elco VG 2.210 V Operating Instructions Manual

Page 1
VG 2.210 V
en
Operating instructions
Gas burners ........................................... 2-31
de, fr..................................... 4200 1053 2700
it, nl ...................................... 4200 1053 2800
............................................. 4200 1053 2600
09/2013 - Art. Nr. 4200 1053 2900A
Page 2
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.
Page 3
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
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Page 4
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).
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Page 5
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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.
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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.
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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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Page 8
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
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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
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Page 10
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
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Page 11
Assembly
en
Burner assembly
Burner assembly
Burner flange 3 is equipped with elongated holes and can be used with a hole circle diameter of 150 - 184mm. These dimensions comply with EN 226. Sliding pipe bracket 2 on the burner pipe makes it possible to adjust the installed depth of the mixing unit to the geometry of the combustion chamber concerned. The installed depth remains the same during fitting and removal. Pipe bracket 2 secures the burner to the connecting flange and therefore to the boiler. This completely seals off the combustion chamber.
Caution : do not block the burner pressure the pF.
Installation:
• Secure connecting flange 3 to the boiler using screws 4
• Fit pipe bracket 2 to the burner pipe and secure using screw 1. Tighten screw 1 to a maximum torque of 6 Nm.
• Turn the burner slightly, guide it into the flange and secure using screw 5.
Removal:
• Loosen screw 5
• Turn the burner out of the bayonet socket and pull it out of the flange.
Burner tube installation depth and brickwork surround
Unless otherwise specified by the boiler manufacturer, heat generators without a cooled front wall require brickwork or insulation 5 as shown in the illustration opposite. The brickwork must not protrude beyond the leading edge of the flame tube, and should have a maximum conical angle of 60°. Space 6 must be filled with an elastic, non-flammable insulation material.
DOn boilers with reverse firing, minimum flame tube insertion depth A should be observed as per the boiler manufacturer's instructions.
Inspection glass cooling
The burner housing can be equipped with an R1/8" connection to support a line for cooling the inspection glass of the boiler.
• To do this, drill through boss 6 and cut
an 1/8" thread.
• Use accessories article No. 12 056 459 for the connecting nipple and connection hose.
For assembly in the position with
the volute facing upwards, unclip the display, turn it over 180°, and refit it.
Exhaust gas evacuation system
To avoid unpleasant noise emissions, right-angled connectors should not be used on the flue gas side of the boiler.
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Assembly
Gas train Pressure take-off pipes
Gas train assembly
• Check the correct position of the
O-ring J1 in the gas connecting flange.
• Secure the gas train on the burner head so that the gas train coils are in the upper vertical position.
• Pay attention to the direction of circulation.
• Route the connection cable for the gas train through clamp 7 and connect it to the gas train.
On burners VG 2.210 V, fit the restricting piece 2 (comes with gas train fittings bag, with the burner flange.
Connecting pressure take-off pipes pF and pL
• Release cable clamp 9.
• Insert the two C cables and the PL pressure release cable into the cable camp.
• Connect the furnace pressure take-off pL on the mixing unit cover and the union pL on the gas train using the flexible tube pL (blue), shorten the tube depending on the assembly scenario.
• Connect the furnace pressure take-off pF on the burner blast tube and the union pF on the gas train using the flexible tube pF (grey), shorten the tube depending on the assembly scenario.
• Manually screw in the unions (max. 5 Nm) and check tightness.
If pulsations are observed when the burner is operating, fit the nozzle Ø 0.4 (comes with the burner) between connection pL and the valve.
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Assembly
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VG 2.120
Checking the mixing unit
Checking the mixing unit
• Loosen the three cover screws W.
• Remove the cover.
• Loosen lock nut E on the gas pipe
bracket
• Loosen the retaining bolt.
• Remove the mixing unit.
Setting to liquid gas operation
• Remove stabilising stop 3 and baffle plate 4.
• Fit adaptor 5 (supplied with the housing).
• Refit baffle plate 4 and stabilising stop
3.
Checking the mixing unit
• Check the adjustment of the ionisation sensor and the ignition electrode in accordance with the illustrations.
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Assembly
Electrical connection Checks before commissioning Ionisation current measurement
General regulations applying to the gas connection
• The gas train must only be connected to the gas mains by a recognised specialist.
• The cross-section of the gas line should be of a size designed to guarantee that the gas flow pressure does not drop below the specified level.
• A manual shut-off valve (not supplied) must be fitted upstream of the gas train.
• In Germany, a thermally triggered shut-off valve (to be installed by the customer side) must be fitted as
All electrical installation and connection work must only be carried out by a suitably qualified electrician. The applicable guidelines and directives must be observed, as well as the electrical circuit diagram supplied with the burner!
Electrical connection
• Check to ensure that the power supply is as specified (230V, 50 Hz single phase with neutral and earth)
Boiler fuse: 6.3 A
specified by the draft combustion
ordinance. It is the responsibility of the fitter or his representative to obtain approval for the system at the same time as the burner is commissioned. Only the fitter or his representative can guarantee that the system meets applicable standards and regulations. The fitter should be in possession of the corresponding official permit, and should carry out the corresponding sealing tests and purge the system of air.
The burner motor has its own separate power supply (no. 3).
Fuse on the motor circuit: 6 A gM
Electrical connection
It must be possible to disconnect the burner from the mains using an omnipolar shutdown device complying with the standards in force. The burner and heat generator (boiler) are connected by a 7-pin connector 1 and a 4-pin connector 2 (not supplied). The diameter of the cables connected to these connectors must be between 8.3 and 11 mm.
Connecting the gas train
Connect the gas train to the plugs on the burner (black to black, grey to grey).
Checks before commissioning
The following must be checked before initial commissioning:
• That the burner is assembled in accordance with the instructions given here.
• That the burner is pre-set in accordance with the values in the adjustment table.
• Setting the combustion components.
• The heat generator must be ready for operation, and the operating regulations for the heat generator must be observed.
• All electrical connections must be correct.
• The heat generator and heating
system must be filled with water and the circulating pumps must be in operation.
• The temperature regulator, pressure regulator, low water detectors and any other safety or limiting devices that might be fitted must be connected and operational.
• The exhaust gas duct must be unobstructed and the secondary air system, if available, must be operational.
• An adequate supply of fresh air must be guaranteed.
• The heat request must be available.
• Sufficient gas pressure must be available.
Ionisation current measurement
To measure the ionisation current, disconnect connector B10 and connect a multimeter with a measuring range of 0-100 µA. The ionisation current must be at least 8 µA. It is also possible to read the ionisation current on the display.
• The fuel supply lines must be assembled correctly, checked for leaks and bled.
• A standard-compliant measuring point must be available, the exhaust gas duct up to the measuring point must be free of leaks to prevent anomalies in the measurement results.
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Commissioning
en
Mini. Maxi. Ignition Mini. Maxi. LL UL G20 G25 G20 G25
150 20 35 25 60 25
50 -
-2 / -1 -
170 25*/35** 30 25 90 25 50 2,5 / -1 2,5 / -1
2,5 / 0
2,5 / 0
210 35 40 30 90 25 50 2,5 / -2 - 2,25 / -0,5 -
* : p=300mbar; ** : p=20 mbar
VG 2.210V
Air flap setting
Parameter
Burner
power
Frequency converter
setting
Gas valve setting
Screw V / Screw N
MB-VEF407
80
Y
(mm) MB-VEF412
Adjustment data
Dimension
The adjustment values above are guide values and facilitate commissioning. The factory settings are in bold set against a grey background The final settings are essential in ensuring that the burner functions as well as possible
Setting the gas pressure switch
• Remove the transparent cover.
• Provisionally set to 15mbar.
Setting the air pressure switch
• Remove the transparent cover.
• Provisionally set to 1 mbar.
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Commissioning
Air regulation Gas valve adjustment
The combustion air is regulated via three parameters:
• On the pressure side by means of the opening gap between the turbulator and burner tube.
• On the suction side by means of the air flap actuated by servomotor Y10.
• Air regulated by fan speed, setting via frequency converter.
The regulation of air in the burner head affects not only the air flow but also the mixing zone and the air pressure in the burner tube. Turning screw A
- right: more air
- left: less air
• Adjust dimension Y in accordance with
the settings table.
Air regulation by air flap
Air is regulated on the vacuum side by an air flap. This is driven by servomotor
Y10.
Gas valve adjustment
V Setting the maximum power
N Setting the minimum power
- For more CO scale.
- For less CO scale.
turn upwards on the
2
turn downwards on the
2
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Commissioning
Pre-setting without flame
Setting is carried out in 2 phases:
- pre-adjustment without flame
- setting the flame, to fine tune the settings based on the combustion results
When the burner is switched on, the control unit displays the screen below.
• For the next step, press any button.
Important
At this point, no setting position for the servomotor has been defined, therefore the burner cannot be started under these conditions.
The control unit then opens the settings mode. The screen displays the factory pre­settings for the different positions of the air flap (here for example: for a VG 2.210 V).
The following positions for the air flap are presented:
The overall view of the menus is displayed, and the air flap positions settings menu is selected.
• Open the settings menu by pressing the key.
You must now enter the access code (see the label on the back of the display)
• Increase or decrease the value in increments by repeatedly pressing or
.
• When the first figure has been set, move the cursor to the right by pressing .
• Repeat the operation until you reach the last figure.
• Confirm the access code by pressing
- ignition position (when the menu is opened, the curser goes to this position)
- the position of the air flap at minimum pressure
- the position of the air flap at maximum pressure
Modifying a settings value for the servomotor position:
- To modify the value of a position, move the cursor to the corresponding location with the or key.
- Select the value to be modified using the key, the selected value will flash.
- Increase or decrease the value in increments of 0.1° by repeatedly pressing or . For large modifications, press and hold the or key the value will scroll quickly up or down.
- Confirm the new value using the key. The value stops flashing.
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Commissioning
Pre-setting without flame General advice before starting the burner
End of presetting menu without flame
When all the positions of the servomotor have been determined according to the required settings, it is then possible to move on to the next section for commissioning - "Setting the flame".
To do this, place the cursor in the lower part of the screen on the symbol and confirm by pressing the key.
If it is necessary to quit the menu without saving the pre-settings, position the cursor on the symbol and confirm with the key.
Optimising combustion values
Optimum combustion values can be achieved by adjusting the position of the turbulator (dimension Y) if necessary. Doing this can have an effect on starting characteristics, pulsation and combustion values. Any reduction in dimension Y increases the CO However, starting characteristics become harsher. Compensate for the change in airflow if necessary by adjusting the air flap position.
Precautions: To avoid condensation, observe the minimum required flue gas temperature specified by the boiler manufacturer and comply with the requirements for flue gas ducts.
Risk of deflagration
Continuously check CO, CO and soot emissions when adjusting. Optimise combustion values if CO is present. The CO level must not exceed 50 ppm.
value.
2
2
Function check
Flame monitoring must be checked for safety as part of initial commissioning and also after servicing or if the system has been out of operation for any significant period of time.
- Starting attempt with gas valve closed: once the safety time has elapsed, the control and safety unit should indicate a lack of gas or switch to malfunction mode.
- Starting with the air pressure switch closed: after an 8-second test period, the burner switches to malfunction mode.
- Starting attempt with air pressure switch open: after a 60-second waiting period, the control and safety unit locks.
- Starting attempt with brief opening of the air pressure switch during pre­ventilation: the control and safety unit restarts the pre-ventilation programme (air pressure detected again within 60 seconds) ; otherwise a lockout occurs.
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Commissioning
Setting the flame
- If the boiler heating request is not present, the boiler
remains on standby.
In this case, it is still possible to return to the previous setting menu "Pre-setting without flame". To do this, position the cursor on the symbol and confirm with the key.
- If a boiler heating request is present (T1-T2 contact closed), the burner starts.
The air flap is opened to move to the pre-ventilation position.
Air pressure switch test
The air flap switches to the ignition/pre-ignition position.
The fuel valve opens.
Awaiting flame signal
If no flame is detected at the end of the safety time, the
control unit switches to malfunction mode.
Pre-ventilation
If the flame is detected
Flame stabilisation
The control unit awaits the regulation authorisation.
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Commissioning
Setting the flame
Setting the minimum pressure
If the flame has been detected and stabilised, the control unit sets the burner to minimum power as soon as it receives the regulation authorisation.
- Check the combustion values (CO, CO (see page16).
- Read the ionisation current value.
- Read the gas flow rate on the gas counter.
Modification of the air flow via the "manual output control"
The "manual output control" function allows the burner output to be modified. To do this, position the cursor on the corresponding line on the display and confirm with the key. It is then possible to adjust the burner output upwards or downwards using the , keys.
The servomotor reacts in real time. This is why the combustion values must be continuously
monitored.
Where required, correct the burner power through the fan speed (UL parameter) and/or by the opening of the air flap.
Precautions: The fan speed must not go below 30 Hz at partial load (value read on the display of the converter).
, soot test). If necessary, adjust screw N on the valve
2
Setting the maximum output
Slowly increase the burner to the maximum output using the "manual power control" function. At this point, adjust the gas flow using the regulator V on the gas train. The preset limit values for the minimum output and the maximum output cannot be exceeded. If necessary, exit the "manual output control" function again using the key and modify the limit value for the maximum or minimum output. Where required, correct the burner power through the fan speed (LL parameter) and/or by the opening of the air flap.
Precautions: The fan speed must not exceed 50 Hz at full load (value read on the display).
Definitive limitation of the maximum output position
Limit the maximum opening of the air flap according to the position determined for the maximum output. In this example, the new position determined for the maximum output is below the value set manually. Using the "manual output control" function, it is now possible to reduce the burner output, but this cannot be set above the new maximum position, which here is 50°.
Definitive limitation of the minimum output position
Using the "manual output control" function, reduce the burner output to the minimum output. If necessary, limit the minimum output position, in the same way as for the maximum output.
Specific function: ignition checking
If the ignition position has been modified, it is possible to carry out a new burner start-up to check the new ignition position, without having to quit the settings menu. To do this, after modifying the ignition position, position the cursor on the symbol, and initiate the new start-up using the key.
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Commissioning
Setting the flame Operating mode
Closing the "Setting the flame" menu
The burner setting is now complete. If necessary, it is possible to again correct each of the settings values. To do this, position the cursor on the value to be modified, using the or key.
Otherwise, at any point, there are 3 possible ways of closing the "Setting the flame" menu, as follows:
- either restart the burner setting procedure, passing through the presetting phase (without entering a password). To do this, position the cursor on the symbol and confirm with the key. All the settings values already saved therefore remain available. This is essential for testing a new ignition position.
- or: Save the fixed values and end the setting procedure. To do this, position the cursor on the symbol and confirm with the key . The burner is then ready to operate and can now be controlled by the boiler regulation.
- or: Quit the settings menu without reaching the end of the setting procedure. To do this, position the cursor on the symbol and confirm with the key . All the servomotor positions saved up to this point are recovered by calling up the settings menu again.
Pulsations optimisation
If some pulsations are observed , due to furnace or chimney configurations, it is possible to change valve operation behaviour by fitting the nozzle D on the valve, between pL fitting and the pressure take-off tube.
Operating mode - Display of the operating status, the flame signal and the operating time
After setting of the burner has been completed, it switches to operating mode.
The burner's instantaneous operating status (operation at minimum or maximum power) is shown by the cursor.
The lower cell shows the intensity of the signal. The display range is from 0 µA to 7 µA. A good quality signal is above 7 µA. The following limit values are valid:
• When checking an unwanted flame: the signal must be < 0.7 µA
• During the safety time: the signal must be > 1.0 µA
• During operation: the signal must be > 0.9 µA
The cell at the bottom right displays the current operating time of the burner.
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Commissioning
Air regulation
Air regulated via frequency converter
The fan speed is controlled via the frequency converter, depending on the position of the air damper. The minimum and maximum fan speed are set via the LL and UL parameters as a frequency (50 Hz ~ 2800 U/min). Depending on the reduced position of the air damper, the frequencies set within the LL and IL parameters are not fully obtained during operation. During operation, the actual frequency is shown in the display of the frequency converter.
Converter control panel
RUN button : starts running if the
function is configured
Door
Example: The operating speed of the fan must not exceed 50 Hz.
Four "7-segment" displays
STOP button : stops the motor . Allows to reset a fault.
MODE button
Switches between the different modes. The MODE button is only accessible with the door open.
Jog dial
- Acts as a potentiometer in local mode.
- For navigation when turned clockwise or counterclockwise
- and selection / validation when pushed.
Action Display Description
0 Displays the operation frequency (operation stopped).
AUH Displays the first basic parameter [History (AUH)].
CMOd Turn the setting dial, and select "CMOd".
1 Press the center of the setting dial to read the parameter value.
0 Turn the setting dial to change the parameter value to 0 (terminal block).
0<->CMOd Press the center of the setting dial to save the changed parameter.
(Standard default: 1).
CMOd and the parameter set value are displayed alternately.
EASY button : switches to the easy setting mode : the converter displays only the most frequently used parameters.
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Factory setting
Parameter Function
VG 2.210 V
Unit
CMO d C om m and m ode 0 -
FMO d Frequency setting m ode 0 -
ACC Acceleration 5 s
dEC Deceleration 5 s
FH Maxim un frequency 50 Hz
UL Upper lim it frequency 50 Hz
LL Lower limit frequency 25 Hz
Pt V/F control m ode 1 -
Sr1 Preset speed 1 25 Hz
Menu S ub-m enu Param eter Function Unit
F201 V/I input point 1 s etting 0 %
F202 V/I input point 1 frequency 30 Hz
F203 V/I input point 2 s etting 98 %
F204 V/I input point 2 frequency 50 Hz
Menu S ub-m enu Param eter Function Unit
F701 Current/Voltage unit 1 -
Menu S ub-m enu Param eter Function Unit
F405 Motor rated pow er 0,25 kW
F415 Motor rated current 1,20 A
F417 Motor rated speed 2900 rpm
Menu
Main
Main
F2--
Main
F4--
Main
F7--
en
Commissioning
Air regulation
Setting the LL and UL parameters
For the operation VG 2.210 V, all parameters are pre set at the factory, so that it’s only necessary, without exception, to adjust the settings LL, UL parameters.
Abstract of parameters list
Only are represented the parameters required for the operation of the burner, as well as those who differ from the pre factory settings provided by the manufacturer.
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Commissioning
Setting the gas pressure switch Setting the air pressure switch Saving the adjustment values in the display
Setting the gas pressure switch
• To set the switch-off pressure: remove the cover from the gas pressure switch.
• Install a gas pressure pBr measuring instrument.
• Start the burner. Switching to maximum power.
• Reduce the pressure upstream of the gas train by gradually closing the manual valve, until
- the gas pressure pBr upstream of
the gas train drops
- the stability of the flame is reduced
- the CO level increases
- or the flame signal deteriorates
considerably
Réglage du manostat d’air
• Installer un appareil de mesure de pression. Pour cela, installer un raccord en T dans le tube d’air.
• Mettre le brûleur en fonctionnement à la puissance minimale.
• Régler le point de coupure environ 15% en dessous de la pression de coupure constatée.
• Turn the dial clockwise until the gas pressure switch shuts down the burner.
• Continue turning the dial clockwise to set the gas pressure switch to 10% above the shutdown value determined above.
Checking the switch-off pressure
• Open the manual shut-off valve
• Start the burner
• Close the manual shut-off valve
The gas failure procedure should start without the control unit locking.
Saving the adjustment values in the display
If the burner setting procedure has been successfully completed, the servomotor positions for all the operating states will be fixed in the control unit. It is possible to store a backup copy of the values in the display. To do this, press the key , the screen opposite is displayed. Using the key select the menu "Save adjustment values" and confirm with the key .
The screen opposite appears. Place the cursor on the symbol , press the key to begin loading the adjustment values from the control unit to the display.
At this point, it is possible to:
- store the values in the display; to do this place the cursor on the symbol and confirm with the key.
- quit the menu without storing the data, with the symbol.
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en
Servicing
Maintenance
Burner and boiler servicing must only be carried out by a professionally qualified heating engineer. The system operator is advised to take out a maintenance contract to guarantee regular servicing. Depending on the type of installation, shorter maintenance intervals may be necessary.
• Before all maintenance and cleaning work, switch off all electrical power supplies (7P socket + separate motor power supply).
• Use original spare parts.
Work recommended as part of annual burner maintenance:
- Burner test run, input measurement in the boiler room
- Clean the combustion components and replace defective parts if necessary
- Clean the fan wheel and the blower
- Clean the gas filter; replace it if necessary
- Visual inspection of the burner's electrical components; eliminate malfunctions if necessary
- Check burner start characteristics
- Leakage test
- Burner safety devices function check (air pressure/gas pressure switches)
- Flame monitor and automatic combustion control unit function check
- Commissioning the burner
- Check the gas flow
- Correct the adjustment values if necessary
- Draw up a measurement report
General checks
- Emergency stop button function check
- Visual inspection of gas lines in the boiler room
Checking the mixing unit
• Remove the burner hood.
• Disconnect the ignition cable on the transformer side.
• Loosen the three cover screws W.
• Remove the cover.
• Loosen lock nut E on the gas pipe bracket
• Loosen the retaining bolt.
• Remove the mixing unit.
• Check the condition of the baffle plate.
• Check the position of the ignition electrode and the ionisation sensor.
• When refitting, make sure that the cable is routed correctly and that O-ring J2 is correctly seated.
• Check for leaks.
Cleaning the fan wheel
• Remove the equipment plate and attach it in the service position (see illustration).
• Remove and clean the fan wheel and replace it if necessary. Reassemble in the reverse order.
Fitting the fan wheel
When changing the motor or the fan wheel, refer to the positioning diagram opposite. The internal flange A of the fan wheel must be aligned with plate B. Insert a ruler between the vanes of the fan wheel and bring A and B to the same height. Tighten the cone-point screw on the fan wheel.
Resetting the maintenance indicator
The maintenance symbol appears on the control unit display after 30,000 start-ups. This is why it is necessary to reset the maintenance counter after each service. To do this, press the control unit unlocking button for at least 9 seconds.
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Servicing
Maintenance
Replacing the flame tube
It is necessary to remove the burner for this work.
• Loosen the clamping screw on the connecting flange.
• Turn the burner out of the bayonet socket, lift it slightly and pull it out of the connecting flange.
• Place the burner on the floor.
• Loosen the 4 screws S on flame tube.
• Pull the flame tube out towards you.
• Fit and secure the flame tube.
The flame tube may be very hot
Filter replacement
• The filter element of the multiblock must be checked at least once a year and replaced if clogged.
• Loosen the screws of the filter cap on the multiblock.
• Remove the filter element and clean its housing.
• Do not use any pressurised cleaning products.
• Replace the filter element with a new element.
• Screw the cover back into place.
• Reopen the manual shut-off valve.
• Check it is airtight.
• Check the combustion values.
Cleaning the air intake box
• Unscrew securing screws V on the air intake box.
• Remove and clean the air intake box. Reassemble in the reverse order.
• Note the correct position of the air flap and the servomotor.
Cleaning the cover
• Do not use abrasive products or products containing chlorine.
• Clean the cover with water and a suitable cleaning product.
• Refit the cover.
Precautions After any operation: check the combustion performance under real operating conditions (doors shut, cover fitted etc.). Record the results in the relevant documents.
Checking the flue gas temperature
• Check the flue gas temperature at
regular intervals.
• Clean the boiler if the flue gas
temperature is more than 30 °C above the value measured at the time of commissioning.
• Use a flue gas temperature gauge to
make the check easier.
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en
Servicing
Troubleshooting
Malfunction diagnosis and repair
In the event of a malfunction, first check that the prerequisites for correct operation are fulfilled:
1. Is there any current?
2. Is there gas pressure?
3. Is the gas shut-off valve open?
4. Are all control and safety devices, such as the boiler thermostat, low water detector, limit switches, etc. correctly set?
If the fault is still present, check that each of the burner components is operating. Important safety components must not be repaired; these components must be replaced by parts with the same part number.
Symbol Observation Cause Corrective action
Burner does not start after thermostatic closure. No malfunction indicated on the control and safety unit.
No heat requested. Thermostats defective or
Only use original spare parts. Switch off the power supply before carrying out maintenance or cleaning.
After any work on the system:
• Under normal operating conditions (doors closed, cover fitted, etc.), check combustion and check the individual lines for leaks.
• Record the results in the relevant documents.
Drop in supply voltage or power failure.
Control unit malfunction.
incorrectly adjusted
Check the cause of the drop in voltage or the power failure.
Replace the control unit.
Adjust the thermostats, replace if necessary.
The burner starts briefly when switched on, then switches off and the red indicator light comes on.
Burner does not start. Air pressure switch: not in rest
Burner does not start.
Gas pressure normal
The control unit has intentionally been manually locked.
position. Incorrect adjustment
Contact welded
Insufficient gas pressure.
Gas pressure switch wrongly set or defective
Unlock the unit.
Readjust the pressure switch. Check the wiring. Replace the pressure switch.
Check the gas lines. Clean the filter. Check the gas pressure switch or replace the compact gas unit.
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Servicing
Troubleshooting
Symbol Observation Cause Corrective action
Burner blower starts up. Burner does not start.
Burner blower starts up. Burner does not start.
The burner starts, the ignition switches on, then failure
Air pressure switch: Contact does not close.
Flaring during pre-ventilation or pre-ignition.
No flame at the end of the safety time.
Gas throughput set incorrectly. Malfunction in flame monitoring system
Incorrect polarisation (live/neutral position) of the power supply on the 7P connector/socket
Readjust the pressure switch. Check the wiring. Replace the pressure switch.
Check the valve. Check flame monitoring.
Adjust the gas flow stage Check the condition and position of the ionisation probe in relation to earth. Check the condition and connections of the ionisation circuit (cables and measurement bridge).
Check that the polarisation of the 7P connector is correct.
No ignition sparks. Electrode(s) short-circuited.
Ignition cable(s) damaged or defective.
Igniter defective. Control and safety unit
Solenoid valves do not open.
The burner switches off during operation.
Servomotor fault Clogging of the air flap
Valves jamming. Air pressure switch: contact opens during start-up or during operation.
Flame failure during operation.
Locking of the air flap Internal fault with the servomotor
Adjust, clean or replace the electrodes.
Connect or replace the cable(s).
Replace the igniter. Replace the control unit. Check the cabling between the control unit and external components.
Replace the compact gas unit.
Replace the valves. Adjust or replace the pressure switch.
Check the ionisation probe circuit Check or replace the control and safety unit.
Replace the servomotor
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en
Servicing
Maintenance Troubleshooting of the frequency converter
Maintenance
The converter does not require any preventive maintenance. However, the following should be performed at regular intervals:
- check the condition and tightness of the connections,
- ensure that the temperature in proximity to the device is acceptable, and that there is adequate ventilation (average service life of blowers: 3 to 5 years depending on the operating conditions),
- remove dust from the drive if necessary.
Failure Cause Corrective action
OC1
OC2 OC3
OCL
EPH1
OP1 OP2
OP3
OL1
OL2 OL3
OT oh e
Overcurrent during acceleration Ramp too short. Increase the acceleration time ACC.
Overcurrent during deceleration Ramp too short.Increase the deceleration time dEC.
Overcurrent during constant speed operation Reduce the load fluctuation.
Overcurrent (An overcurrent on the load side at start-up)
A phase failure occured in the input line of the main circuit or the capacitor in the main circuit lacks capacitance
Overvoltage during acceleration System voltage too high. Check system voltage.
Overcurrent during deceleration Increase deceleration time.
Overcurrent during constant speed operation the load causes the motor to run at a frequency higher than the
Inverter overload Check motor load, converter ventilation and environment. Wait for the
Motor overload Check the setting of the motor thermal protection and the motor load.
Main module overload The carrier frequency is high and load current has increased at low
Over-torque trip Over-torque reaches to a detection level during operation. Enable
Overheat or failure of the overheat detector Check the overheat detector. Wait for the system to cool down so that
Emergency stop -
Mass inertia or load too high. Check matching between motor/ converter/load. Mechanical blockage. Check the status of the mechanics.
Mechanical blockage. Check the status of the mechanics.
Check the load.
Check settings. Check matching between motor/converter/load. Check the status of the mechanics. Check the secondary wiring and insulation state.
Check the power connection and the fuses. Check the main circuit input line. Check/reactivate the capacitor.
Where required, fit a braking module and a brake resistor.
inverter output frequency. Install an optional brake module.
system to cool down so that restart can be performed.
Wait for the system to cool down so that restart can be performed.
speeds (mainly at 15Hz or less). Raise the operation frequency. Reduce the load. Reduce the carrier frequency.
F615. Check system error.
restart can be performed.
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Servicing
Fault diagnosis menu Operating statistics menu
Fault diagnosis menu
To access the fault diagnosis menu, press any key when the burner is ready to operate, when the burner is in operation, or when it is in malfunction mode. It is not possible to access the fault diagnosis menu during the start-up phase. The general menu screen will appear. Using the , , , or key, place the cursor on the fault diagnosis menu symbol, and confirm using the key.
The details of the last fault to appear are indicated by the flashing symbol. The flame intensity, network voltage, air flap position, number of burner start-ups as well as the operating time of the burner at the time it switched to malfunction mode are displayed underneath.
Using the keys and , it is possible to call up the details of the last 5 faults to have appeared (the fault number is displayed in the upper left corner of the display). After the details of the last 5 faults, the telephone number of the after-sales department as well as the maintenance contract number are shown (no values are entered in the factory).
• Quit the menu using the key.
Entering a telephone number for the maintenance company and the maintenance contract number
When the corresponding symbol appears on the display:
• Keep the key held down until the first figure starts to flash (a short press will exit the menu).
• Using the or key, change the figure to the required value (underscore = empty field)
• Using the key, move on to the next figure.
• When the number is complete, save using the key.
Operating statistics menu
To access the operating statistics menu, press any key, when the burner is ready to operate, when the burner is in operation, or when it is in malfunction mode. It is impossible to access the operating statistics diagnosis menu during the start-up phase. The general menu screen will appear. Using the , , , or key, place the cursor on the operating statistics menu symbol, and confirm using the key. The operating statistics menu comprises 7 screens. Navigation between the different screens is done using the keys and .
- Flame detection time for last start-up
- Average flame detection time for the last 5 start-ups
- Total number of burner start-ups
- Total number of faults
- Total number of operating hours
- Total number of operating hours at rated output
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Servicing
en
Operating statistics menu
- Total number of burner start-ups since the last meter reset
- Total number of faults since the last meter reset
- Total operating time since the last meter reset
- Total number of operating hours at rated output since the last meter reset
- Number of "unwanted flame" faults
- Number of "No flame after safety time" faults
- Number of "Flame loss during operation" faults
- Number of "Air pressure switch stuck" faults
- Number of "Air pressure switch does not close during operation" faults
- Number of "Air pressure switch switching over" faults
- Number of "servomotor" faults
• Quit the menu using the key .
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www.elco.net
Made in EU. Non contractual document.
09/2013 - Art. Nr. 4200 1053 2900A32
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