 58.71 63.42 71.91 75.81

15.00 57.43 62.91 67.95 77.05 81.23

16.00 61.26 67.10 72.48 82.19 86.65

17.00 65.08 71.29 77.00 87.31 92.05

18.00 68.91 75.48 81.53 92.45 97.47

20.00 76.57 83.87 90.60 102.7 108.3

22.00 84.23 92.27 99.66 113 119.14

24.00 91.88 100.7 108.7 123.27 129.96

26.00 99.54 109.04 117.8 133.5 140.8

28.00 107.2 117.4 126.8 143.8 151.6

Fuel oil, standard: 3.4 cst viscosity, .84 voluminal mass @ 20° C EN 293

Nozzle size Flow in l/hr at a pressure of (bar):

MONARCH

7 8.8 10.4 12.2 14

10.5 39.7 44.3 48.8 52.6 56.4

12 45.2 50.7 55.6 60.2 64.3

13.5 51.1 57 62.6 67.8 72.5

15.5 58.66 65.6 71.7 77.8 82.8

17.5 66.2 74.2 81 87.8 93.9

19.5 73.9 82.5 90.5 97.6 104.5

21.5 81.4 90.9 99.9 107.5 115

24 90.9 101.4 111.3 120.4 128.7

28 106 118.5 129.8 140 149.9

30 113.5 127.2 139.3 150.3 160.9

35 132.5 148 162.4 175.2 187.4

40 151.4 169.2 185.5 200.6 213.8

45 170.3 191 209 225.2 241.1

50 189.2 211.6 232 250.2 267.6

55 208.2 232.8 255.1 275.2 294.1

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09/2011 - Art. Nr. 4200 1040 7900A28

Commissioning

Control and safety unit LFL 1.../LGK...

LFL 1.../LGK... is designed for controlling and monitoring burners that operate on the basis of a stepped or modulating principle. The following control and safety units are installed as standard:

• Hot water applications - LFL 1.333 series 02

• Steam and hot water applications LGK 16.333A27

The safety times for these control and safety units are listed in the table below. Before commissioning, a check must be carried out to determine whether the safety times comply with national and

regional regulations. Other control and safety unit variants can be obtained on request.

N.B. Do not press the reset button for more than 10 sec!

R Reset button



R = Temperature or pressure

controller M = Fan motor Z = Ignition transformer BV= Fuel valve(s) LR= Load regulator LK= Air flap RV= continually adjustable fuel valve

or load stage valve FS= Signal of flame

A = Starting type interval A-B= Flame development interval B = Burner has reached operating

position

B-C= Burner operation (heat genera-

tion)

C-D= regular shut-off

Functional diagramLFL 1.../LGK... Safety times

(sec)

t1 Pre-ventilating time 31,5 t3 Pre-ignition time 6 t4 Fuel valve enable 11.5 t5 output regulation release LR 11.5 t6 Post-ventilation time 17 t7 Interval between start command and voltage on terminal 7 3 t11 "OPEN" run time of air flap any t12 "CLOSE" run time of air flap any t13 Permissible post-combustion time 17 TSA Start-up safety time 3

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09/2011 - Art. Nr. 4200 1040 7900A 29

Commissioning

Electrical servomotor

Field of application

The SQM5... series servomotors are designed for driving gas and air flaps in medium to high output fuel oil and gas burners. It is primarily designed for use in the regulation of gas and combustion airflow depending on the load.

• In conjunction with regulation with 3point or continuous (e.g. 4 ... 20 mA) control signals or by the control and safety units directly.

Technical documentation

SQM5... L&G 7815 D

Limit switches

The limit switches are actuated by control cams which are set to a basic position in the factory.

Disengaging mechanism

The drive shaft and camshaft can be disengaged separately.

A = Disengaging of drive shaft N = Disengaging of camshaft

Warning! The drive shaft and camshaft must not be disengaged at the same time.

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09/2011 - Art. Nr. 4200 1040 7900A30

Commissioning

Electrical servomotor

Technical data SQM servomotor

Voltage 230 V -15%

50 / 60 Hz

240 V +10%

50 / 60 Hz Power input 20 VA Max. contact load 250 V 7.5 (3) A Installation position as required Ambient temperature- 20°C + 60°C Protection level IP 54 Weight 3.3 kg

SQM 50.381A2

Duration with 130° rotation angle

22 sec

Torque 10 Nm

Description

The "SQM" servomotor is designed for use in fuel oil, gas or two-stage burners that operate in accordance with the sliding or modulating principle. The reversible servomotor comes with a synchronous motor which drives a shaft via a gearbox. The shaft end carries a coupling to drive the fuel and combustion air actuator.

The SQM servomotor has been designed for dual-wire control by controller or switching units with changeover contacts. Suitable potentiometers can be fitted for a very wide range of applications. The 60 Hz frequency will reduce the running times by approx. 17 %.

Limit switch factory setting

The limit and auxiliary switches are set by means of manually adjustable latching cam plates. Scales are fitted between the disks to facilitate the selection of the switching points. The cam plates are provided with a small pointer for indicating the switching point of a scale between the setting ranges. An additional scale fitted to the end of the cam roller serves to indicate the position of the servomotor.

The drive unit may be disengaged from the controlling element by changing over a rocker arm mounted to the gearbox. This will allow any desired position of the controller plate to be selected by hand. Drive and output will be coupled in the vertical position of the rocker arm.

The fuel-air curve must be set over the entire adjustment range of the cam disk so that safe operation can still be guaranteed even if the limit switch is overridden.

SQM servomotor, standard configuration of limit switch

Limit switch Function Standard setting [°]

Full load setting, gas,

Pre-ventilation setting gas/fuel oil

120

Basic load, gas,

Zero setting if burner is shut down, gas/fuel

oil

3 Ignition position, gas 20*

Air flap position, stage 1. Fuel oil

release stage 1, fuel oil

5 Fuel release stage 2, fuel oil 60

6 Air flap position, stage 2. Fuel oil 78

7 Fuel release, stage 3, fuel oil 90

8 Air flap position, stage 3. Fuel oil 120

9 Vessel, red part for anti-clockwise, black part for clockwise

P Potentiometer kit for further control functions (optional)

* The angle of limit switch 3 must be set a little higher than that of limit switch 2

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09/2011 - Art. Nr. 4200 1040 7900A 31

Commissioning

Flame monitor Probe current measurement

Using a UV probe for flame monitoring

For the monitoring method, the UV radiation from hot flame gases is used to create the flame signal. A radiation detector is a UV-sensitive tube with two electrodes to which voltage is constantly applied. When illuminated with light from the 190...270 nm range of the spectrum, it fires and applies current to the flame signal amplifier. The UV tube does not react to the after-glow of fireclay in the furnace, sunlight, daylight or the lighting used to illuminate the boiler room. The tubes have a service life of approx. 10,000 hours at ambient temperatures

of up to 50°C; higher ambient temperatures reduce the service life considerably.

Burners used for constant or intermittent operation for more than 24 hours without a break (e.g. boiler sequence control) or burners used in conjunction with steam boilers must be fitted with control and safety unit LGK 16... and the self-monitoring flame monitoring circuit (QRA

5...).

UV current measurement with QRA 5

In order to carry out accurate UV current measurement, we recommend the use of test device KF 8832. For UV current measurements with normal test equipment (microammeter) we recommend that the measurement be carried out as shown in the diagram. A suitable capacitor must be integrated into the test circuit (for details see the table entitled "Probe currents and test devices"). Connect the test device between the control and safety unit and the UV flame probe QRA 5... (terminals 22 (-) and 5 (+)). Flame probe current test device KF8832 must not be left in constant use because self-monitoring is not guaranteed during the test process.

Ensure that the polarity is correct! Flame probe current test device KF8832 must not be left in constant use because self-monitoring is not guaranteed during the test process.

Alignment of UV probe QRA 5...

The movable connecting flange on the probe tube facilitates precise alignment of the probe window with the direction of incidence of UV radiation.

Please note!

The terminal (22) must always be earthed.

Cleaning the probe

The UV probe window must be regularly inspected for dirt and cleaned. The probe window must be kept free of dust. If this measure proves unsuccessful, the tubes must be replaced.

Test circuit for probe current measurement QRA2…, QRA10…, QRA5… series D and QRA5… series G

QRA2.

QRA5.

QRA2.

QRA5.

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09/2011 - Art. Nr. 4200 1040 7900A32

Commissioning

Flame monitor Probe current measurement

Probe currents and test equipment

Min. required or max. achievable probe current in µA (DC)

QRA2 Ionisation

QRA5x.C... QRA5x.E…

QRA5x.D...

QRA5x.G…

Automatic control unit min max min max min max min max

LFL1… 70 700 6 200 - - - -

LGK16… - - 12 100 35 50 120 270

Test equipment

Recommended Tester KF 8832

Alternative

M1 - microammeter Ri max. 5000 Ω; 0 - 1000 µA C - electrolyte capacitor 100...470 µF; DC 10...25 V

M1 - microammeter Ri max. 5000 Ω; 0 - 1000 µA C - electrolyte capacitor 470 µF; DC 25 V

Page 33

09/2011 - Art. Nr. 4200 1040 7900A 33

Commissioning

Gas train connection Electrical connection Checks before commissioning

Checks before commissioning

The following must be checked before initial commissioning:

• That the burner is assembled in accordance with the instructions given here.

• That the burner is pre-set in accordance with the values in the adjustment table.

• Setting the combustion components.

• The heat generator must be ready for operation, and the operating regulations for the heat generator must be observed.

• All electrical connections must be correct.

• The heat generator and heating system must be filled with water and the circulating pumps must be in operation.

• The temperature regulator, pressure regulator, low water detectors and any other safety or limiting devices that might be fitted must be connected and operational.

• The exhaust gas duct must be unobstructed and the secondary air system, if available, must be operational.

• An adequate supply of fresh air must be guaranteed.

• The heat request must be available.

• Sufficient gas pressure must be available.

• The fuel supply lines must be assembled correctly, checked for leaks and bled.

• A standard-compliant measuring point must be available, the exhaust gas duct up to the measuring point must be free of leaks to prevent anomalies in the measurement results.

All electrical installation and connection work must only be carried out by a suitably qualified electrician. The applicable guidelines and direc-

tives must be observed, as well as the electrical circuit diagram supplied with the burner!

Before connecting the burner, it is essential to ensure that the entire burner has reached the ambient temperature. Otherwise, there is a risk that condensation will form on electronic components resulting in damage to property and personal injury!

Gas train connection

The connectors on the burner must be used for connecting the gas train. Cognisance must be taken of the equipment labelling and the electrical circuit diagram.

Electrical connection

The electrical connections, i.e. the installation materials and all the connectors and earth/ground connections, must be installed in compliance with the specifications. The electrical installation of the burner must be carried out in accordance with the circuit diagram drawn up for the

furnace. The electrical connection of the burner may only be performed by authorised professionals.

Please note:

When installing the connection cable, the cable loops selected must be large enough to allow the boiler door to swivel open. When electrical connection work is complete, the wiring for the burner electrics must be checked. This includes checking the direction of rotation of the fan or the fuel oil pump motor.

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09/2011 - Art. Nr. 4200 1040 7900A34

Commissioning

Gas connection

The gas lines and valve groups should be installed and taken into operation in accordance with the applicable engineering standards and regulations.

The connection between the gas distribution network and the gas ramp must be done by authorised persons.

All the gas ramp components must be fitted and installed without bending or distortion or any other form of mechanical stress.

The section of the pipings must be calculated so that the loss of load doesn’t exceed 5% of the supply pressure.

A quarter turn manual valve (not supplied) must be provided for upstream of the gas ramp and the filter.

The max. operating pressure for the shut-off device must be 1.5 times the max. connection pressure. Ease of access must be guaranteed. Precautions must be taken to prevent unintentional actuation. The operating position of the gate valve must be quite obvious. The manually operated valve should have fixed stops in the "OPEN" and "SHUT" positions.

The filter must be installed on a horizontal nozzle with the cover in the vertical position to enable cleaning.

Depending on the current specification, a thermally triggered gate valve must be provided for on site (not supplied).

All the gas ramp components must be protected against condensation and if necessary, a condensate trap (not supplied) must be provided for on site.

The threaded unions used must be in conformity with present standards (tapered male thread, straight female thread with sealing provided in the thread).

Sufficient space must be provided for setting and maintaining the gas ramp components (gas pressure switch, valves, pressure regulator, gas filter, test burner etc.) (see technical data).

Gas properties

Prior to any installation work make sure to obtain the following data from the gas supply company:

1. Type of gas

2. Calorific value Hu

= kWh/m3 (kJ/m3)

3. Max. CO

content of exhaust gas

4. Gas connection pressure and rest pressure

Type of gas test

Prior to mounting the burner to the gas feed line check the available type of gas and burner type against the data given on the burner nameplate (attached to burner). Be sure the description of the burner and the type of gas are the same as indicated on the nameplate.

Gas connection pressure

A minimum connection pressure must be available upstream of the burner gas valve to ensure the proper functioning of the burner. For the installation of the valves and instruments group take care to observe the mounting instructions supplied by their manufacturers (these are packed with the equipment). The gas line installed to the burner must be dimensioned in accordance with the throughput rate and the available pressure.

For selecting the nominal bore "DN" of the gas valve group care should be

taken to observe the flue resistance of the boiler and the gas pressure loss of the burner and valve group.

Warning!

The absence of impurities and foreign bodies must be checked before installation and commissioning of the gas ramp, the lever valves and unions.

Gas valve group

The gas valve group can be connected directly to the gas feed line. Take care

to observe the correct order of installation and direction of flow (arrow on housing).

Check the valves and instruments and connection pieces for absence of dirt particles and foreign matter before installation and initial operation. To

provide effective conditions for startup make sure the distance between the burner and the gas stop valve is as short as possible.

Leak test

The gas line upstream of the burner gas valve group must be installed in accordance with the applicable regulations, checked for absence of leaks, vented and certified accordingly by the gas installation company. The screwed unions and flanged joints must be checked for proper tightness (by making a pressure test). The leak test must be made under pressure using approved foaming agents which do not cause corrosion. For steam boiler furnaces the result of the leak test must be duly certified.

Venting Please note!

Prior to taking the burner into operation or after any repair work make sure to vent the complete gas feed line and the gas valve group into the open atmosphere (e.g. by means of a hose) taking care to avoid any hazards.

In no case should the gas line be vented into the heating or furnace chambers.

Make use of a test burner to check the gas-carrying spaces are free from an inflammable gas mixture.

Support

The valve group must be supported with a telescopic jacking member or similar during and after installation (e.g. on filter and valve).

Joint

It is recommended to provide an easyto-disconnect joint (with planar sealing faces) to facilitate repair work on the boiler (furnace) and allow the boiler door to be swivelled out if required.

Page 35

09/2011 - Art. Nr. 4200 1040 7900A 35

Commissioning

Fuel-air coupler control

This finely tuned coupler control system allows the relevant fuel-air ratio to be set across the entire control range. For use in gas mode, fuel and air are evenly varied in sliding mode. For use in fuel oil mode, 3 output stages are available. The output stages are switched on or off depending on the air supply.

With the sliding, two-stage regulator, part and full load are available within the regulation range. These two load points are started up in sliding mode depending on the heat request. Large volumes of fuel are not switched on or off suddenly. In continuously adjustable regulation mode, the system starts up at any point within the control range depending on the heat requirement. The only difference between the sliding two-stage burners and the stepless burners is the burner's electrical control system. There are no mechanical differences. The 3-stage regulator has 3 distinct output stages which are started up depending on the system's heat requirement (temperature or pressure level). The fuel volumes of the stages are switched on or off once. As with the other regulators, the mechanics remain the same.

Mechanical coupler

When using the 3-stage fuel oil system, only the air flap is moved via the drive. Depending on the drive or air flap setting, the output stages can be switched on or off via the limit switch on the servomotor. In order to ensure optimum matching of air and fuel over the entire control range, the air flap can be set using the adjustable set screw on the coupler control.

N.B.:

The air curve is first set in gas mode. With the same air curve setting, oil mode is set up via the limit switch on the servomotor.

BURNER

BOILER

AIR

GAS

FUEL OIL

Page 36

09/2011 - Art. Nr. 4200 1040 7900A36

Commissioning

Switch cabinet door layout

-K02 load regulator

-P210 Ignition transformer lamp

-P144 Main oil valve lamp

71 Supply line

-P146 Fuel oil valve lamp

71 Stage 1

-P147 Fuel oil valve lamp

71 Stage 2

-P148 Fuel oil valve lamp

71 Stage 3

-P244 Gas valve lamp

-P246 Gas valve lamp

-SP051 Switch /control voltage-

71 lamp

-S051 Burner switch 230V/50Hz

-S057 Burner switch LOCAL-0-

71 REMOTE

-S061 Load regulator +/-

-S063 Load regulator 1-2-3

-S064 Fuel selector switch

-SP070 Unlocking burner

71 fault

-P064.1 Fuel: fuel oil

-P064.2 Fuel: gas

Page 37

09/2011 - Art. Nr. 4200 1040 7900A 37

Commissioning

Dual fuel load regulator (gas)

Commissioning of the burner

General warnings:

The drive can be disengaged both from the camshaft and the drive shaft (see chapter on servomotor). The camshaft can be disengaged to move the drive display to where it can be seen. Normally, however, this should not be necessary since the settings have already been made at the factory. Warning: if the camshaft is moved, this also modifies all the switching positions of the limit switch. Therefore, each time a change is made, the switching positions must be checked and may need to be reset; the burner may also need to be checked to ensure it is working properly! If this warning is ignored, the possibility of dangerous operating conditions and faulty combustion cannot be ruled out! This may result in damage to property and the environment and personal injury. Therefore, the camshaft should only be set before the system is commissioned for the first time. During commissioning, only the drive shaft may be disengaged to facilitate a manual coupler control procedure! The camshaft and drive shaft must not be disengaged at the same time.

Note on setting the ignition position:

The ignition position must be set so as to ensure that the burner ignites evenly and noiselessly. The ignition power should not exceed a max. of 33% of the maximum possible burner power (see technical data)

1. Commissioning, gas

• Set the Local-0-Remote switch (S057) on the switch cabinet to local (manually).

• Set limit switches [1], [2] and [3] to the setpoints (empirical or standard values). Set limit switch [3] for the ignition position just above limit switch [2] (~ +2°). The standard settings for the limit switch are shown in the table below.

• Set the fuel selection via remote control (S064) to gas .

• Switch on the burner, set the burner switch (S051) to 1. The burner program begins and following ignition, the basic load position is started up. Set the air pressure switch in accordance with the chapter on commissioning the gas pressure switch/ air pressure switch.

• Adjustment of the air rate (O2 value) in basic load. The combustion air rate is set by rotating the set screw (item 1). Clockwise: less air (O2). Counterclockwise: more air (O2).

• With switch""+/-"" (S061) or with the servomotor disengaged [A], gradually raise the system to full load while presetting the air rate using the set screw

(item 1); check combustion! N.B.: For satisfactory regulation, the curve characteristic must be set in such a way that where possible, the entire adjustment range of the curve characteristic, from part load to full load, can be utilised. Warning: Be careful when disengaging the drive: it is spring-loaded! Only disengage the drive shaft!"

• Adjusting the full load by adjusting the air rate (O2 value) and matching the gas pressure (burner output). Resetting the full load limit switch. The burner output must not be higher than the equivalent of the maximum combustion heat output of the heat generator (see chapter on the exhaust gas test). The maximum burner output must come within the permissible working field (see technical data). Set the gas pressure switch in accordance with the chapter on commissioning the gas pressure switch / air pressure switch

• Use the "+/-" switch (S061) to gradually increase to basic load while adjusting the air rate precisely in line with the change in gas pressure.

• The most important data (flow, output, gas pressure, burner air pressure, emission rates, ...) must be logged in at least three output items (low load, medium load, full load)*

• Set limit switch [2] for basic load (minimum combustion heat output) to the desired minimum load

• Switch off the burner, set the burner switch (S051) to 0

• Proceed to 2. Fuel oil commissioning

VGD ...

MBC ...

Gas pressure setting

Gas train VGD

• Remove protection cap on SKP25

• Set gas pressure pBr using screw S1 (hidden by the cap)

• Check setting : position of the index in relation with the scale X

Gas train MBC

• Set gas pressure pBr using screw S2

Please note!

Gas output pressure (regulator gas pressure) must be adjusted lower than the input pressure, but higher than the

total gas pressure loss of the heating plant.

Page 38

09/2011 - Art. Nr. 4200 1040 7900A38

Commissioning

Dual fuel load regulator (fuel oil)

2. Fuel oil commissioning

• Set limit switches [4], [5], [6], [7] and [8] to the setpoints (empirical or standard values). N.B.: The limit switch positions [4], [6] and [8] for the three load stages are approximately located at the points at which the same output is produced in gas mode. For switching the oil stage, limit switches [5] and [7] are located between the positions for [4] and [6] or [6] and [8]. The standard setting values for the limit switch are shown in the table below.

• Set the fuel selection via remote control (S064) to fuel oil .

• Set the timed fuel oil circuit breaker (S063) to 1.

• Switch on the burner, set the burner switch (S051) to 1.

• The burner program starts up. When the burner pump starts up, check the fuel oil supply pressure and pre-set it (see chapter on fuel oil supply, fuel oil pump). After preventilation, the system ignites in load stage 1.

• Adjustment of air rate and fuel oil output in stage 1. The fuel oil output is preset by the fuel oil pressure regulation valve (see chapter on fuel oil supply, fuel oil pump). The combustion air rate is set via the position of limit switch [4]. The curve characteristic for the air flap is not adjusted.

O2 rate too low: gradually move the limit switch to a higher position until the required rate is reached. O2 rate too high: disengage the servomotor [A] and move forwards until the required O2 rate is reached; set the limit switches [4] to the new position. Check whether the new limit switch position starts up correctly. Warning: Be careful when disengaging the drive: it is spring-loaded! Only disengage the drive shaft! The output release of the output stages does not depend on the output stage set at the timed fuel oil circuit breaker (S063). In the case of the manual drive procedure, limit switches [5] and [7] may be started up for fuel release for load stages 2 and 3. When these limit switches are started up, the fuel oil valve, and consequently the output of the corresponding stage, are released! In order to avoid early switching, limit switches [5] and [7] must be set correspondingly high.

• Set the timed fuel oil circuit breaker (S063) to 2.

• Adjustment of the air rate in stage 2. The combustion air rate for the 2nd stage is set using the limit switch [6] in the same way as for stage 1.

• Set the timed fuel oil circuit breaker (S063) to 1 and check the performance of the burner at the switching point for stage 2 fuel release. If necessary, readjust the limit switch [5] and check it again by changing the load stage between stages 1 and 2. The switching point must be selected so as to ensure that there is adequate stability in stage 1 at precisely the switching point and that acceptable characteristic emission rates (soot) are achieved at stage 2. An O2 rate of

approx. 7....9 % at the switching point

has been proven reliable (O2 rate shortly before switching to the next highest stage). In order to set the switching point for the next load stage change, it can be approximated from the next lowest stage. From the next lowest load stage, the drive is gradually increased (disengage servomotor [A], note the spring tension!) until the desired O2 rate is reached (7 ...9 % O2 or possibly higher). The flame should still be sufficiently steady. The limit switch [5] switching position is set to this point. When switching to the next load stage, the characteristic combustion values must be checked. It may be necessary to readjust the limit switch [5] at the switching point. N.B.: If switching occurs before the desired O2 rate is reached, limit switch [5] must be set higher.

• Set the timed fuel oil circuit breaker (S063) to 3

• Air rate adjustment in stage 3. The combustion air rate for the 3rd stage is

set using the limit switch [8] in the same way as for stages 1 and 2 The burner output must not be higher than the equivalent of the maximum combustion heat output of the heat generator (see chapter on the exhaust gas test) The maximum burner output must come within the permissible working field (see technical data) Set the fuel oil pressure switch min. in accordance with the chapter on commissioning the fuel oil pressure switch.

• Check the burner's combustion performance at the switching point for stage 3 combustion release. The procedure is in line with that applied in stages 2 and 1.

• The most important data (flow, output, gas pressure, burner air pressure, emission rates, ...) must be logged for the 3 load stages*

• Set the timed fuel oil circuit breaker (S063) to 1

• Switch off the burner

• Set the Local-0-Remote switch ( S057) to remote (automatic)

* The following values must be recorded at a minimum:

- Type of fuel, type of gas

- Wobbe index (heat value); calorific value

- Volumetric gas flow, fuel oil mass flow

- Lowest and highest combustion efficiency; also 1 to 2 intermediate values

- Gas, fuel oil and air pressures (gas connection, gas regulator, burner head, setting pressure, fan pressure, furnace pressure, fuel oil pressures)

- Exhaust gas emissions (NOx, O2, CO, CO2, soot) as a percentage/ ppm

- Temperature and humidity of the combustion air

- Flue gases temperature

- Atmospheric air pressure

The following table lists the standard values (equipment on delivery) for the control cam setting of the limit switches:

Limit

switch

Standard setting [°]

1 120 218 320 445 560 678 790 8 120

Page 39

09/2011 - Art. Nr. 4200 1040 7900A 39

Before commissioning the system for the first time, the following controls must be carried out:

• Observe the operating instructions of the boiler manufacturer. The boiler must be fitted and ready to operate

• The heating system must be filled with sufficient water

• The entire system must be checked to ensure that the electrical wiring of all the system components is correct

• Check the direction of rotation of the burner motor

• Ensure that the temperature or pressure regulator, the limiter, the safety switches and electrical limit switches are set correctly

• Check the gas connection pressure

• Check for leaks in the gas supply elements

• Check venting of the fuel supply lines (no trapped air)

• Is there fuel oil in the tank, in the lines and the fuel oil pump, has the correct fuel oil nozzle been installed?

• Check the fuel oil hydraulics for leaks

• Are exhaust gas ducts open and is there an adequate supply of fresh air?

• Is the burner in the start position: air flap in the "CLOSED" position?

• The control and safety unit for the electronic coupler is unlocked and in the starting position

Before the first fuel release, a function test must be carried out on the burner program sequence.

Fuel oil system:

• Open the fuel oil gate valve

• First disable the fuel oil solenoid valve (see burner/hydraulics diagram)

• Start the burner and monitor the program sequence to ensure that the correct start-up sequence is followed:

1. Fan on

2. Preventilation of air flaps

3. Air pressure regulation

4. Part load of air flap

5. Ignition

6. Valves open (disconnected valve

remains shut)

7. Lockout after safety time expires

(see control and safety unit)

• Valve closes again

• Unlock the control and safety unit for the electronic coupler

Gas system:

• Open the gas shut-off valve on the valve group briefly until there is pressure, then shut it again

• Start the burner and monitor the program sequence to ensure that the correct start-up sequence is followed:

1. Fan

2. Preventilation of air flaps

3. Air pressure regulation

4. Part load of air flap

5. Ignition

6. Open the valves

7. Lockout after safety time expires (see control and safety unit) or system shuts down for a lack of gas

• Unlock the control and safety unit for the electronic coupler.

Gas commissioning

Please note! Adjust the gas section before adjusting the fuel oil section. Set the fuel selection switch via remote control to "gas".

• Connect the test devices for the gas head pressure on the test connection after the gas control butterfly and the air pressure on the test connection for the burner.

• Connect the test devices for measuring the flame monitoring current.

• Open the gas shut-off valve before the gas trains and check the gas pressure from the pressure gauge.

• Set the "Manual-automatic" selector switch to "Manual" or "Manual operation".

If a valve leak test is being carried out, wait until there is a positive result from the leak test. If the valves prove to be leaky, the system does not move on to the control and safety unit. The burner starts up in accordance with the program sequence for the control and safety units for the electronic coupler.

Fuel oil commissioning

Open all the gate valves on the fuel oil supply system.

• Set the fuel selection via remote control to "Fuel oil"

• Fill the pump with fuel oil

• Set the pressure gauge for supply line and possibly for return pressure regulation (only in the case of burners with return nozzles)

• Set the pressure gauge for pressure regulation on the intake side of the pump or check the ring line pressure.

Venting

Switch on the burner briefly and check whether the direction of rotation is correct. Vent the fuel oil tube and the fuel oil pump.

Warning!

At the factory, the hydraulic system is filled with test oil. When commissioning the unit for the first time, this may cause ignition problems. When delivered from the factory, the fuel oil pressure regulator is released to protect the pump, i.e. no pressure is set. When commissioning the burner, the fuel oil pressure must be raised slowly to the operating value.

Commissioning

Control

Page 40

09/2011 - Art. Nr. 4200 1040 7900A40

Commissioning

Preventilation

Preventilation:

Care must be taken to ensure that the boiler system is adequately ventilated. The system-specific instructions must be complied with. The burner is designed so that it is preventilated when

the full load setting is selected. The preventilation times depend on the control and safety units and can be referred to in the relevant chapter. Assuming the conditions in the area or the boiler unit are the same for preventi-

lation and standard burner operation (loss of boiler pressure, temperatures), the air rate delivered by the burner for preventilation may be calculated as follows:

amb

Luft

Lüft

mbart











273

1013)273(

min



air

hBm

mbarK

mbarKC

NmkWh

NmNmkW

Lüft

/³35 97

98 0273

1013)27320(

³/35,10

17,1³/³56,93000















air

Example

Nominal heat output setting QN 3000 kW Combustion air requirement VL min 9,56 Nm

/Nm3; Nm3/kg

Calorific fuel value Hi 10,35 kWh/Nm

; Nm3/kg Intake air temperature tair 20 °C Barometer level pamb 980 mbar Excess air λ 1,17 Preventilation rate Vair ? Bm

Guide values

Calorific value

Combustion air requirement VLmin

Natural gas E 10.35 kWh/Nm

9.56 Nm3/Nm

Natural gas L 8.83 kWh/Nm

8.45 Nm3/Nm

Fuel-oil EL 11.86 kWh/Nm

11.1 Nm3/kg

Page 41

09/2011 - Art. Nr. 4200 1040 7900A 41

Commissioning

Fuel oil start-up mode Fuel oil operating mode General safety functions

Fuel oil start-up mode

As soon as the furnace is required to supply heat, the burner control circuit will close and the program flow started. When the program has come to its end, the burner will be turned on.

When the burner is not shut down, the air flap is at zero (basic load setting for gas).

The control and safety unit controls and monitors start-up. The burner fan starts up and the electrical servomotor opens the air flap to the full load position so the furnace and the exhaust hoods are ventilated at the specified air rate. Shortly after the preventilation process has been started the safety device used to detect an absence of air is switched to the operating position within a certain time, i.e. the minimum air pressure setting must be reached and maintained until the burner is shut down. At the end of the specified preventilation time, the air flap is moved to the part load position in a linked control concept with the gas control butterfly. The ignition transformer is activated. Pre-ignition takes place and the fuel oil is then released. The solenoid valves open and supply the fuel oil under pressure to the nozzle. The fuel oil is nebulised, mixed with the combustion air and ignited. A normal, steady flame must be formed within the safety time. When the safety time elapses, a flame signal must be sent to the control and safety unit via the flame monitor and must remain in place until the control system is switched off. The start-up programme for the burner is completed.

Fuel oil operating mode

After the flame has developed the load regulator will be enabled This brings the burner to its operating position. From this point on, the regulation automatically controls the burner between part load and full load. The 3 stage load regulator for fuel oil is implemented with two temperature switches or pressure switches. These are calibrated to two different values for temperature and pressure respectively. The high temperature / pressure switch value controls the transition from the 1st to the 2nd load stage while the low value controls the transition from the 2nd to the 3rd stage. When the system reaches the low temperature or pressure value on account of the relevant heat requirement, the 2nd and 3rd output stages are released and the burner starts up the 3rd output stage. Alternatively, the burner may also be fitted with PID regulation for fuel oil operation; in this case, however, the regulator is still 3-stage as before and only the proportional function of the PID regulation is used. Only the proportional function of the regulation is used. The burner is always shut down from the part load setting. As far as possible, the air flap is closed when the burner is shut down (basic gas mode load setting) in order to reduce the flow of cold air through the combustion chamber, heat exchanger and chimney. The interior cooling losses will be greatly minimised.

Warning: If gate valves have been installed in the exhaust gas tract, they must be fully opened during the start-up phase, otherwise there is a risk of a lowspeed detonation or an explosion! The open-position of the flue damper can be assured by the integration of the opening contact of the shut-off damper in the safety chain of the heat generator.

General safety functions

In case a flame does not develop when starting the burner (fuel release), the burner controller will shut off at the end of the safety period (lockout).. A lockout will also occur in the case of flame failure during operation, air flow failure during the preventilation phase and pressure failure during the whole period of burner operation. Any flame signal failure that occurs after the safety time elapses, and any signal during preventilation (external light control) will result in a lockout and the control and safety unit is locked. The fault is indicated by the fault signal lamp lighting up. The Control and safety unit can be unlocked immediately after a lockout by pressing the unlocking key. The program unit will return to its starting position and proceed with the restart of the burner. If there is a power failure, the control system is shut down. After voltage recovery, the burner can be automatically restarted unless another interlock is active, e.g. one caused by the safety circuit. The fuel oil supply will always be stopped immediately upon occurrence of any fault. At the same time, the program unit and consequently the fault indicator will stop. The symbols indicate the type of fault.

Full load

Operating position

Load regulator

Release

Part load

Ignition valves Pump

Fuel oil regulation: 3-stage, sliding

ON OFF

Page 42

09/2011 - Art. Nr. 4200 1040 7900A42

Gas start-up mode

If the furnace is required to supply heat, the burner control circuit closes and the program sequence commences. When the program sequence ends, the burner starts up.

An automatic test is made for the tightness of the gas valves prior to each burner start.

When the burner is shut down, the air flap is at zero (basic load setting for gas).

The electric servomotor opens the air flap to the full load position so that the burner ventilates the furnace and the exhaust hoods at the specified air rate. Shortly after the preventilation process has been started the lack-of-air cut-out must change over to operating position within a certain time, i.e. the minimum air pressure setting must be reached and maintained until the burner is turned off. At the end of the specified preventilation time the air flap is moved to the part load position in a linked control concept with the gas control butterfly. The ignition transformer is activated.

After the pre-ignition time, the main gas valves are open and the gas comes out from injectors where it is mixed in the combustion components with air coming from the fan. The gas-air mixture is ignited by the high-voltage ignition sparks directly. A steady flame must be formed within the safety time. The ignition is stopped before the end of the safety time and the burner operates at its minimum power. The start-up programme is completed.

Gas operating mode

After the flame has developed the load regulator will be enabled This brings the burner to its operating position. From this point on, the regulation automatically controls the burner between part load and full load. Depending on the heat demand, the electric servomotor of the compound control system will be fed with the OPEN or CLOSE command via the regulator and thus increase or decrease the gas and air flow rates. This coupler control is used to set the gas control butterfly and the air flap so that it controls the gas rate in the coupler with the air. For burner regulation, a two-stage sliding system or a suitable continuously adjustable regulator may be used. The continuously adjustable control makes it

possible to operate the burner at any desired stage between its part-load and full-load positions. The burner is always switched off from the Part load setting. As far as possible, the air flap is closed when the burner is shut down (basic gas mode load setting) and this reduces the flow of cold air through the combustion chamber, heat exchanger and chimney. The interior cooling losses will be greatly minimised.

Warning: If gate valves have been installed in the exhaust gas tract, they must be fully opened during the start-up phase, otherwise there is a risk of a lowspeed detonation or an explosion! The open-position of the shut-off damper can be assured by the integration of the opening contact of the shut-off damper in the safety chain of the heat generator.

General safety functions

In case a flame does not develop when starting the burner (fuel release), the burner controller will shut off at the end of the safety period (lockout). A lockout will also occur in the case of flame failure during operation, air flow failure during the preventilation phase and pressure failure during the whole period of burner operation. Any failure of the flame signal at the end of the safety period and a flame signal during the preventilation phase (external light control) will result in a lockout with the Control and safety unit being locked.

The fault is indicated by the fault signal lamp lighting up. The Control and safety unit can be unlocked immediately after a lockout by pressing the unlocking key. The program unit will return to its starting position and proceed with the restart of the burner.

A voltage failure will result in a regular shut-off of the burner. After voltage recovery, the burner can be automatically restarted unless another interlock is active, e.g. one caused by the safety circuit. The fuel oil supply will always be stopped immediately upon occurrence of any fault. The control unit will stop at the same

time causing also the fault indicator to stop. The symbols will indicate the kind of fault.

Commissioning

Gas start-up mode Gas operating mode General safety functions

Full load

Operating position

Load regulator

Release

Part load

Gas valves Ignition

Gas control: 2-stage sliding Stepless

ON OFF

Full load

Operating position

Load regulator

Release

Start load

Part load

Gas valves Ignition

Page 43

09/2011 - Art. Nr. 4200 1040 7900A 43

Servicing

Maintenance

Burner and boiler servicing must only be carried out by a professionally qualified heating engineer. The system operator is advised to take out a maintenance contract to guarantee regular servicing. Depending on the type of installation, shorter maintenance intervals may be necessary.

Warning:

If maintenance is not carried out properly in accordance with these instructions, system malfunctions and dangerous operating conditions could ensue. This may result in a breakdown, damage to property and the environment and personal injury. A log must be kept of all maintenance and servicing work. All wear parts must be replaced in accordance with the specified cycle times (see table below).

Before carrying out any maintenance or cleaning work on the burner, the following steps must be followed. For maintenance work, the floor of the work area must be free of dirt and slip-resistant. Provision must be made for adequate lighting. When maintaining heavy components (e.g. the fan motor), suitable lifting equipment must be used.

1. Turn off the power supply and protect the system from accidental start-up

2. Interrupt the supply of fuel

3. Check the system for residual power and ensure that steps 1 and 2 have been effective

4. Before opening the burner casing, ensure that the fan motor has stopped completely.

Failure to observe these instruction may result in severe or fatal injuries and/or damage to property.

• Use original spare parts. If original spare parts are not used, the system may no longer be CE-compliant!

Warning:

Each time maintenance work is carried out, it is essential to ensure that no tools, cleaning cloths or other items are left in the burner body. Any items left behind could affect the functionality of the burner and could result in damage to property or personal injury!

Work recommended as part of annual burner maintenance:

- Burner test run, input measurement in the boiler room

- Clean the combustion components and replace defective parts if necessary

- Clean the fan wheel and the fan

- Clean the gas filter; replace it if necessary

- Visual inspection of the burner's electrical components; eliminate malfunctions if necessary

- Check burner start-up (combustion performance, emissions, burner output)

- Leakage test

- Function tests on the burner's safety equipment, the safety chain for the boiler system (air pressure, gas pressure and fuel oil pressure switches, the flame monitor, the leak detection device, the safety valves, the safety chain components). The maintenance and safety specifications for the boiler system must be complied with.

- Flame monitor and automatic combustion control unit function check

- Checking the gas circulation pressure upstream and downstream of the gas train and checking the static gas pressure

- Check the gas flow

- Correct the adjustment values if necessary

- Draw up a measurement report* * The following values must be recorded at a minimum:

- Type of fuel, type of gas

- Wobbe index (heat value); calorific value

- Volumetric gas flow, fuel oil mass flow

- Lowest and highest useful combustion efficiency; also 1 to 2 intermediate values

- Gas, fuel oil and air pressures (gas connection, gas regulator, burner head, setting pressure, fan pressure, furnace pressure, fuel oil pressures)

- Exhaust gas emissions (NOx, O2, CO, CO2, soot) as a percentage/ ppm

- Temperature and humidity of the combustion air

- Flue gases temperature

- Atmospheric air pressure

General checks

- Emergency stop button function check

- Visual inspection of gas lines in the boiler room



The list contains the minimum number of switching cycles and the shortest possible service life for wear parts* and safety-related components. The actual service life could be much higher and this depends on the operating conditions. For reasons of operational and functional safety, the recommended periods of use should not be exceeded.

* Wear parts in the case of 25 years of machine usage

Safety-related components Recom. useful

service life

Min. operating cycles

Valve testing systems 10 years 250 000 Gas and air pressure switches 10 years - Safety and control unit with flame monitor for the burner 10 years 250 000 Flame monitor (UV cells) 10,000 hours of operation Flame monitor (not UV cells) 10 years 250 000 Gas pressure regulator 15 years - Gas valve with valve testing system after a fault is detected Gas valve without valve testing system 10 years 250 000 Pressure relief valve 10 years - Fuel-air ratio control 10 years - Servomotor SQM 1../2.. (Siemens) Depends on usage 150 000 Servomotor SQM 5... (Siemens) Depends on usage 250 000 Servomotor STM 30/40 (Schneider Elektrik) 10 years 500 000 Servomotor 01-15/30 Schimpf 10 years 2 000 000 Oil hoses 5 years - Fuel oil valves 10 years 250 000 Pressure relief valve 10 years -

Useful service life of wear parts *

Auxiliary relay Depends on usage 50 000 Cooling fan frequency converter 25,000 hours of operation Motor 37,000 hours of operation

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09/2011 - Art. Nr. 4200 1040 7900A44

Servicing

Maintenance

Checking the combustion components

• Unscrew the 2 screws S, remove the burner cover.

• Remove the 7 screws W to remove the combustion components access cover.

• Remove the combustion components.

• Check the ignition electrodes and ignition leads, replace them if necessary (see chapter on control / maintenance, combustion components).

• Clean the baffle plate.

• Check adjustments and settings during installation.

Cleaning the fan

• Disconnect the motor by unplugging it from the power supply.

• Remove the fan wheel.

• Clean the fan wheel.

• Do not use pressurised materials.

• Reassemble.

N.B.:

To install and dismantle the air fan, refer to the chapter on maintenance/ air fan.

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09/2011 - Art. Nr. 4200 1040 7900A 45

Servicing

Maintenance Checking / assembling the combustion components

Filter replacement

• The multiblock filter screen (only applies to MBC...) must be checked at least once a year and if it is clogged it must be replaced (see page 13).

• Loosen the screws on the multiblock cover.

• Remove the filter element and clean its housing.

• Do not use any pressurised cleaning products.

• Replace the filter element with a new element.

• Screw the cover back into place.

• Reopen the manual gate valve.

• Check it is airtight.

• Check the combustion values.

Cleaning the cover

• Do not use abrasive products or products containing chlorine.

• Clean the cover with water and a suitable cleaning product.

• Refit the cover.

Important After every operation: check the combustion parameters and real operating condition (doors closed, cover fitted etc.). Record the results in the relevant documents.

Important Once the pressure switches have been set, they must be protected to prevent settings from being altered. For example, this can be done by placing a spot of varnish on at least one of the screws on the equipment's protective cover. After the burner is maintained or after safety device equipment settings for the burner have been changed (e.g. pressure switches), the safety equipment for the burner must be checked to ensure it is working properly. After burner maintenance, the boiler safety chain must also be checked to ensure that it is working properly in accordance with the current specifications. This check must be carried out with the user's agreement.

Checking the flue gases temperature

• Check the flue gases temperature at regular intervals.

• Clean the boiler if the flue gases temperature is more than 30 °C above the value measured at the time of commissioning.

• Use a flue gases temperature gauge to make the check easier.



Assembling the combustion components

• Check that the O-Ring J1 is in the correct position in the gas elbow.

• Check the deflector (if it is dirty or sooty, clean it).

• Check the nozzles (if they are clogged, dirty or damaged replace them).

• Check the ignition transformers

• Check the electrode settings

• Check the ignition leads

• Check the quick-action coupling for the fuel oil connection

• Connect the ignition lead to the electrodes and the transformers (warning: do no mix up the connections for the fuel oil and gas)

• Install the connection with the fuel oil supply system (valve block - fuel oil system)

• Connect the electrical lead wire to the solenoid valves

• Insert the combustion components into the flame tube, tighten the mounting screws S3.

• Connect the ionisation cable and the ignition lead to the combustion components

• Connect the ignition lead to the ignition transformer T1.

Important

If the system is converted from natural gas type E to L or LL or vice versa, the burner

must be reset. It is not necessary to modify the combustion components in any way.

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09/2011 - Art. Nr. 4200 1040 7900A46

Servicing

Setting for ignition electrodes

Cleaning and replacing nozzles

Only use suitable box spanners for installing and removing the nozzles; it is important to ensure that the electrodes are not damaged. Fit the new nozzle with the same care. N.B.: Always check the position of the electrodes after fitting the nozzles (see figure). Positioning them incorrectly could result in a faults during ignition.

Burner V [mm] W [mm] X [mm] Y [mm] Z [mm] N6.2400 2 2 8 13 3... 5 N6.2900 2 2 8 13 3... 5 N7.3600 2 2 8 13 3... 5 N7.4500 2 2 8 13 3... 5

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09/2011 - Art. Nr. 4200 1040 7900A 47

Servicing

Air fan setting

The air fan can be stopped at any position on the motor shaft. To achieve a high slipping torque, the surface of all the parts to be inserted into one another must be clean and greasefree.

Removing the air fan

N.B.: Before removing the air fan, a mark must be made on the shaft in order to ensure that the wheel is in the same position after reinstallation. If the wheel position on the shaft is changed axially, efficiency may be reduced and this could result in reduced air output.

To remove the wheels, undo the screws (items 1 and 2); screw one of them into the hole in the bushing to half a thread fitting (item 3) as a lever screw and pull. This loosens the bushing. The loosened disc unit can now be removed by hand without force and without causing damage.

Air fan installation

- Clean all the bare surfaces and degrease them

- Insert the discs and bushings into one another, align the holes.

- Align the screws on opposite sides (items 1 and 2) and tighten them evenly.

The following tightening torques must be complied with:

SM 16, bushing no. 1615 - hub bore 28 :

Tightening torque 20 Nm

SM 20, bushing no. 2012 - hub bore 38 and 42 mm:

Tightening torque 30 Nm

SM 25, bushing no. 2517 - hub bore 42 and 48 mm:

Tightening torque: 50 Nm

SM30 bushing no. 3030 - hub bore 55 mm

Tightening torque: 90 Nm

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09/2011 - Art. Nr. 4200 1040 7900A48

Servicing

Exhaust gas test

In order to ensure efficient and fault-free operation, the burner must be adjusted with reference to the specific system. The fuel combustion air coupler controller, which is used to set the burner to clean combustion, is used for this. To do this, exhaust gas tests must be carried out. To determine the efficiency and quality of combustion, the percentage of CO

or O2 and the flue gases temperature must be measured. Before the test is carried out, it is essential to ensure that the boiler and/or the exhaust gas system are properly sealed.

False air distorts the measurement

If possible, the exhaust gases should not have any residual oxygen content (O

) and/or they should contain as much carbon dioxide (CO2) as possible. In all load stages, the carbon monoxide content of the exhaust gases must be below the limit values specified in the relevant

current specifications. If fuel oil is being used, the permissible smoke spot number in the exhaust gas must not be exceeded.

Calculating the volumetric flow rate for gas

The combustion output (Q

) of a boiler is the amount of heat supplied by the gas in a time unit. When commissioning the system, the fuel volume flow must be set in accordance with the nominal heat output of the boiler.

Example:

Volumetric flow for gas in its normal state:

Volumetric flow for gas in the operating state:

Nominal heat output

1000 kW Efficiency rating of the boiler

0,88

Calorific value of the gas

9.1 kWh/m³

Gas pressure

100 mbar Barometer level

amb

980 mbar

Gas temperature

gas

15 °C

Standard pressure pn 1013 mbar

Mean barometer readings

Height above sea level [m]

Mean barometer readings [mbar]

Aachen 205 991 Berlin 50 1009 Dresden 120 1000 Erfurt 315 978 Frankfurt/M. 104 1004 Hamburg 22 1011 Cologne 45 1009 Leipzig 130 998 Magdeburg 79 1005 Munich 526 955 Nuremberg 310 980 Rostock 4 1013 Stuttgart 297 984 Schwerin 59 1010 Ulm 479 960

Relationship between O2 and CO2 rate for natural gas H (CO

max =11.86%)

Relationship between O

and CO2 rate

for domestic fuel oil (CO

max

=15.40%)

O221

2max

2gem

–

2max

------------------------------------------------ -

 %==

measured

%O2 %CO2 %O2 %CO2

0,00 11,86 3,00 10,16 0,10 11,80 3,10 10,10 0,20 11,75 3,20 10,04 0,30 11,69 3,30 9,99 0,40 11,63 3,40 9,93 0,50 11,58 3,50 9,87 0,60 11,52 3,60 9,82 0,70 11,46 3,70 9,76 0,80 11,41 3,80 9,70 0,90 11,35 3,90 9,65 1,00 11,29 4,00 9,59 1,10 11,24 4,10 9,53 1,20 11,18 4,20 9,48 1,30 11,12 4,30 9,42 1,40 11,07 4,40 9,36 1,50 11,01 4,50 9,31 1,60 10,95 4,60 9,25 1,70 10,90 4,70 9,19 1,80 10,84 4,80 9,14 1,90 10,78 4,90 9,08 2,00 10,73 5,00 9,02 2,10 10,67 5,10 8,97 2,20 10,61 5,20 8,91 2,30 10,55 5,30 8,85 2,40 10,50 5,40 8,80 2,50 10,44 5,50 8,74 2,60 10,38 5,60 8,68 2,70 10,33 5,70 8,63 2,80 10,27 5,80 8,57 2,90 10,21 5,90 8,51

% O2 % CO2 % O2 % CO2

0,00 15,40 3,00 13,19 0,10 15,33 3,10 13,12 0,20 15,25 3,20 13,04 0,30 15,18 3,30 12,97 0,40 15,11 3,40 12,89 0,50 15,03 3,50 12,82 0,60 14,96 3,60 12,75 0,70 14,88 3,70 12,67 0,80 14,81 3,80 12,60 0,90 14,74 3,90 12,53 1,00 14,66 4,00 12,45 1,10 14,59 4,10 12,38 1,20 14,52 4,20 12,31 1,30 14,44 4,30 12,23 1,40 14,37 4,40 12,16 1,50 14,29 4,50 12,08 1,60 14,22 4,60 12,01 1,70 14,15 4,70 11,94 1,80 14,07 4,80 11,86 1,90 14,00 4,90 11,79 2,00 13,93 5,00 11,72 2,10 13,85 5,10 11,64 2,20 13,78 5,20 11,57 2,30 13,71 5,30 11,49 2,40 13,63 5,40 11,42 2,50 13,56 5,50 11,35 2,60 13,48 5,60 11,27 2,70 13,41 5,70 11,20 2,80 13,34 5,80 11,13 2,90 13,26 5,90 11,05

Height in meters above the sea

Medium air pressure in mbar

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09/2011 - Art. Nr. 4200 1040 7900A 49

Example: Data measured in natural gas mode: CO

content of the exhaust gases 10.8 % Flue gases temperature 195°C Air intake temperature 22°C

The exhaust gas loss can be calculated as follows:

Measured values in fuel-oil operation: CO

content of the exhaust gases 12.8 % Flue gases temperature 195°C Air intake temperature 22°C

The exhaust gas loss can be calculated as follows:

Fuel-oil EL Fuel-oil S

Natural

gas

Town

gas

Liquid gas

= 0.50 0.490 0.370 0.350 0.420

B = 0.007 0.007 0.009 0.011 0.008

Servicing

Exhaust gas test Diagnosing and remedying faults

Exhaust gas loss

Exhaust gas loss by way of free heat will occur as a result of the temperature difference between the fuel-air mixture entering the furnace chamber and the gases discharged. Any increase in the excess of air and the resultant higher exhaust gas volume will cause the exhaust gas loss to rise. It is calculated as follows:

= exhaust gas loss in %

= flue gases temperature in °C

= combustion air temperature

in °C

CO2 = carbon dioxide content in %

tAt

–

------------

B+









=

In a fault occurs, proceed with checking the basic conditions for proper operation of the boiler system:

1. Is electric power available?

2. Is there fuel oil in the tank?

3. Is there any gas pressure?

4. Are the shut-off valves opened?

5. Are all control and safety devices, e.g. boiler thermostat, low water detector, limit switches, etc. properly set?

1. Ignition - ignition failure

Cause Remedy

Ignition electrode short circuit.

Adjust.

Wide ignition electrode spacing.

Adjust.

Dirty and wet electrodes.

Clean.

Cracked insulator.

Replace.

Defective ignition transformer.

Replace.

Defective control and safety unit.

Replace.

Burnt ignition cable.

Replace; search for cause and eliminate.

Pilot burner failure.

Adjust ignition gas pressure

Ignition gas valve does not open.

Search for cause and eliminate

Defective solenoid.

Replace

2. Motor is not running

Cause Remedy

Motor protection relay and fuses.

Check and replace if required.

Air pressure switch not changed over or defective.

Check and replace if required.

Defective motor. Replace. Defective power

contactor.

Replace contactor.

Air fan motor starts but stops after 20-25 secs.

Check for solenoid leaks

Air fan motor starts, but stops after about 10 secs in pre-ventilating mode.

Air pressure switch does not switch, defective : replace, clogged: clean, electrical connections: check

3. Pump not supplying fuel oil

Cause Remedy

Gate valves closed

Open

Filter clogged Clean or replace

the filter cartridge

Filter not properly sealed

Replace

Leak in fuel oil tube

Tighten the unions

Leak in intake valve

Remove and clean or replace

Direction of rotation of pump

Check

Gearbox damaged

Replace pump

Capacity has deteriorated

Replace pump

- Loud mechanical noises Pump is taking in

air

Tighten the unions

Fuel oil tube vacuum too high

Clean the filter, open valves completely

For heavy-grade fuel oil: incorrect oil temperature

Check reheater: Thermostat setting, cracked dirt

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09/2011 - Art. Nr. 4200 1040 7900A50

Servicing

Exhaust gas test Diagnosing and remedying faults

8. Cleaning and lubricating instructions

Depending on the cleanliness status of the combustion air, the fan impeller, ignition electrodes, flame probes and air flaps must be cleaned as required.

For burner with mechanical coupler: lubricate ball heads on the adjusting screws for the coupler controller.

The bearing points of the burner moving parts require no maintenance. Damage to ball bearings should be detected and eliminated at an early stage to avoid greater consequential damage. Listen to the motor bearing noise to identify possible irregularities.

4. Nozzle - uneven atomisation

Cause Remedy

Nozzle loose Tighten Bore partially

clogged

Remove and clean or replace

worn as a result of prolonged usage

Replace

- No fuel oil supply: Nozzle clogged Remove

clean Nozzle leak Replace Leak in nozzle

line shut-off

Replace

5. No response to flame by Control and safety unit with flame sensor

Cause Remedy

Dirty flame sensor.

Clean.

Burner fails to start.

Check connec-

tion with the

control and

safety unit Control and

safety unit warning light on; flame fault

Unlock and

search for cause

Ionisation current too weak.

Check combus-

tion setting

Burner starts without flame formation:

solenoid valve not opening

Coil, detector

defective, check

connection

Lack of gas or gas pressure too low.

Check gas

pressure regulator,

gas valve, gas

filter.

Is the equipment

gas cock open?

6. Combustion components (due to poor combustion values) oiled too much internally

or heavy coke deposits

(fuel oil mode)

Cause Remedy

Incorrect settings.

Correct settings.

Incorrect burner head

Replace

Nozzle too big or too small

Replace

Incorrect nozzle spray angle

Replace nozzle

High or low combustion air flow rate.

Readjust burner.

Furnace chamber not sufficiently ventilated.

The boiler room must be ventilated through an unlockable opening with a cross section of at least 50 % of all chimney cross sections in the furnace.

7. Solenoid valve fails to open

Cause Remedy

Defective coil. Replace coil or

valve

Defective Control and safety unit.

Replace Control and safety unit.

Will not close properly: dirt on sealing surfaces

Open valve; remove foreign matter; replace valve if required.

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09/2011 - Art. Nr. 4200 1040 7900A 51

Smell of gas, danger of gas

• Shut down the burner

• Close the gas shut-off valve

• Keep away fire and naked flames

• Switch off the emergency switch

• Ensure there is adequate ventilation

• Notify the gas company and customer services

• According to DIN 4788, components

with technical safety-related functions may not be repaired. On the other hand, they may be replaced by original parts or parts of equal quality.

How to proceed in case of danger

• Switch off the emergency switch

• Close fuel valves

• If there is a smell of gas, notify the gas supply company

• Use suitable extinguishing equipment, e.g. fire extinguisher in acc. with DIN 14 406, fire class B,C.

• Servicing work on pressure switches, automatic actuators, limiters and control and safety units or other safety devices may only be carried out by the relevant manufacturer or by service engineers authorised to service the individual items of equipment on their behalf.

• If third parties work on the system, our obligations under our warranty become void.

If system faults occur, proceed with checking the basic conditions for proper operation of the system.

Make a check for the following:

1. Is fuel available, is it flowing through the

lines and is the supply pressure adequate?

2. Is power being supplied to the system?

3. Are all the control and safety

instruments, e.g. temperature controller, safety limiter, low water detector, electri-

cal limit switches etc. in proper working order and set correctly? If it is found that none of the above reasons for the fault applies, the burner functions must be thoroughly checked.

Prevailing conditions:

The burner will be found to be out of operation and in faulty and interlocked position. Identify the cause of the fault and rectify it. Unlock the Control and safety unit by pressing the fault eliminate key and start the burner.

Do not press the fault eliminate key longer than 10 seconds.

The start-up program will be initiated and should be carefully monitored. The possible cause of the fault may be quickly found by reference to the fault indicator of the Control and safety unit and watching the start-up and operating program.

Servicing

Faults

Control program if faults occur and fault indicator LFL 1... /LGK...

a - b Starting program.

b-b' In the case of some time variants;

spaces in the application up to automatic cut-out after the burner is started up (b‘= application operating position).

b(b')-aAfter-flushing program after

regular stop. In starting position "a", the application automatically stops or initiates an immediate restart of the burner, e.g. after rectification of faults.

 Duration of the safety times for

single-tube burners.

 Duration of the safety period for

burners with ignition gas valve.

Basically, any type of fault will result in the immediate stop of the fuel supply. At the same time, the program

unit and consequently the fault indicator will stop. The type of fault can be identified by the symbol opposite to the reading mark of the indicator:

 Does not start, because the "Off"

limit switch for the "Closed" air flap does not have a signal on terminal (8) or because a contact has not closed between terminals (12) and (4) or (4) and (5); the contacts for all the control and safety units in the control loop have failed to close (e.g. gas or air pressure switch, temperature or pressure switch, temperature or pressure regulator).

 Operating stop because the

"OPEN" signal from the "air flap OPEN" limit switch is missing on terminal (8). Control and adjustment of the relevant limit switch is required.

 Lockout because the air pressure

was not displayed at the start of air pressure regulation. Any air

pressure failure after this time will also lead to a lockout.

 Lockoutbecause of a fault in the

flame monitoring circuit.

 Operating stop because the

position signal of the "Part load" limit switch (air flap in "Part load" position) is not available on terminal (8). Check and adjust the limit switch concerned.

1 Lockout because a flame signal is

not available on the expiry of the (1st) safety time.

Any failure of the flame signal on the expiry of the safety time will also lead to a lockout.

2 Lockout because the flame signal

has not occurred on the expiry of the (2nd) safety time (flame signal of main flame with burners having an ignition gas valve).

Lockout because the flame signal failed during burner operation or a lack of air has occurred.

 Lockout after the control program

ends; caused by external light (e.g. by unextinguished flame, leaking fuel valves) or a faulty flame signal (e.g. fault in flame monitoring circuit or similar); see flame monitor.

If the lockout occurs at any other time between start and pre-ignition that is not identified by a symbol as above, this will normally be due to an early flame signal which is considered to be a faulty flame signal.

The Control and safety unit may be unlocked immediately after a lockout

using the unlock button with integrated fault signal lamp or an external switch. After it has been unlocked (and after a defect with resultant operating stop has been eliminated and after a voltage failure), the program unit will in any case return to its starting position with voltage being only supplied to terminals 7, 9, 10 and 11 as preset by the control program. It is only at this stage that the program of the Control and safety unit will restart the burner.

LFL 1.../LGK...

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09/2011 - Art. Nr. 4200 1040 7900A56

Made in EU. Non contractual document.

www.elco.net

Hotline

ELCO Austria GmbH

Aredstr.16-18 2544 Leobersdorf

0810-400010

ELCO Belgium nv/sa

Z.1 Researchpark 60 1731 Zellik

02-4631902

ELCOTHERM AG

Sarganserstrasse 100 7324 Vilters

0848 808 808

ELCO GmbH

Dreieichstr.10 64546 Mörfelden-Walldorf

0180-3526180

Elco Industry Italy

Corte degli Speziali 10/14 28100 Novara

+39 0321 338600

ELCO Burners B.V.

Amsterdamsestraatweg 27 1411 AW Naarden

035-6957350

OOO «Ariston Thermo RUS LLC»

Bolshaya Novodmitrovskaya St.bld.14/1 office 626 127015 Moscow -Russia

+7 495 783 0440

elco N6.2400 GL-RZ3/LFL, N6.2900 GL-RZ3/LFL, N7.3600 GL-RZ3/LFL, N7.4500 GL-RZ3/LFL Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual