elco VG 2.210 V Operating Instructions Manual
VG 2.210 V
en
Operating instructions
For specialist installation engineers
Gas burners ........................................... 2-31
de, fr..................................... 4200 1053 2700
it, nl ...................................... 4200 1053 2800
............................................. 4200 1053 2600
09/2013 - Art. Nr. 4200 1053 2900A
Overview
Contents
Overview Contents .........................................................................2
Important information .....................................................2
Burner description ..........................................................3
Operation Description of the function, safety functions...................4
Control and safety unit ............................................... 5-7
Terminal allocation chart, connection socket ............. 8-9
MB-VEF gas train .........................................................10
Assembly Burner assembly ..........................................................11
Gas train, pressure take-off pipes ................................12
Checking the mixing unit ..............................................13
Electrical connection, testing before commissioning....... 14
Ionisation current measurement...................................14
Commissioning Adjustment data ........................................................... 15
Air regulation, gas valve adjustment ............................16
Pre-adjustment without flame, general advice
before starting the burner ....................................... 17-18
Setting the flame .................................................... 19-21
Air regulation .......................................................... 22-23
Setting the gas pressure switch, the air pressure switch....... 24
Saving the adjustment values in the display ...............25
Servicing Maintenance .......................................................... 25-26
Troubleshooting...................................................... 27-28
Maintenance / Troubleshooting of the
frequency converter......................................................29
Fault diagnosis menu,
Operating statistics menu ....................................... 30-31
Important information
VG 2.210 V 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.
Burner description
VG 2.210 V burners are two-stage fully
automatic monoblock devices. 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 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 packaging also contains:
1 Gas connection flange
1 Compact gas train with gas filter
1 Burner flange
with insulation
Page
1 Bag containing mounting parts
1 Bag containing Technical
Documentation
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
per additional kW: : + 2.0 cm
2
2
CH: QF [kW] x 6= ...cm2; but at least
200 cm2.
Variations may arise as a result of local
regulations.
09/2013 - Art. Nr. 4200 1053 2900A2
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
en
Burner description
A1 Control and safety unit
A4 Display
F6 Air pressure switch
M1 Blower motor
T1 Igniter
Y10 Air flap servomotor
1 Frequency converter for speed
control
3 Adjusting screw for dimension Y
4 Sealing washer for Liquefied
Petroleum Gas
5 Housing
6 Plate hanging device
(Maintenance)
8 Burner tube
10 7-pin connector
10.1 4-pin connector
10.2 3-pin connector (auxiliary motor
supply relay)
16 Gas train connecting flange
18 Cover
19 Release knob
20 Hood securing screw
113 Air intake box
pF Measuring nipple for furnace
pressure
pL Measuring nipple for air
pressure
09/2013 - Art. Nr. 4200 1053 2900A 3
Compact train
Operation
Description of the function
Safety functions
Description of the function
A pre-ventilation time of 24 seconds
begins 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.
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
8µA.
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
heat 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 shut-off valve (to be
installed by the installer)
104 Gas pressure regulator
106 Screen
108 Gas cut-out valve (to be installed
by the installer)
119pBrGas pressure measuring point at
the valve outlet
119.1Gas pressure measuring point
upstream of the valves
119.2Air pressure measuring point
pF Furnace pressure
pG Gas pressure at the head
pL Air pressure
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).
09/2013 - Art. Nr. 4200 1053 2900A4
en
Operation
TCG 8xx control unit
The TCG 8xx control and safety unit
controls and monitors the forced draught
burner. The microprocessor-controlled
program sequence ensures maximum
stability of time periods, regardless of
fluctuations in the power supply voltage
or the ambient temperature. The
automatic combustion control unit is
designed to cope with brownouts.
Whenever the supply voltage drops
below its rated minimum level (< 185V),
the control unit shuts down - even in the
absence of a malfunction signal. The
control unit switches itself back on again
once the voltage has returned to normal
levels (> 195V).
Pressing the
unlocking button on
the unit for
... 1 second ... the control unit to
... 2 seconds ... the control unit to
... 9 seconds ... the statistics to
… causes …
unlock.
lock.
be deleted
Locking and unlocking
The control unit can be locked (switched
to malfunction mode) by pressing the
unlocking button and unlocked (fault
deleted), provided the unit is connected
to the mains power supply.
Always switch off the power
supply before installing or
removing the control unit. Do not
attempt to open or carry out
repairs on the control unit.
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Reduces the marked value.
Modifies/Confirms the value
shown.
Unlocks the control unit.
Red LED (flashes if a fault is
present).
Screen Description Screen Description
Awaiting the heat request from
the boiler
Air flap is forced open for pre-
ventilation.
Pre-ventilation
Closing the air flap to the ignition
position, pre-ignition
Opening the gas valve and
safety time
Flame is present, awaiting
authorisation of regulation
Burner in operation. The lower
cell shows the strength of the
signal and the operating time of
the burner.
09/2013 - Art. Nr. 4200 1053 2900A 5
Operation
TCG 8xx control unit
In parallel with its control and safety
functions, the TCG8xx control unit
allows the following to be set:
(see illustration)
- the position of the air flap during
ignition
- the position of the air flap at minimum
pressure
- the position of the air flap at maximum
pressure
• menu for setting the
servomotor
• menu for storing the
servomotor setting
points in the display
The parameters for the control unit are
set using the display and 5 keys.
Operating values are shown in real time
on the display.
Pressing the keys gives access to 9
menus:
• menu for setting
industrial applications*
• menu for manual control*
• fault diagnosis menu
• operating statistics
menu
• menu for setting/
adjusting the standard
configurations*
• Parameter mode menu*
• Menu for adjusting
screen contrast and
brightness settings
* In these menus, it is
possible to adjust the
control unit's standard
configurations. These
are pre-set in the
factory. No
modifications may be
carried out on-site
without prior
consultation with ELCO.
The access code and
the setting setpoints for
these menus are
available on request.
09/2013 - Art. Nr. 4200 1053 2900A6
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Operation
TCG 8xx control unit
Operating cycle phases:
1: No voltage
2: Powering up, no heat request
3: Heating request
4: Opening an air flap, arrival in pre-
ventilation position
5: Checking the rest status of the air
pressure switch
6: Pre-ventilation: energizing of the
motor, checking the air pressure
7: Pre-ventilation
8: Air flap closes to the ignition position
9: Switching on the igniter, unauthorised
flame monitoring
10:Opening of the solenoid valve, flame
formation, safety time: max. 3 s.
11:Awaiting regulator release
12:Opening the air flap, until the
maximum output is reached
13:Closing of the air flap until the
minimum regulation position is
reached
14:Operation at intermediate regulation
power
15:Operation at minimum regulation
power
16:Regulator shutdown, closure of the
air flap
17:Awaiting a new heating request
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Operation
Earth
Flame check
Fault
display
Air pressure
switch
Igniter
Burner motor
Connector
Terminal
Terminal
Connector
Remote
unlocking
L1 power
supply
Solenoid valve
Control
thermostat
Heating
request
Earth
Gas pressure
switch
Terminal allocation chart
230 Volt connection
Terminal Description Connector Terminal Description Connector
1 Burner motor live
2 Earth 21 Heating request signal (option T2)
3 Neutral 22 Flame monitoring signal
5 Neutral 24 Live
6 Earth 25 Air pressure switch signal
7 Solenoid valve live 26 Live
8 Live 27 Live
9 Live L1
10 Earth 29 Neutral
11 Neutral 30 Signal fault live
12 Earth 31 Live
13 Earth 32 Live
14 Igniter live
15 Earth 34 Not used
16 Neutral
17 Control thermostat live
18 Signal T7
19 Signal T8
4
2
6
5
T6/7/8
20 Minimum output thermostat live (T1)
23 Earth
28 Remote unlocking signal
33 Not used
34
19
114 Solenoid valve live
10
20
21
8
09/2013 - Art. Nr. 4200 1053 2900A8
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Operation
Display-PC interface
Air servomotor
Connector
Terminal
Terminal
Connector
Speed converter
Terminal allocation chart
Low voltage connections
Terminal Description Connector Terminal Description Connector
1 not used
2 not used 19 not used
3 not used 20 not used
4 not used
5 not used 22 not used
6 not used 23 not used
7 not used 24 not used
8 not used 25 not used
9 not used 26
10
11 28
12 29
13 30
Display or PC interface
14 31
15 32
16 33
17
30
27
28
29
16
17
/
18 not used
21 not used
27
Speed converter
Air servomotor
14
33
32
15
09/2013 - Art. Nr. 4200 1053 2900A 9
Operation
MB-VEF gas train
1 Electrical connection of solenoid
valves (DIN 43650)
2 Electrical connection of the
gas pressure switch (DIN 43650)
3 Gas pressure switch
4 Inlet flange
5 Pressure measuring nipple
R1/8, upstream of filter (option)
6 Filter (under the cover)
7 Connection for furnace pressure
release pipe pF, R1/8
8 Adjusting screw for V ratio
9 Adjusting screw for zero point
offset N
10 Connection for pressure pipe pL,
R1/8
10.1 Nozzle Ø0.4 mm to be fitted
according to applications between
pL and the valve
12 Outlet flange
18 Impulse flange
The MBVEF compact gas valve
assembly is a combination of filter, gas/
air ratio regulator, valves and a pressure
switch:
- Screen with 0.8mm mesh
- GWA5 pressure switch
- Servo-pressure control part with
adjustable ratio V, correction of the
zero point offset N and furnace
pressure connection.
- V1 and V2 fast-opening and closing
solenoid valves
Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +70°C
Voltage 230 V/ 50 Hz Max.
Absorbed output 50 VA
Protection rating IP 21
09/2013 - Art. Nr. 4200 1053 2900A10
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