elco N6.2400 G-R, N7.3600 G-R, N6.2900 G-R, N7.4500 G-R Operating Instructions Manual
10/2010 - Art. Nr. 4200 1030 6900A
N6.2400 G-R
N6.2900 G-R
N7.3600 G-R
N7.4500 G-R
Operating instructions
For specialist installation engineers
Gas burners ........................................... 2-25
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de, fr ..................................... 4200 1030 7000
it, nl ...................................... 4200 1031 9200
............................................. 4200 1028 8600
10/2010 - Art. Nr. 4200 1030 6900A2
Overview
Contents
We accept no responsibility for
damage arising from:
- 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 firing system 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.
Depending on the type of installation,
shorter maintenance intervals may be
necessary! It is advisable to take out a
maintenance contract to guarantee
regular servicing.
Overview Contents.................................................................... 2
Important information................................................2
Burner description..................................................... 3
Operation Gas start-up mode, gas operating mode ..................4
General safety functions........................................... 4
Fuel-air compound control........................................ 5
Gas valves and instruments group ...........................5
Automatic furnace controller LFL 1.../LGK... ............6
Gas valve VGD with SKP regulator .......................... 7
Gas valve MBC-SE...................................................7
Assembly Boiler lining for G-R burner, burner assembly...........8
Gas connection.........................................................9
Checking, assembling the combustion components10
Gas connection, electrical connection .................... 11
Checks before commissioning................................ 11
Commissioning Burner power adjusting sequence .......................... 12
Mechanical compound, electrical actuator.............. 13
Limit switch setting.................................................. 13
Monitoring of the flame by ionisation ...................... 14
Sensor current measurement ................................. 14
Gas pressure switch, air pressure switch ............... 15
Gas valves and instruments group
Description.............................................................. 16
Basic construction.............................................. 17-19
Gas valve leakage controller................................... 20
Servicing Maintenance ..................................................... 21-22
Exhaust gas test, trouble shooting instructions..23-24
Operating trouble .................................................... 25
Declaration of conformity
for gas burners
We,
Elco Burners GmbH, HerbertLiebsch-Straße 4a, 01796 Pirna,
Germany,
declare under our sole responsibility
that the products
N6.2400 G-R
N6.2900 G-R
N7.3600 G-R
N7.4500 G-R
conform to the following standards
EN 50165
EN 12953-7
EN 12952-8
EN 61000-6-2
EN 61000-6-4
EN 676
These products bear the CE mark in
accordance with the stipulations of the
following directives
2006/42 /EC Machinery directive
2004/108/EC EMC directive
2006/95/EC Low voltage directive
2009/142/EC Gas appliances
Directive
97/23/EC Pressure Equipment
Directive
Pirna, 26th May 2010
D. HOFFMANN
Important information
N6 and N7 G-R burners are designed for
the combustion of natural gas. The
design and function of the burners meet
standard EN 676. They are suitable for
use with all heat generators complying
with standard within their respective
performance range. Any other type of
application requires the approval of
ELCO.
Installation, start-up and maintenance
must only be carried out by authorised
specialists and all applicable guidelines
and regulations must be complied with.
Burner description
N6 and N7 G-R burners are progressive
mechanical fully automatic monoblock
devices.
Emissions values may differ, depending
on combustion chamber dimensions,
combustion chamber load and the firing
system (three-pass boilers, boilers with
reverse firing). For specifying warranty
values, the conditions for the measuring
equipment, tolerances and humidity
must be observed.
Packaging
The burner is supplied packaged in
three boxes on a pallet:
- Burner body with:
- integrated switch cabinet
- flange seal and securing screws
- operating instructions, circuit
diagram and spare parts list
- Combustion head
- Compact gas train with integrated or
external filter
The following standards should be
observed in order to ensure safe,
environmentally sound and energyefficient operation:
EN 226
Connection of fuel oil and forceddraught gas burners to a heat generator
EN 60335-1, -2-102
Specification for safety of household
and similar electrical appliances,
particular requirements for gas burning
appliances
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: - G1 instruction text from SSIGE
- EKAS form no. 1942,
liquefied gas directive, part 2
- Cantonal authority guidelines
(e.g. directives for the pilot valve)
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).
If no connection to an air exhaust
system is provided for the air supply,
there must be a supply air inlet
measuring:
DE: up to 50 kW: 150 cm
2
per additional kW: : + 2.0 cm
2
CH: QF [kW] x 6= ...cm2; but at least
200cm2.
Variations may arise as a result of local
regulations.
10/2010 - Art. Nr. 4200 1030 6900A 3
Overview
Burner description
2 Power controller (option)
5 Housing
6 Gas inlet flange
8 Burner flame tube
10 Integrated electrical cabinet
11 Burner fixing flange
13 Air intake box
14 Mechanical compound
19 Hoisting eyes
F6 Air pressure switch
M1 Blower motor
Y10 Actuator for air and gas dampers
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10/2010 - Art. Nr. 4200 1030 6900A4
Gas start-up mode
As soon as the furnace system 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.
An automatic test is made for the
tightness of the gas valves prior to
each burner start.
The air damper is in its closed
position when the burner is out of
operation.
The electric actuator will open the closed
air damper to its full-load position so that
the burner will ventilate the furnace and
the exhaust hoods with the specified air
rate. Shortly after the pre-ventilation
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
pre-ventilation time the air damper will
be moved into its partial-load position in
a linked control concept with the gas
damper.
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 head with air coming from
the fan. The ignition of the gas air
mixture is done directly by a high voltage
spark on a gas injector. During the
safety time, a stable flame is formed and
is monitored by an ionisation sensor.
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 which brings
the burner into its operating position.
The load regulator will now control the
burner automatically between its partialload and full-load stages. Depending on
the heat demand, the electric actuator 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
compound control system will vary the
positions of the gas control valve and air
damper and thus regulate the gas flow
rate in a linked concept with the air flow
rate. The burner can either be controlled
by a 2-stage sliding or, if a respective
controller is provided, a stepless control
concept. The stepless control will allow
the burner to be operated at any desired
stage between its partial-load and fullload positions. The burner will always be
turned off out of its partial-load position.
The air damper will be closed when the
burner is out of operation and will thus
prevent cold air flowing through the
burner chamber, heat exchanger and
chimney. The interior cooling losses will
thus be greatly minimized.
Attention:
If there are shut-off dampers in the flue
gas tract they must be complete open.
Otherwise there will be a high danger of
low-speed detonation or 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 (shut-off on trouble).
A shut-off on trouble 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 pre-ventilation
phase (external light control) will result in
a shut-off on trouble with the automatic
furnace controller being locked.
The trouble is indicated by the trouble
signal lamp lighting up. The automatic
furnace controller can be unlocked
immediately after a shut-off on trouble
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. In any case, the fuel oil
supply will be immediately stopped upon
occurrence of a trouble.
The control unit will stop at the same
time causing also the trouble location
indicator to stop. The symbols will
indicate the kind of trouble.
Operation
Gas start-up mode
Gas operating mode
General safety functions
Full load
Operating position
Load regulator
Release
Partial load
Ignition/Gas valves
Gas control:
2-stage sliding Stepless
ON OFF
ON OFF
Full load
Operating position
Load regulator
Release
Start load
Partial load
Ignition/Gas valves
10/2010 - Art. Nr. 4200 1030 6900A 5
Operation
Fuel-air compound control
Gas valves and instruments group
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Fuel-air compound control
This compound control system with
precision-adjustment capability has
been designed to allow the fuel and air
flow rates to be steadily varied in sliding
mode for an adjustment of the fuel-air
ratio over the whole control range.
In the two-stage sliding control concept
the partial-load and full-load positions
are within the control range. Depending
on the heat demand these two load
points will be selected in sliding mode. A
larger fuel feed will not be suddenly
turned on or off. In the stepless control
mode the load will be controlled at any
point within the control range depending
on the heat demand. The two-stage
sliding and the stepless control concepts
are different only in the control systems
used with the burners. The same mode
of operation is used for both versions.
Mechanical compound control:
The compound control system will be
operated by the steplessly reversible
electric drive unit in dependence of the
heat requirement. The air damper and
the gas damper will be controlled by the
same system.
To ensure an optimum air-to-fuel
adjustment over the full control range, it
will be possible to vary the position of the
air damper by means of stud bolts
incorporated in the compound controller.
Gas valves and instruments group
The gas valves and instruments group
used with the furnace will be selected
according to the specific requirements to
be met by a burner system.
The following factors must be taken into
account:
• burner output
• furnace back pressure
• gas pressure loss of the burner head
• gas pressure losses of the gas valves
and instruments group
The total gas pressure loss must always
be smaller than the available gas flow
pressure.
NOTE: Use should only be made of gas
valves and instruments that have been
approved in accordance with the burner
test specifications.
100 Burner
120 Air damper
141 Ball valve
142 Gas filter
143 Pressure gauge with stop valve
147 Test burner with stop valve
(optional)
150 Gas damper
153 Main gas solenoid valve
154 Safety solenoid valve
310 Blower
311 Minimum air pressure switch
313 Minimum gas pressure switch
314 Leak test
349 Actuator
10/2010 - Art. Nr. 4200 1030 6900A6
O peration
Autom atic furnace contro ller LFL 1.../LG K ...
The LFL 1…/LGK... type controller is
designed to control and monitor burners
working according to a stepwise or
modulating principle. A detailed
functional description with technical data
and project planning information with
respect to the automatic combustion
controllers can be found in the annex
and in the documents:
LFL 1...-7451/LGK...
Functional diagram
LFL 1.../LGK...
A = Starting type interval
A-B= Flame development interval
B = Burner has reached operating
position
B-C= Burner operation
(heat generation)
C-D= regular shut-off
t1 Pre-ventilating time
t2 Safety time
t3 Pre-ignition time
t4 Fuel valve enable
t5 Load regulator enable
t11 „OPEN“ run time of air damper
t12 „CLOSE“ run time of air damper
R = Temperature or pressure
controller
M = Fan motor
Z = Ignition transformer
BV= Fuel valve(s)
LR= Load regulator
LK= Air damper
RV= Steadily adjustable fuel valve
FS= Signal of flame
10/2010 - Art. Nr. 4200 1030 6900A 7
O peration
G as valve VG D with SKP actuator
G as valve M BC-SE
Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +50°C
Voltage 230 V/ 50 Hz max.
Protection rating IP 54
1 Gas ball valve (option)
2 Filter (under the cover)
3 Gas manometer with push button
(upstream) (option)
4 Test burner with push button
(option)
5 Actuator SKP 15
6 Actuator SKP 25
7 Gas main valve VGD..
8 Gas manometer with push button
(downstream) (option)
9 Gas tightness control unit
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Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +50°C
Voltage 230 V/ 50 Hz max.
Absorbed output (in operation)
250 W max
Protection rating IP 54
1 Gas ball valve (option)
2 Filter (under the cover)
3 Gas manometer with push button
(upstream) (option)
4 Test burner with push button
(option)
5 Compact gas train (safety valve +
main valve)
8 Gas manometer with push button
(downstream) (option)
9 Gas tightness control unit
10/2010 - Art. Nr. 4200 1030 6900A8
Assembly
Boiler lining for G-R burner
Burner assembly
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 be done at a diameter not below
70% of the combustion chamber
diameter. The space between the flame
pipe of the burner and the boiler lining
should be lined with heat resistant
material, such as Cerafelt.
This space is not allowed to be lined
with brickwork
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 50 mm ahead
the opening for flue gas turning back.
D = see dimensioned drawings
D1 = see dimensioned drawings
DF = combustion chamber diameter
T1 > 80 mm
T = depth of boiler lining
(option: extensions: see technical data)
Burner assembly
• Take the burner tube (delivered in a
separate box).
• Fit it on burner body.
• Remove cover.
• Tighten the 2 fixing screws S1.
• Lift the burner, using the 2 hoisting
eyes 19 (see page 3) and fasten to the
boiler.
• Tighten the 4 fixing screws S2.
• Place cover back on.
10/2010 - Art. Nr. 4200 1030 6900A 9
Assembly
Gas connection
Gas connection
The gas lines and valves and
instruments group 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.
The section of the pipings must be
calculated so that the loss of load
doesn’t exceed 5% of the distribution
pressure.
A quarter turn manual valve (not
supplied) must be provided for upstream
of the gas ramp and the filter.
The filter must be installed on a
horizontal nozzle with the cover in the
vertical position to enable cleaning.
The threaded unions used must be in
conformity with present standards
(tapered male thread, straight female
thread with sealing provided in the
thread).
Provide for sufficient space to access
the gas pressure switch adjustment.
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 H
un
=kW/m³ (kJ/m³)
3. maximum CO2 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 valves and instruments group
care should be taken to observe the
flue resistance of the boiler and the
gas pressure loss of the burner and
valves and instruments group.
Caution!
The absence of impurities and foreign
bodies must be checked before
installation and commissioning of the
gas ramp, the lever valves and unions.
Gas valves and instruments group
The gas valves and instruments 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
valves and instruments 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
Caution! Prior to taking the burner into
operation or after any repair work make
sure to vent the complete gas feed line
and the gas valves and instruments
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 valves and instruments 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 easytodisconnect joint (with planar sealing
faces) to facilitate repair work on the
boiler (furnace) and allow the boiler door
to be swivelled out if required.
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