elco VECTRON G 05.700 MODULO, VECTRON G 05.1000 MODULO Operating Instructions Manual

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09/2005 - Art. Nr. 13 019 526A

Operating instructions

For the authorised specialist

Gas burners .........................................2-31

VECTRON G 05.700 MODULO VECTRON G 05.1000 MODULO

Ersatzteilliste Spare parts list Pièces de rechange Wisselstukkenlijst

Elektro- und Hydraulikschema Electric and hydraulic diagrams Schémas électr. et hydraulique Elektr. en hydraulische schema

Art. Nr.

13 018 839

}

Art. Nr.

13 019 525

}

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09/2005 - Art. Nr. 13 019 526A

Contents

Overview

Contents, Declaration of

conformity ............................................2

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

Description of burner, Scope of

delivery, Optional accessories.............4

Technical data, Power graphs ............5

Gas valve selection .............................6

Dimensional drawings and

measurements.....................................7

Gas valve assembly ............................8

Hydraulics diagrams ............................9

Control panel .....................................10

Overview of combustion control unit MPA22

Function description ..........................11

Display and operating unit ................12

Programme structure .......................13

Assembly

Burner head, burner housing ............14

Gas valve assembly ..........................15

Checking/Setting Mixer unit for

natural gas/propane gas....................16

Gas supply, Electrical supply............17

Start-up

Default settings..................................18

Burner head, gas and air pressure switch settings,

gas pressure regulator ......................19

Checks before start-up......................20

Control unit auto-test.........................20

Adjustment mode .........................21-25

Access....................................21

Parameters menu..............21-22

Cold adjustment menu ...........23

Hot adjustment menu........24-25

Operating mode .................................26

Info mode ..........................................27

Voice mode ....................................... 28

Maintenance................................ 28-29

Burner-specific adjustment

settings of the MPA 22 .....................30

Troubleshooting ................................31

Declaration of conformity for

gas burners

We, CEB, of 18, rue des Bûchillons Ville-la-Grand F-74106 ANNEMASSE Cedex declare under our sole responsibility that the products

VECTRON G 05.700 MODULO VECTRON G 05.1000 MODULO

conform to the following standards

EN 60335 EN 50081 EN 50082 EN 676

In accordance with the stipulations of the European Directives

90 / 396 / EEC Gas device guidelines 89 / 336 / EEC EMC directive 73 / 23 / EEC Low voltage

directive

92 / 42 / EEC Working efficiency

directive

these products bear the CE marking

Ville-la-Grand, 01 January 2005 J. HAEP

Overview

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09/2005 - Art. Nr. 13 019 526A

Overview

Important notes

Important instructions

The G 05.700/1000 MODULO burners are designed to burn natural gas or propane gas in category II 2 ELL 3P. The special construction of the burner head with internal recirculation of exhaust gases means that combustion is very low in nitric oxide when burning natural gas. The design and function of the burners meet standard EN676. Assembly, start-up and maintenance must be carried out only by authorised specialists and all applicable guidelines and regulations complied with. Gas pipes and fittings must likewise be installed in compliance with all applicable guidelines and regulations (e.g. DVGW-TRGI 1986/96; TRF 1988; DIN 4756). Only DVGW-tested and -approved sealing materials should be used. Connections should be leak-tested using non-corrosive foam-producing materials or similar. Gas piping should be vented before start-up. Under no circumstances should venting be carried out over the furnace. Repair work to switches, limiters, control and safety units and other individual items of safety equipment must be carried out by the relevant manufacturer or his representatives. The replacement of original parts must be carried out by specialist staff.

Basic regulations

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

DIN 4705 Calculation of flue dimensions EN 676 Forced-draught gas burners EN 226 Connection to heating systems of vaporising-fuel-oil and forced-draught gas burners VDE 0116 Electrical equipment for furnace systems EN 60335-1 Safety of electrical equipment for domestic use and similar purposes VDE 0722 Electrical Equipment for non-electrically powered heating devices.

Installation location

The burner must not be used in rooms with aggressive vapours (e.g. hair spray, perchlorethelen, carbon tetrachloride), high levels of dust or high air humidity (e.g. washhouses). An air inlet must be present:

–

up to 50 kW: 150 cm²

–

for every further kW: +2 cm² Variations may arise as a result of local regulations.

The guarantee does not cover damage resulting from:

Inappropriate use

Incorrect installation and/or initial start-up on the part of the buyer or any third party, including the fitting of non-original parts.

Operation of the system at excessive pressure.

Final delivery and instructions for use

The combustion system manufacturer must supply the operator 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 heating unit, and 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 enter into a maintenance contract in order to ensure trouble-free running.

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Overview

Description of burner

Burner description

The G 05.700/1000 MODULO burners are low emission, modulating gas burners with a monoblock type electronic connection. They are suitable for use with all heat generators in accordance with DIN 4702/EN 303 within the respective performance range.

Scope of delivery

The burner is supplied in three packaging units:

Burner housing with operating

instructions, flow diagram, spare parts

list, combustion chamber board.

Burner head with flange seal and

fixing screws.

Gas valve assembly with gas throttle

module, DMV gas valve with built-in

pocket filter or with external filter,

connection parts, screws, seals.

Optional accessories:

–

Separate air intake box

–

Air intake silencer

–

Gas stop valve

–

Thermal safety cut-out valve

–

Compensator

–

Power regulator

–

Potentiometer

–

Test burner

–

Pressure gauge

A1 Combustion control unit A4 Display and operating unit B10 Ionisation bridge F6 Air pressure switch F12 Protective motor relay K1 Motor contactor M1 Burner motor T1 Ignition transformer (concealed) Y10 Servomotor air flap 7 Control panel 8 Blast tube 13 Burner cover 113 Air box

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Overview

Technical Data Power graphs

Power graph When selecting the burner and gas valves, the boiler efficiency must be taken into account.

Power graphs are expressed as burner power relative to furnace pressure. This corresponds to the maximum value in accordance with EN676, measured on the test blast tube.

Calculation of the burner power:

= Burner power (kW)

= KRated boiler power (kW)

hK = Boiler efficiency (%)

QF=

Type description

G 05.700 MODULO G 05.1000 MODULO

Burner power kW

140-700 170-1040

Operating mode

two-stage sliding/modulating

Fuel

Natural gas (LL, E) Hi = 8.83-10.35 kWh/m

or propane gas (F) Hi = 25.89 kWh/m

Gas valve DMVSE

512-T

DMVSE

520-T

DMVSE

512-T

DMVSE

520-T

DMVSE

525-R

DMVSE

5065-R

Gas connection

Rp 1, 1/2 Rp 2 Rp 1, 1/2 Rp 2 Rp 2 DN 65

Gas flow pressure m bar

20-100

Burner motor 2800 ¹/min

230/400 V, 50 Hz, 1.1 kW 230/400 V, 50 Hz, 1.5 kW

Combustion control unit/flame sensor

MPA 22/ionisation/alternative IRD probe

Power consumption W

1800 2000

Protection level

IP 41

Ambient temperature max. °C

60° C

Ignition transformer

EBI-M; 2 x 7.5 kV

Air flap drive

Servomotor STE 4.5 Q5.51/6-02R; Runtime: aspprox. 40 sec with adjustment travel of 90°

Gas throttle drive

Servomotor STE 4.5

Burner tube-Ø x Insertion depth mm

170 x 215 (KN)/325 (KM)/KL (435)

Air pressure switch

LGW 10 A 2

Burner weight incl. gas valve kg

100 kg

CE Mark

1312 AQ 0924 1312 AQ 0925

Note on type designation

G = Natural gas/Propane gas 05 = Size 700 = Power rating MODULO = Modulating with

electronic connection

KN = Normal burner head length KM = Medium burner head length

KL = Long burner head length

daPa mbar

335

100

100 300 500 700 900 1100

daPa mbar

530

1040

100

100 300 500 700 900 1100

G 05.700 MODULO G 05.1000 MODULO

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Overview

Burner

power

(kW)

DMV512-T

Rp1,1/2

DMV520-T

Rp 2

DMV512-T

Rp1,1/2

DMV520-T

Rp 2

DMV512-T

Rp1,1/2

Natural gas E Hi = 10.365 kWh/m

Natural gas LL Hi = 8.83 kWh/m

Propane gas

Hi=25.89kWh/m³

Gas pressure loss (from gas valve inlet)

550 16 15 17 15 15

600 19 15 21 16 15

650 22 18 24 19 17

700 26 21 28 22 20

Gas valve selection

The gas pressure loss specified in the table is to be added on to the combus

tion chamber pressure in mbar.

N.B.:

The calculated gas flow pressure is to be complied with at the gas valve inlet. To calculate the gas flow pressure required at the transfer station, the resistance of the burner supply conduit including valves (ball valve, TAS, addi

tional filter or counter) must also be taken into account.

Example (for Burner G 05.1000 MODULO):

System data:

–

Gas type: natural gas E

–

Gas flow pressure: 20 mbar (N.B.: at gas valve inlet)

–

Required burner power: 700 kW

–

Combustion chamber pressure with boiler rated load: 2.5 mbar

Condition: working point must be within the burner’s permissible field of work.

Selected gas valve: DMV 520-T

Checking the selection:

–

Gas pressure loss (from table): 17 mbar

–

Combustion chamber pressure: 2.5 mbar

Total 19.5 mbar

–

Hence: Gas flow pressure 20 mbar >19.5 mbarðSelection of DMV520-T correct.

Burner

power

(kW)

DMV512-T

Rp1,1/2

DMV520-T

Rp 2

DMV525-R

Rp 2

DMV5065-R

DN65

DMV520-T

Rp 2

DMV525-R

Rp 2

DMV5065-R

DN65

DMV512-T

Rp1,1/2

Natural gas E Hi = 10.365 kWh/m³ Natural gas LL Hi = 8.83 kWh/m³

Propane gas

Hi=25.89kWh/m³

Gas pressure loss (from gas valve inlet)

550 17 15 15 15 15 15 15 15

600 20 15 15 15 17 15 15 15

650 23 15 15 15 20 17 17 16

700 27 17 15 15 24 20 20 18

750 31 20 18 18 27 23 23 21

800 35 23 20 20 31 26 26 24

850 40 26 23 23 35 29 29 27

900 44 29 25 25 39 33 33 30

950 49 32 28 28 44 37 37 34

1000 55 36 31 31 48 41 41 38

G 05.700 MODULO

G 05.1000 MODULO

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Space requirements

There should be a space of no less than 0.60 m on each side of the burner for maintenance purposes.

Gas valve assembly

The valve assembly can be fitted on the left or the right.

Overview

Dimensional drawings and measurements G 05.700/1000 MODULO With DMV SE gas valve

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Overview

Gas valve assembly

Installation position:

Vertical with upwards facing magnet.

Description, technical data

The compact gas valve DMV SE 512,520 is a compact unit with 2 class A solenoid valves, class A servo-pressure regulator, pocket filter and pressure switch. For the DMV SE 525, 5065 types the tube filter is installed externally.

–

Pressure switch GW A5:

adjustment range 5.....50 mbar

–

Magnetic valve V1/V2 quick opening/quick closing.

–

Servo-pressure regulator, can be adjusted via a spindle.

–

Max. operating overpressure 500 mbar

–

Inlet pressure range pe 15-500 mbar

–

Voltage/frequency: 230 V/50-60 Hz

The gas valve assembly consists of:

–

a gas throttle controlled by a servomotor

–

a DMV-SE gas valve

–

a gas filter (pocket filter or external filter)

–

a thermally triggered safety cut-off valve and a gas ball valve are to be provided by the manufacturer.

DMV SE gas valve

1 Electrical connection of the

solenoid valves (DIN 43650)

2 Electrical connection of the gas

pressure switch (DIN 43650) 3 Gas pressure switch 4 Gas inlet flange 5 Pocket filter (under cover) 6 Gas pressure adjusting screw pBr 8 Gas pressure measuring nipple G1/8 9 Pipe filter

DMV SE 512, 520 with pocket filter

DMV SE 525 with pipe filter

DMV SE 5065 with pipe filter

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Overview

Hydraulics diagram

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Overview

Control panel

Function

A2 Standardised position for

fitting three-point regulator

A4 Display and operating unit

A4.1 Mounting location with clips

for removing the display and operating unit

B10 Flame signal measuring

bridge (concealed)

F10 Fuse

S1/H10 Main switch

0 Off 1On (operating light in switch lights up).

S2 Operating mode selector

switch Auto/Manual N

S3 + Manual increase of

burner power

- Manual reduction of burner power

All control elements are visible externally. A removable transparent cover clipped to the burner cover gives access to the monitoring and control elements for setting and operating the burner. The control panel contains the switching circuit cut-out.

To remove the cover, press in one or both sides gently and pull out at the same time.

To replace the cover, position the two clips at the appropriate openings and push in.

N.B.:

The main switch of the control panel only operates the control voltage. Before working in the control area of the burner, disconnect it fully from the mains, incl. burner motor AC connection.

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Overview Combustion control unit MPA22

Function description

In addition to the function of a gas combustion control unit, the MPA 22 combustion control unit also realises power modulation of the burner via the actuation of air flaps and gas throttle in an electronic connection. The electronic connection controls the opening of the gas throttle proportional to the air flap along a curve based on 10 adjustment points. During start up, the adjustment points are defined based on the measurement values of the exhaust gas analysis. This guarantees optimal combustion across the entire performance modulation of the burner. With adjustment point P0, a separate ignition load can be defined for the burner. The thresholds for the normal range are defined with adjustment points “bu” and “bo” (lower operasssting point and upper operating point). In addition, other optional functions, such as leak checks, reventilation or waiting times can be activated. The combustion control unit is operated via a display and operating unit.

1 Additional propane gas valve ¬

2 Safety gas valve Y15

3 Main gas valve Y13

4 Burner motor M1

5 Ignition transformer T1

6 Power 230V-50Hz

7 GW max: Bridge connector

(Safety chain inlet ¬)

8 GW min F4

9 GW VPS ¬

10 Air pressure switch F6

11 Light sensor ¬

12 Flame monitor UV/Ion ¬

13 Pulse counter ¬

14 Gas servomotor Y11

15 Air servomotor Y10

16 Display and operating unit

connection A

17 e-Bus connection ¬

18 Power regulator connection 4P

19 Boiler control panel connection 7P

¬ Option

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Access to Info mode (t < 5 s).

Access to voice mode (t > 5 s).

Return to next highest program level.

· Activating a function.

· Confirming a value.

· Moving the cursor anti-clockwise.

· Increasing the marked value.

· Moving the cursor clockwise.

· Reducing the marked value.

Unlocking the combustion control unit.

Red light diode flashes in the event of a fault.

Overview Combustion control unit MPA 22

Display and operating unit

Display

Button

Current values and operating statuses are displayed via the display and operating unit. By activating certain keys, it is possible to switch to info mode, operating mode or voice mode in addition to adjustment mode.

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Overview Combustion control unit MPA 22

Program structure

Adjustment mode

Enter access code

Set key data

P9/P1/P0

Start burner via

boiler regulator

for hot

adjustment

Operation at bu

(lower operating

point)

Back to

operating display

–

eBus address

–

Reventilation time

–

Waiting time

–

Pulses per L/m³

–

Rest pos. Air flap

–

Delete error list

–

Check for leaks

–

Valve 1 check time

–

Valve 2 check time

–

Address regulation

Voice mode

Parameters SettingsCountersErrors

Info mode

Burner start-up

Adjustment of

upper/lower threshold

points

Setting for points P0

to P9

Temperature

controller on

Operating mode

Ready for operation

Temperature controller on

Operation

t>5 s

t<5 s

Start-up

Check air pressure

switch

Pre-ventilation

Safety time

Stabilization time

Error 0

Error 1

Error 2

Error 3

Error 4

Error 5

Fuel

Value P0

Value P1

Value P2

Value P3

Value P4

Value P5

Value P6

Value P7

Value P8

Value P9

Hot adjustment

Parameter

adjustment

Cold adjustment

Burner burns in

ignition setting

Calculation of

characteristics curve

points P2 .....P8

Francais

English

Deutsch

Italiano

Nederlands

eBus address.

Rest pos. Air

Check for leaks

Reventilation

Error list

Software

Automatic control unit

Version

Date

Product

No.

Fuel consumption (m)

Total operating time (hours)

Successful burner starts

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Boiler door preparation

Prepare the burner plate/boiler doors as per the drawing.

Stipulate interior diameter Ø 195 mm.

Four M10 holes (220-260 mm diameter circle) are required, as indicated in the accompanying diagram.

Assembly

Burner head Burner housing

Fitting the burner housing

Dismantle the mixing unit before fitting the burner housing.

Undo the fixing screw (M10 counter nut and Allen screw) on the side of the unit (opposite the gas connection) and withdraw the mixing unit.

If the burner housing hangs below the burner head axis, proceed as follows:

Unscrew and remove the two lower nuts on the burner housing and unscrew the two upper nuts as far as possible.

Place the burner housing sloping diagonally forwards and fit the two upper bolts into the two slots in the burner head flange.

Press the burner housing against the burner head flange and tighten the 4 nuts.

The housing can be mounted above the axis of the burner head if required. In this case, the procedure must be reversed. No other positions for the burner housing are possible.

Fitting the burner head

Screw M10 stay bolts into the burner plate/boiler door and add the insulation. If the bolt circle is <260, cut slots to the required size.

Fix the burner head with 4 hexagonal nuts M10

Blast tube installation depth

On boilers with reverse firing or on three-pass boilers, the blast tube installation depth must be complied with for correct operation. The following standards are to be reconciled with the boiler manufacturer’s specifications.

–

Boiler in reverse firing chamber

Dimension A = Boiler front to reverse edge of second pass

–

Three-pass boiler

80-190 mm Insertion depth

-20 to +90 mm Insertion depth

Øa Øb c d

195 220-260 M10 45°

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Assembly

Gas valve assembly

Assembly Gas valve assembly

Press the gas throttle module 5 against the burner head and tighten the 4 nuts. Then secure the gas connection pipe 3 to the gas throttle module. Check that O-Ring 6 and flat gasket 4 are in the correct position.

Secure gas valve 2 so that the solenoids of DMV SE are positioned vertically over the gas valve.

Fit the supplied gas pressure tube 7 between the gas throttle module and DMV SE.

If available, secure external filter 1.

Note the direction of the flow.

Fit a thermally triggered safety valve and a gas ball valve (provided by manufacturer) before the gas valve.

If the position of the gas train is angled, use the enclosed right-angled pressure release pipe with screw connection. If the gas valve is changed, the applicable guidelines and regulations must be observed. All connections should be leak-tested using foam-producing or similar materials.

Caption

1 External filter 2 Gas valve 3 Gas connection pipe 4 Flat gasket between gas

connection pipe and gas throttle

module 5 Gas throttle module 6 O-Ring between gas throttle

module and burner head flange 7 Gas pressure tube

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Assembly

Checking/Setting Mixer unit for natural gas/propane gas

Recommended setting for propane gas

On the gas diffusers labelled C, 2 outwards-facing slots and 1 inwards-facing slot should be left covered by sleeve E.

Secure the turbulator with 5 solid M5x6 screws (diffuser D) and 1 drilled M5x6 screw F (diffuser C).

On the gas diffusers labelled D, 2 outwards-facing slots and 0 inwards-facing slots should be left covered by sleeve E.

Checking the mixing unit

Check and adjust the setting of the ignition electrodes and the turbulator.

Recommended setting for natural gas

On the gas diffusers labelled A, 5 outwards-facing slots and 1 inwards-facing slot should be left covered by sleeve E.

Secure the turbulator with 6 drilled M5x6 screws F.

On the gas diffusers labelled B, 5 outwards-facing slots and 0 inwards-facing slots should be left covered by sleeve E.

Fitting the mixing unit

Release and remove the mixing unit cover by unscrewing the three Allen screws 1.

Check the gas connection O-ring.

Fit the mixing unit and tighten with screw at side (M10 counter nut and Allen screw).

Fit the extension rod with 0-40 scale (loose in accompanying pack) for setting the turbulator.

The extension rod must be pushed into the steel sleeve until it makes contact.

Feed ignition cable 2 and ionisation cable 3 through the opening and push in the rubber bushing.

Screw down the cover, connect the ignition cables 2 and ionisation cable 3.

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Assembly

Gas supply Electrical supply

Electrical supply to the burner

For connection of the burner and regulator, the corresponding circuit diagram is mandatory. The power supply and the electrical connections must comply with the applicable standards.

N.B.:

Before connecting the burner to the electrical supply, close the gas ball valve.

· Set the main switch of the burner control panel to zero.

Before any intervention on the connector of the gas and air servomotors, the display or the e-Bus connection, the burner must be switched off by disconnecting the 7-pin plug.

Burner motor connection

The burner is delivered with a neutral wire and earthing for a mains voltage of 400V-50Hz AC. The connection cable for the burner motor must be run through the cable fittings and wired to the terminal strip as indicated in the electrical diagram. Check the direction of rotation of the fan motor (see arrow on burner casing) via manual activation of the burner protection device.

Gas valve connection

Connect the gas valve to the plugs located on the burner (black to black, grey to grey).

Insert connector 1 between burner and gas throttle servomotor in accordance with the diagram below.

Burner and regulation connection

Insert the 4-pin and 7-pin plug of the boiler control panel in the correspond

ing sockets of the burner.

General regulations for the gas supply

Connection of the gas valve assembly to the gas mains must be carried out by a recognised specialist.

The cross-section of the gas cable must be such that the prescribed gas flow pressure at the gas valve

inlet is not undershot. Burner start-up automatically implies acceptance of the system. This is the responsibility of the installer or his representative as he alone can guarantee that the system conforms to the current standards and regulations.

The installer must hold a licence issued by the gas authority, must have checked the system for leaks and must have vented it.

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Start-up

Default settings

Burner power Dimension

Air flap opening Gas throttle opening Pressure

adjustment

setting

pVA mbar

Low loadkWRated load

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

140 400

10 0 0 25 23 23 39 15

150 500

20 0 0 29 23 23 43 15

160 600

35 5 5 40 24 24 50 15

170 700

40 5 5 45 24.5 24.5 62 15

Natural gas settings table G 05.700 MODULO

Natural gas settings table G 05.1000 MODULO

Burner power Dimension

Air flap opening Gas throttle opening Pressure

adjustment

setting

pVA mbar

Low loadkWRated load

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

170 600

20 0 0 38 26.5 26.5 56 15

170 700

25 2 2 41 26.5 26.5 65 15

200 800

30 6 6 68 27 27 90 18.5

220 900

35 8 8 68 28 28 90 18.5

250 1000

40 9 9 68 29 2 90 18.5

Propane gas settings table G 05.700 MODULO

Propane gas settings table G 05.1000 MODULO

Burner power Dimension

Air flap opening Gas throttle opening Pressure

regulator

setting

pVA mbar

Low loadkWRated load

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

140 400

10 4 4 20 19 19 30.5 15

150 500

20 4 4 29 19 19 36 15

160 600

30 4 4 36 19 19 41 15

170 700

40 4 4 40 19 19 45 15

Burner power DimensionY

Air flap opening Gas throttle opening Pressure

regulator

setting

pVA mbar

Low loadkWRated load

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

Ignition

load

P0 (°)

Low load

P1 (°)

Rated load

P9 (°)

170 600

15 6 6 36 19.5 19.5 42 17.5

170 700

20 6 6 63 19.5 19.5 75 17.5

200 800

25 7 7 63 19.5 19.5 75 17.5

220 900

35 7 7 68 19.5 19.5 75 17.5

250 1000

40 8 8 68 22 22 75 17.5

The above setting data are basic settings. The factory setting data are in boxes with thick black borders. The burner can normally be run using these settings. Check the setting values carefully in each case. System-specific corrections may be necessary.

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Start-up

Burner head position setting, Gas pressure switch and air pressure switch

Burner head position

Dimension Y is set by turning screw V. Set the burner head setting in accordance with the table. The burner head setting can influence the starting performance and burner performance.

Gas pressure switch

Remove the transparent cover.

Set the setting scale to 5 mbar (natural gas and propane gas).

The gas pressure switch min. is installed between the valves. The gas safety valve Y15 is actuated one second before the safety time. Within this time, the gas pressure switch must release. If there is insufficient gas pressure, the burner starting is interrupted and a waiting time of 2 minutes starts. Start-up is then attempted again. The waiting time can

only be reset by cutting the power supply to the device. Waiting times: 3 x 2 minutes, then 1 hour

Air pressure switch

Remove the transparent cover.

Provisionally set the air pressure switch to the minimum setting.

Pressure regulator setting

The gas pressure regulator is set to the default setting in the factory (see page

18). Check the gas pressure after the first time the burner is started up (measuring point: gas valve output flange) and if necessary correct the gas pressure pBr using setting screw S. Do not change it again after start-up.

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Start-up

Checks before start-up Control unit auto-test

Air Gas

Burner check

Control unit unprogrammed

Control unit auto-test

Switch the burner on via the main switch. The combustion control unit executes an auto-test. If the control unit has not yet been programmed, the display shows “Control unit unprogrammed”

Auto-test of the control unit and of the air and gas servomotors

This display loads the values contained in the combustion control unit.

The control unit has not yet been programmed.

Loading values

100%

Pre-start-up check

Disconnect the burner by unplugging

it from the power supply.

Close gas valves.

Note the operating regulations of the

heat generator and regulation

producer.

Check that the gas type and gas

pressure are appropriate to the

burner.

Check the gas conduit for leaks

Vent the fuel supply pipes.

Check the flame pipe insertion depth in accordance with the boiler manufacturer’s instructions.

Check:

–

if the fresh air supply and the exhaust gas paths correspond to the burner power.

–

if there is water pressure in heating circuit,

–

if the circulation pump is running,

–

if the mixer opens,

–

if the draught regulator in the chimney opens,

–

if the power supply is in order,

–

thermostat settings,

Check the direction of rotation of the fan motor (see arrow on burner casing) via manual activation of the burner protection device.

If all the checks were successful, then ensure that:

Main switch 0/1 is set to zero

Manual/Auto operating type selector switch is at the centre position

Gas ball valve is closed

Re-energise the burner.

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Start-up

Access to adjustment mode Parameters menu: Programming additional functions

Access to adjustment mode

Press and hold the key and after 0.5 seconds, press the key.

Enter the numbers for the access code with the or key.

· Confirm each number with .

· For input fields, switch back to the next highest level with .

After entering the correct code, three menus are available for selection.

 Parameter: for programming additional functions.  Cold adjustment: for pre-adjusting the burner for initial start-up.  Hot adjustment: for only partial programming, e.g. after regulator

shutdown during adjustment or with subsequent correction of the adjustment values.

 Parameter

The “Parameters” menu item is selected from adjustment mode. This allows various additional functions and function parameters to be configured.

–

E-Bus address: 03H: standard address (factory setting). This parameter is required for communication with a PC. The following addresses are possible: F3H, 73H, 33H, 13H.

Access to next parameter: continue with key.

–

This parameter allows you to configure a reventilation time. Adjustment range: 0 seconds (= no reventilation) to 240 seconds

–

This parameter allows you to configure a waiting time between a regulator shutdown and a burner restart. Adjustment range: 0 minutes (= no waiting time) to 100 minutes

–

The pulse factor gives the number of pulses that the control unit receives from the gas counter with the flow rate of a cubic metre of natural gas (accessory). Adjustment range: 1 (1 pulse = 1m

) to 255 ( 255 pulses = 1m3).

Cold adj. Hot adj.

Parameters

Code ____

Accessing the adjustment settings

It is only possible to access adjustment mode when the burner is idle (display: “Control unit unprogrammed” or “Ready for operation”.) To do this, set the Manual/Auto operating type selector switch on the burner control panel to the centre position. In addition, the access code must be entered to activate adjustment mode.

N.B.: Only a specialist with sufficient training in and authorisation to deal with MPA 22 may activate adjustment mode via the access code and adjust the burner. The access code is located at the bottom of the information label on the MPA 22.

During the setup process, a timeout of 30 minutes is active, which is reset by pressing a key on the keypad. Upon expiry of the timeout, a safety shutdown is executed. This ensures that a longer operating time is not possible without the setup process being completed. In adjustment mode, all safety functions are activated. A flame failure, air pressure switch failure or an error in the servomotor actuation leads to a malfunction shutdown or safety shutdown.

E-Bus address

03H

Next Back

Reventilation time

000s

Next Back

Waiting time (0-100 min)

000 min



Pulses per l/m

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09/2005 - Art. Nr. 13 019 526A

Next Back

Rest pos. Air flap

00.0°

Next Back

Delete error list

Next Back

Check for leak

Next Back

Valve 1 check time

006s

Next Back

Valve 2 check time

006 s

Next Back

Address Regulation

10H

Connection setup

Save parameters

–

This parameter allows you to adjust the rest position of the air flap. This parameter (in degrees) may be required after reventilation. Default setting 00.0°

–

With this function, accumulated errors are deleted from the error log (display information: “Empty”). The next new error is written under No. 0 in the error log.

–

Leak check: Y= Yes/N= No With this function, you can deactivate the valve leak check.

–

Valve 1 check time: For proper execution of the leak check, at least the 6 seconds set in the factory are required. Adjustment range: 1-240 s

–

Valve 2 check time: For proper execution of the leak check, at least the 6 seconds set in the factory are required. Adjustment range: 1-240 s

–

Address regulation (factory setting to 10H) Other addresses are possible: F7H, F0H, 77H, 70H, 37H, 30H, 17H.

–

After confirming “Next” in the “Address regulation” menu item, the newly adjusted parameters are saved in the control unit. The control unit then switches back to “Ready for operation”.

Start-up

Adjustment mode Parameters menu: programming of additional functions

Control unit unprogrammed

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Start-up

Adjustment mode Cold adjustment menu: Burner pre-adjustment

 Cold adjustment (with ball valve closed)

In the “Cold adjustment” menu item, the P9/P1/P0 key data are pre-adjusted in accordance with the setting table (page 18) for the desired burner power. The control unit then calculates the intermediate points P2 to P8 and switches to the “Hot adjustment” menu.

Accessing the adjustment mode.

Select cold adjustment with or .

Confirm with .

Adjust air and gas setting.

Position the cursor on air or gas with or .

Activate with (cursor flashes).

Set new value with or .

Confirm with .

Switch between adjustment points P9/P1/P0.

· Position cursor on “Next” or “Back” with or .

· Confirm with .

· If the position “Next” is confirmed for adjustment point P0 with , the

control unit calculates the intermediate points P2 to P8 and then switches to the hot adjustment menu .

Direct access to this menu via adjustment mode/hot adjustment

.

Next Back

Low load

Air: .. ` . Gas: ..´ .

Next Back

Ignition load P0

start adjustment

Burner via boiler

regulator for hot adj

Air: .. ` . Gas: ..´ .

Full load P9



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09/2005 - Art. Nr. 13 019 526A

Start-up

Adjustment mode Hot adjustment menu: Adjusting the burner

 Hot adjustment (with first start for function check, still with closed ball valve)

Hot adjustment of the burner

In the “Hot adjustment” menu items, the fine adjustments for the air and gas flap are made for the ten adjustment points P0 to P9 using the exhaust gas analysis. Then, the definitive working range of the burner is defined based on the bu (lower operating point) and bo (upper operating point) thresholds.

Note: if normal shutdown takes place during the adjustment procedure, select the “Hot adjustment” menu item immediately after activating adjustment mode. By doing this, you will keep the values of the points that have already been adjusted, while a recalculation is carried out in the “Cold adjustment” menu.

For burner start, set the Manual/Auto burner selector switch to manual on the control panel, ensure heat request via boiler regulator.

The burner starts with the following function sequence:

–

Air flap opens for ventilation. Air: .........................

–

Blower motor on. ....................................

–

Check air pressure switch

–

Pre-ventilation 20 seconds: time remaining is displayed.

–

Gas throttle moves to ignition position. Gas: .................

–

Servomotor air flap moves to ignition position. Air: ............

–

Ignition on .........................................

Because the ball valve is closed, the burner shuts down after the safety time as the gas pressure is too low. The display shows: “Gas pressure too low”.

If the function check was successful, the gas valve is opened. After a two-minute waiting time, the burner is automatically restarted and the above-mentioned process is repeated.

–

Valve energised. ....................................

–

Safety time 3 seconds. After the safety time, the ignition transformer is

de-energised.

–

Flame signal present. .................................

During the stabilisation time, the burner remains in ignition setting.

Burner check

Air: - Gas: -

Start-up

Air pressure check

Pre-ventilation: 20 s

Air: - Gas:

Pre-ignition

Air: Gas: -

Safety time

Stabilisation time

Air: Gas: -

Air: - Gas: -

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09/2005 - Art. Nr. 13 019 526A

Start-up

Adjustment mode Hot adjustment menu: adjusting the burner

Ignition load P0

Air: .. ` . Gas: ..´ .

Next Back

Low load P1

Next Back

Adjustment point P2

Point P3 .... Point P8

Next Back

Full load P9

Lower load point bu (lower

operating point)

Upper load point bo

(upper

operating point)

Operation

Burner remains in ignition load, adjustment point P0.

Check gas pressure pBr (for factory setting, see default setting on page 18). In the event of a later change, all adjustment settings must be corrected. Therefore, start fine adjustment of the burner at P9. In each adjustment point, check the combustion values and, if necessary, change the gas throttle setting or air flap setting. To do this:

Select air or gas with or .

Activate with (cursor flashes).

Change value with or .

Confirm with .

Access to the next adjustment point by selecting Next and confirm by pressing key .

Important:

The values for each adjustment point are only saved when you access the next adjustment point.

Enter the adjustment values in the log (page 30).

Move the individual adjustment points to point 9 (full load).

· Check gas flow rate full load, if necessary increase or reduce gas and air.

· If all adjustment points from P0 to P9 are optimised in adjustment point P9,

confirm with “Next” .

The burner moves to the lower operating point (bu).

· Check the low load exhaust gas temperature and gas flow rate, if necessary

adjust the burner power by correcting bu (lower operating point).

· Confirmation “Next”.

The burner moves to the upper operating point (bo).

Check the high load exhaust gas temperature and gas flow rate. If necessary adjust the burner power by correcting bo (upper operating point). The adjustment is made by changing the air flap.

Confirm with “Next” to complete the adjustment procedure. The burner switches to operating mode.

Burner moves to lower operating point and waits for a request for heat.

Manual/Auto operating type selector switch to manual: burner power can be changed manually via the +/- switch.

Manual/Auto operating type selector switch to Auto: burner adjusts bu/bo within the specified power range in accordance with the requirements of the regulation thermostat.

Adjust air pressure switch

When the burner is running at rated load, calculate the blower pressure.

Set air pressure switch approx. 15% below calculated value.

Air: .. ` . Gas: ..´ .

Air: .. ` . Gas:

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09/2005 - Art. Nr. 13 019 526A

Start-up

Operating mode

Burner check

Air: Gas:

Start-up

Air: Gas:

Air pressure check

Pre-ventilation: 20 s

Pre-ignition

Safety time

Stabilisation time

Operation

Burner ready for operation

Boiler thermostat requests heat.

Burner start flowchart:

The burner starts with the following function sequence:

–

Air flap opens for ventilation. Air: .........................

–

Blower motor on. ....................................

–

Pre-ventilation 20 seconds: time remaining is displayed.

–

Gas throttle moves to ignition position. Gas: .................

–

Air flap moves to ignition position. Air: .....................

–

Ignition on .........................................

–

Valve energised. ....................................

–

Safety time 3 seconds

–

Flame formation. ....................................

After the safety time, the ignition transformer is de-energised.

During the stabilisation time, the burner remains in ignition setting.

The burner is in operation and adjusts bu (lower operating point) to bo (upper operating point) within the specified performance range (manual/Auto operating type selector switch to Auto). The current setting of the air flap is displayed.

Standby

Air: Gas:

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09/2005 - Art. Nr. 13 019 526A

Start-up

Info mode Voice mode

Press key t < 5s.

Select desired menu with or .

Confirm selected menu with .

· Scroll with or .

· Return to the next highest level with .

Error Counter

Parameter Setting

Establishing connection

0% 100%

Info 1

Info 2

Info 3

Parameters SettingsCountersErrors

Comment: info mode can be activated

with the button during burner operation and burner idle time. To exit info mode, press the button again.

Error 0

Error 1

Error 2

Error 3

Error 4

Error 5

Fuel Gas.

Value P0

Value P1

Value P2

Value P3

Value P4

Value P5

Value P6

Value P7

Value P8

Value P9

Voice mode can be activated with the button during burner operation and burner idle time.

Press button t > 5s .

Select desired language with or .

Scroll with or (5 languages possible).

Confirm selected language with . This will close voice mode.

FRANCAIS ENGLISH DEUTSCH

DEUTSCH ITALIANO NEDERLANDS

eBus address.

Rest pos. Air

Check for leaks

Reventilation

Error list

Software

Automatic control unit

Version

Date

Product

No.

Fuel consumption (m)

Total operating time (hours)

Successful

burner starts

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09/2005 - Art. Nr. 13 019 526A

Burner and boiler servicing can only carried out by a trained specialist. The system operator is advised to take out a service contract to guarantee regular servicing.

N.B.:

Before maintenance and cleaning work, completely separate the burner from the mains, including the power supply AC motor, and close the gas ball valve.

Maintenance

Checking the exhaust gas temperature

Check the exhaust gas temperature.

Clean the boiler if the exhaust gas temperature is over 30 K above the start-up value.

Checking the ignition electrodes and the mixing unit.

Disconnect the 2 ignition cables from the ignition transformer.

Remove the grommet for the two cables from the cover by pressing into the burner head.

Unscrew completely the 3 screws securing the cover.

Slip the cover off over the cables.

Loosen the side screw securing the mixing unit.

Pull out the mixing-ignition unit.

Check the condition of the turbulator.

Check the position of the ignition electrodes and the turbulator.

If necessary, remove dust from the parts accessible with the cover removed.

Check the presence and condition of the O-ring seal J1 when assembling.

Cleaning the fan

Disconnect the motor by unplugging it from the power supply.

Unscrew the 7 screws of the motor panel.

Remove the panel and motor, taking care not to damage the gas pressure tube of the differential air pressure switch.

“Dry” clean the air pressure pipes.

Do not use pressurised materials.

Take out the 4 screws securing the air guiding piece.

Thoroughly clean the air duct and fan.

Reassemble.

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09/2005 - Art. Nr. 13 019 526A

Valves

No special maintenance is required for the valves. Valves must not be repaired. Defective valves must be replaced by a qualified professional, who must check the leak, function and combustion values following replacement.

Remove the blast tube.

To carry out this procedure, the combustion chamber door must be opened or the burner removed.

–

Variant 1 -Access via the combustion chamber doors

Remove the mixer control/ignition device.

Loosen the 3 fixing screws on the blast tube support by 1 to 2 turns. N.B.: the screws are threaded to the left (Allen 3).

Remove the blast tube, check, clean, and where necessary, replace if a deformity is found.

Refit the blast tube in the reverse sequence.

The space between the blast tube and the door insulation should be fitted with flameproof material.

–

Variant 2 - Removing the burner

Remove the mixer control/ignition device.

· Loosen the electrical connections.

· Remove the gas valve assembly.

· Unscrew the gas connection

(2 M8 nuts).

· Loosen the burner housing (2 M8 screws) and remove.Do not damage electrical cables.

· Unscrew the burner head and then proceed as under variant 1.

· Refit in the reverse sequence.

Precautions After each intervention, check the combustion performance under real operating conditions (doors shut, cover fitted etc.). Note down the results in the corresponding report forms.

Replacing the filter on the gas valve

The filter must be checked once a year and replaced if dirty. Pocket filter:

Release the cover fixing screws on the filter.

Remove the filter.

Insert new filter.

Refit the cover with the screws.

Tube filter:

Dismantle the gas connection flange at the inlet side.

Remove the filter.

Insert new filter.

Fit a gas connection flange.

Open the manual stop valve; check tightness.

Cleaning the hood

Clean the cover with water and a cleaning product.

Do not use chlorine-based or abrasive cleaning products.

Maintenance

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09/2005 - Art. Nr. 13 019 526A

Burner-specific adjustment settings of the MPA 22

Measurement/Date:

Parameters Dim Range M1/ M2/ M3/ M4/

eBus address

Reventilation time [s] 0-240

Waiting time [min] 0-100

Pulses per L/m³ 1-255

Rest pos. Air flap [°]

Delete error list blank/

Check seals Y/N

Valve check time 1 [s] 0-240

Valve check time 2 [s] 0-240

Address regulation

Software

Product No.

Counters Dim.

Fuel consumption [m³]

Total operating hours [hours]

Successful burner starts

Measurement/Date:

M1/ M2/ M3/ M4/

Measurement Measurement

Air M1 M2 M3 M4 Gas M1 M2 M3 M4

Value P0 [°] [°]

Value P1 [°] [°]

Value P2 [°] [°]

Value P3 [°] [°]

Value P4 [°] [°]

Value P5 [°] [°]

Value P6 [°] [°]

Value P7 [°] [°]

Value P8 [°] [°]

Value P9 [°] [°]

bu/flow rate [°] [m³/h]

bo/flow rate [°] [m³/h]

bu/Value CO2/CO [%] [ppm]

bo/Value CO2/CO [%] [ppm]

System: ..........................................

Burner No.: .....................................

Boiler manufacturer: ...............................

Boiler type: ..............................................

Observer M1: .....................................................

Observer M2: .....................................................

Observer M3: .....................................................

Observer M4: .....................................................

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09/2005 - Art. Nr. 13 019 526A

Service

Troubleshooting

Fault diagnosis and repair

Before carrying out fault diagnosis, check that the basic requirements for correct operation are being fulfilled:

Is there any current?

Is there any gas pressure?

Is the gas stop valve open ?

Are all control and safety devices, such as the boiler thermostat, low-water detector, limit switch, etc. adjusted properly?

Error/fault Cause Corrective action

Display without information No mains voltage present

External cut-out defective Display-control unit plug-and-socket connection interrupted Display defective MPA 22 defective

Check Check/replace Check/establish connection

Replace Replace

Display “Safety chain” No feedback on terminal 7 Insert bridge connector or given

Check switch/limiter

Motor does not start Control unit-motor plug-and-socket

connection interrupted

Capacitor defective

Motor defective

Control unit/servomotors feedback not

correct

Establish connection

Check/replace

Control unit/servomotors

Check/replace

Motor only runs briefly Air pressure switch does not activate

Gas pressure switch does not activate Gas filter dirty Magnetic valve V1 does not open No gas available

Check/change adjustment Check/change adjustment Clean/replace gas filter Check/replace compact valve Notify gas supplier Note: in the event of a gas shortage, the waiting time can be reset by de-energising the burner (7-pin plug)

Burner does not start Compact valve defective

Ignition transformer defective Ignition electrode position/Ignition cable MPA 22 control unit defective Ionisation probe/IRD probe

Replace Replace Check/replace Check/replace Check/replace

Crack formation on ionisation probe Too much gas on probe

Circulation insufficient

Fit solid screws (propane gas set)

If a fault occurs on the burner, the red light diode flashes on the display unit. At the same time, the cause of the fault is displayed and a fault code is displayed.

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09/2005 - Art. Nr. 13 019 526A

Adresse Service-Hotline

ELCO Austria GmbH

Aredstr.16-18 2544 Leobersdorf

0810-400010

ELCO Belgium n.v./s.a.

Pontbeeklaan-53 1731 Zellik

02-4631902

ELCOTHERM AG

Sarganserstrasse 100 7324 Vilters

0848 808 808

ELCO GmbH

Dreieichstr.10 64546 Mörfelden-Walldorf

0180-3526180

ELCO France

18 rue des Buchillons 74106 Annemasse

0450877624

ELCO-Rendamax B.V.

Amsterdamsestraatweg 27 1410 AB Naarden

035-6957350

Fabriqué en EU. Made in EU. Hergestellt in der EU. Gefabriceerd in de EU Document non contractuel. Non contractual document. Angaben ohne Gewähr. Niet-contractueel document