elco VG2.120 M/TC, VG2.160 M/TC, VG2.210 M/TC, VG 6.1600 M/TC, VG 6.2100 M/TC Original Operating Instructions

en

VG2.120 M/TC
VG2.160 M/TC
VG2.210 M/TC

Original operating instructions

For authorised specialist engineers

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

de, fr.....................................4200 1038 2500

it, nl ......................................4200 1038 2600

............................................. 4200 1038 2400

09/2014 - Art. Nr. 4200 1038 2700A

Overview

Contents

Overview Contents .....................................................................................2

Operation Operation, safety function ..........................................................4

Assembly Burner assembly ......................................................................11

Commissioning Setting data ..............................................................................15

Maintenance Servicing............................................................................. 26-27

Important information

VG2.120/160/210 M/TC burners are
designed for the low-pollutant combustion of
natural gas and propane gas. The design and
function of the burners meet standard EN

676. They are suitable for use with all heat
generators complying with standard EN 303
or for use by hot air generators complying
with standard DIN 4794 or DIN 30697 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.
This device is not designed for use by
individuals (including children) whose
physical, sensory, or mental abilities are
reduced, or by persons lacking in experience
or knowledge, except if they have benefited
from supervision or prior instructions
concerning the use of the device given by a
person responsible for their safety. Children
must be supervised to ensure they do not
play with the device.

Burner description

VG2.120/160/210 M/TC burners are
modulating, fully automatic, monoblock type
burners with electronic cam. The special
design of the combustion head enables
combustion with low levels of nitrogen oxide
and increased output. Class 3 type-approval
in accordance with EN676 certifies that the
lowest emission values have been achieved
and means that the national environmental
regulations have been met
AT: KFA 1995, FAV 1997
CH: LRV 2005
DE: 1.BImSChV
Emissions values may differ, depending on
furnace dimensions, furnace 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.

Important information .................................................................2

Burner description ......................................................................3

Control and safety unit BT 3xx ...................................................5

Terminal allocation chart ........................................................ 6-7

Control and safety unit BT 3xx gas operation ............................8

BT 3xx menu overview ...............................................................9

MBC-SE gas train.....................................................................10

Gas train...................................................................................12

Checking the combustion components ....................................13

Electrical connection ................................................................14

Testing before commissioning..................................................14

Ionisation current measurement ...............................................14

Air regulation, MBC SE gas train setting ..................................16

Pressure regulator setting ........................................................16

Confirming the "Manual Handshake" data................................17

Menu 1: setting the servomotors ....................................... 18-23

Pre-setting without flame.................................................... 18-19

Setting with flame ............................................................... 20-23

Operating mode........................................................................23

Setting the gas pressure switch/air pressure switch ................24

Displaying the setting data from the manual control display ....25

Menu 3: Fault memory, Entering a telephone
number for the maintenance company and the

maintenance contract number............................................ 28-29

Menu 4: operating statistics......................................................30

Setting the brightness and contrast of the display....................31

Packaging

The burner is supplied in three packaging
units:

- Burner housing with operating instructions,
circuit diagram and spare parts list.

- Burner head with flange seal and securing
screws.

- Compact gas train with integrated filter

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

EN 226

Connection of fuel oil and gas burners with
blast air to the 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 routing the gas lines and fittings, the
general installation instructions 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).
There must be a supply air inlet measuring:
DE: up to 50 kW: 150 cm

for each additional kW: + 2.0 cm

CH: QF [kW] x 6= ...cm2; but 200 cm2

minimum.
Variations may arise as a result of local
regulations.

Page

Declaration of conformity

for gas burners

We, certified company under the name
"Site A" declare under our sole
responsibility that the products
VG2.120 M/TC
VG2.160 M/TC
VG2.210 M/TC

conform to the following standards
EN 50165
EN 55014
EN 60335-1
EN 60335-2-102
EN 60555-2
EN 60555-3
EN 676
Belgian royal decree dated 08/01/2004

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

92/ 42/EEC Efficiency Directive

Annemasse, June 1st 2012

F. DECIO

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.

2

2

09/2014 - Art. Nr. 4200 1038 2700A2

Overview

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Burner description

A1 Control and safety unit
A4 Display
F6 Air pressure switch
M1 Blower motor
T1 Igniter
Y10 Air flap servomotor
3 Adjusting knob for dimension Y
4 Propane diffuser
5 Housing
6 Plate hanging device

(Maintenance)
8 Burner tube
10 7-pin connector

10.1 4 pin connector
16 Gas connecting flange
18 Cover
19 Release knob
20 Hood securing screw
113 Air intake box

09/2014 - Art. Nr. 4200 1038 2700A 3

Operation

Compact train

Operation
Safety function

Description of functions

When first powering up, after a power
cut or a lockout, after the gas supply has
been cut or after a shutdown for 24
hours, a gas valve sealing test is
performed before the burner is started,
with the fan motor in operation. A pre­ventilation time of 24 seconds begins
after the sealing test.

During the pre-ventilation time

- the air pressure is monitored

- a check is made for the presence of
any abnormal flame signals.

At the end of the pre-ventilation time

- the ignition is switched on

- the main and safety solenoid valves
are opened

- burner start-up

Monitoring

The flame is monitored by an ionisation
probe. The probe is fitted with insulation
to the gas head and is routed through
the turbulator into the flame zone. The
probe must not have any electrical
contact with earthed parts. The burner
switches to malfunction if a short circuit
occurs between the probe and the
burner earth. During burner operation,
an ionised zone is produced in the gas
flame through which a rectified current
flows from the probe to the burner tip.

The ionisation current must be at least
8 µA.

Safety functions

- If no flame is produced when the
burner is started (gas release), the
burner is switched off at the end of the
safety time which lasts no more than
3 seconds and the gas valve closes.

- If the flame is lost during operation,
the gas supply is cut within a second.
A new start-up sequence is activated.
If the burner starts, the operating cycle
starts running. Otherwise a lockout
occurs.

- If there is an air failure during pre­ventilation or operation, a lockout
occurs.

- If there is a gas failure, the burner
either stops or will not start. As soon
as sufficient gas pressure is available
again, the burner restarts.

During the regulator shutdown

- The control thermostat interrupts the
heating request

- The gas valves close

- The flame goes out

- The blower motor stops

- The burner is ready for operation

F4 Gas pressure switch
F6 Air pressure switch
Y12 Safety solenoid valve
Y13 Main solenoid valve
1 Thermal safety valve (to be

installed by the fitter)

103.1 Gas throttle
106 Screen
108 Gas cut-out valve (to be

installed by the fitter)

119pBr Gas pressure measuring point

at the valve outlet

119.1 Gas pressure measuring point
upstream of the valves

119.2 Air pressure measuring point

CH note

In accordance with SSIGE instructions,
it is compulsory to install a gas safety
valve (mark 1) in the pipe.

DE Note

In compliance with the reference layout
applicable to boiler rooms, sites with gas
furnaces must be fitted with a thermal
gas shut-off valve (1).

09/2014 - Art. Nr. 4200 1038 2700A4

Operation

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Control and safety unit BT 3xx

The control and safety unit BT 3xx
controls and monitors the forced draught
gas burner. The microprocessor­controlled program sequence ensures
the maximum consistency of the cycle
times involved, regardless of
fluctuations in the mains voltage or
ambient temperature. The control and
safety unit is designed to detect power
failures. Depending on the parameter
assignment, the unit either switches to
malfunction mode or goes into the
standby position if the power supply falls
below the mains voltage. In the standby
position, there is an automatic restart as
soon as the set threshold value is
exceeded by 105%.

Pressing button

for ...

... 1 second ... the control and safety

... 2 seconds ... the control and safety

… causes ….

unit to unlock.

unit to lock

Manual locking and unlocking

Using the reset button , the control
and safety unit can be locked manually
(interlocked) or unlocked, provided the
unit is connected to the mains power
supply. This function must not be
confused with automatic locking and
fault acknowledgement in case of an
error.

Before installing or removing the unit or
any operation in the connection area,
switch off the supply to the device, check
for the absence of voltage and prevent
any reactivation. Otherwise there is risk
of electric shock. The control and safety
unit must not be
opened or repaired.

- Moves the cursor upwards

- Moves the cursor downwards

- Increases the marked value

- Moves the cursor to the right

- Reduces the marked value

- Moves the cursor to the left

Modifies/confirms the value shown

- Unlocks the control and safety unit

Red LED (flashes if a fault is
present)

09/2014 - Art. Nr. 4200 1038 2700A 5

Operation

Air pressure

switch

Ignition

device

Terminal

Connector

Remote

unlocking

Solenoid valves

(1+2)

Heating
request

Min. gas
pressure

switch

Burner

safety
circuit

Boiler
safety
circuit

Solenoid

valve 3

Flame check

Fault

display

Burner motor

Terminal

L1 power supply

Grounding of

the burner

UV detector

additional

Ionisation

Flame
monitor

Connector

1 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 4

1 2 3

1 2 3

1 2 3

Pin

Pin

1 2 3 1 2 3

1 2 3

1 2 3 1 2 3 1 2

1 2

Terminal allocation chart

Pin Terminal Description Connector Pin Terminal Description Connector

1 1 Phase gas solenoid valve 1

2 2 Earth 1 30 Neutral conductor of the fuel-oil

3 3 Neutral conductor 2 31 Earth
1 4 Phase gas solenoid valve 2 3 32 Phase
2 5 Neutral conductor 1 33 Neutral conductor
3 6 Earth 2 34 Earth
1 7 Phase fuel valve 3 (optional)
2 8 Earth 1 36 Neutral conductor
3 9 Neutral conductor 2 37 Earth
1 10 Phase ignition transformer
2 11 Earth 1 39 Neutral conductor
3 12 Neutral conductor 2 40 Earth
1 13 Phase gas pressure switch min.
2 14 Earth 1 42 Neutral conductor
3 15 Phase 2 43 Earth
1 16 Phase burner safety circuit
2 17 Earth 1 45 UV flame monitor (-)
3 18 Phase 2 46 UV flame monitor (+)
1 19 Phase boiler safety circuit
2 20 Phase 2 48 Phase
1 21 Phase air pressure switch
2 22 Phase 4 50 Flame monitor (-)
1 23 Load (-)
2 24 Load (+)
3 25 Phase
1 26 Malfunction reset
2 27 Burner ON
3 28 Phase

X01

+

X02

X03
X04
X05

X06
X07

X08
X09

X10

1 29 Grounding of the burner

pump

3 35 Phase burner motor

3 38 Alarm output

3 41 L1 power supply

3 44 L1 power supply output

1 47 Ionisation probe

3 49 Flame monitor (+)

X26
X25

X24
X23
X22

X21
X20

09/2014 - Art. Nr. 4200 1038 2700A6

Operation

Terminal

Display

PC interface

Gas

servomotor

Air

servomotor*

Fuel oil

servomotor*

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6

Pin

Connector

en

Terminal allocation chart

Pin Terminal Description Connector

11
22
33
44
55
66
17
28
39
410
511
612
113
214
315
416
517
618
119
220
321
422
523
624
125
226
327
428
529
630

Display

PC interface

Servomotor gas

Servomotor air*

Servomotor fuel oil*

X30

X31

X32

X33

X34

* Terminal allocation depends on the design of the burner

09/2014 - Art. Nr. 4200 1038 2700A 7

Operation

Boiler safety circuit
Gas safety circuit
Burner on
Minimum gas pressure swi t ch

Air pressure switch

Flame signal

Air flap

Gas flap

Transformer

Gas valve 1
Gas valve 2

Air motor
Fault

Control and safety unit BT 3xx gas operation

Legend to the sequence diagram

t1 Awaiting boiler safety circuit

Air pressure switch min. request

t2 Time for pressure build-up in the gas control line (only

when sealing test mode is activated, program sequence
for density test can vary, see sequence diagram for
density test)

t3 Servomotor running time
t4 Closing of gas flap
t5 Ventilation time
t6 Transformer activation time

Sealing test sequence diagram - no gas pressure at start of sealing test. Sealing test sequence diagram - gas pressure present at start of sealing

Legend to the sequence diagrams

t1 Ventilation time, always 2 seconds
t2 Delay time, always 2 seconds
t3 Sealing test time, configurable
t4 Filling time, configurable

The diagrams on this page have been taken from the operating instructions of the BurnerTronic BT300 BT320 BT340 from Lamtec.
Print no. DLT1200-11-aDE-002 Copyright© 2011 LAMTEC

t9 Safety time
t10 Operating phase
t11 Regulation
t12 Time for pressure release in the gas control line
t13 Postventilation time
t14 Servomotors under base load
t15 Post combustion time
t16 Flame extinction test
t17 Sealing test gas valve 2

test.

09/2014 - Art. Nr. 4200 1038 2700A8

Operation

en

BT 3xx menu overview

In addition to the function of control and
safety unit, the control and safety unit BT
3xx also modulates the burner output by
controlling the air flap, gas flap, fuel oil
quantity regulation and frequency
converter (optional) in one electronic
circuit.
The electronic circuit controls the
opening of the gas flap and fuel oil flow
regulation proportional to the air flap
along a curve based on 10 setting points
During start up, the setting points are
defined based on the measurement
values of the combustion gas analysis.
This guarantees optimal combustion

• Menu 1: Setting the

• Menu 2: Display of the

over the burner's entire output
modulation range.
A separate burner ignition load can be
defined with the "Ignition position"
setting point .
The limit values of the control range are
defined by the min. output " " and
max. output " " setting points. In
addition, other optional functions, such
as sealing tests, reventilation or waiting
times can be activated.
The combustion control unit is operated
via a display and operating unit. The
parameters for the control and safety
unit are set using the display and 5 keys.

servomotors

setting points of the
servomotors in the
display unit

Operating values are shown in real time
on the display.
Pressing the keys gives access to 9
menus:

• Menu 6: Setting/
modification of
configurations for
industrial applications

• Menu 7: Manual mode

• Menu 3: Displaying
faults

• Menu 4: Statistical data

• Menu 5: Setting/
modification of
standard configurations

• Menu 8: Setting mode

- Menu 8 currently not
available

• Menu 9: Setting the
brightness and contrast of
the display

In these menus, it is
possible to adjust the
standard configurations of
the control unit. These are
pre-set in the factory.
The nearest customer
service department must be
contacted before any on­site modifications are made.

09/2014 - Art. Nr. 4200 1038 2700A 9

Operation

MBC-SE gas train

The gas train consists of:

- a gas connection flange 1 with O-ring

- a gas throttle 2, controlled by a

servomotor

- a gas connection pipe 3

- an MBC-SE gas valve train with gas

filter 4 (mini filter)

MBC SE gas valve

1 Electrical connection of solenoid

valves (DIN 43650)

2 Electrical connection of gas

pressure switch (DIN 43650)
3 Gas pressure switch
4 Gas inlet flange
5 Mini filter (under cover)
6 Gas pressure adjustment

screw pBr
8 Gas pressure measurement

tap G1/8 (inter-valve pressure)
9 Gas pressure measurement

tap G1/8 (outlet pressure pBr)
10 Gas pressure measurement

tap G1/8 (inlet pressure)

Installation position:

vertical with the coils facing upwards.
Where the lines are vertical, the coils
must be horizontal.

Description, technical data

The MBC-SE gas compact valve train is
a compact unit with 2 Class A solenoid
valves, a Class A servo pressure
regulator, a mini filter and a pressure
switch.

- Pressure switch GW A5: adjustment

range 5.....50 mbar

- Solenoid valve V1/V2 (fast-opening/
fast-closing)

- Adjustable servo pressure regulator

- Max. operating pressure 500 mbar

- Inlet pressure range
15-500 mbar

- Voltage/frequency:
230 V/50-60 Hz

Pressure regulator setting

The outlet pressure is set using
adjustment screw 6.

09/2014 - Art. Nr. 4200 1038 2700A10