elco VG3.290 D, VG3.360 D Operating Instructions Manual

02/2011 - Art. Nr. 4200 1027 9501B

VG3.290 D
VG3.360 D

Operating instructions

For specialist installation engineers

Gas burners ........................................... 2-28

en

de, fr..................................... 4200 1021 2101

it, nl ...................................... 4200 1021 2201

............................................. 4200 1021 2002

Combustion Control ltd

02/2011 - Art. Nr. 4200 1027 9501B2

Overview

Contents

We accept no responsibility for damage
arising from:

- inappropriate use.

- incorrect installation and/or repair on the
part of the buyer or any third party,
including the fitting of non-original parts.

Final delivery and instructions for use

The firing system fitter must supply the
operator of the system with operating and
maintenance instructions on or before final
delivery. These instructions should be
displayed in a prominent location at the
point of installation of the heat generator,
They should include the address and
telephone number of the nearest customer
service centre.

Notes for the operator

The system should be inspected by a
specialist at least once a year. Depending
on the type of installation, shorter
maintenance intervals may be necessary!
It is advisable to take out a maintenance
contract to guarantee regular servicing.

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

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

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

Operation Operation, safety operation ....................................... 4

Automatic combustion control unit ......................... 5-7

Terminal allocation chart, connection socket.........8-9

MB-ZRDLE gas train............................................... 10

Assembly Burner assembly, gas train assembly ............... 11-12

Checking the combustion components................... 12

Electrical/gas connection ........................................ 13

Testing before start up ............................................ 13

Commissioning Adjustment data ..................................................... 14

Air regulation........................................................... 15

Setting the MB-ZRDLE gas train............................. 16

Pre-adjustment without flame ...........................17-18

Setting the flame ................................................ 19-21

Saving the adjustment values in the display ..........22

Servicing Maintenance ..................................................... 23-24

Troubleshooting ................................................. 25-26

Fault diagnosis menu,

Operating statistics menu .................................. 27-28

Declaration of conformity

for gas burners

We, certified company No. AQF030,
F-74106 ANNEMASSE Cedex,
declare under our sole responsibility
that the products
VG3.290 D
VG3.360 D

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 EEC Working

efficiency directive

Annemasse, 6th October 2009
M. SPONZA

Important information

VG3.290 D and VG3.360 D 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, commissioning and
maintenance must only be carried out by
authorised specialists and all applicable
directives and regulations must be
complied with.

Burner description

VG3.290 D and VG3.360 D 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 is supplied packaged in three
boxes on a pallet:

- 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 energy­efficient operation:

EN 226

Connection of fuel oil and forced-draught
gas burners to a heat generator

EN 60335-1, -2-102

Specification for safety of household and
similar electrical appliances, particular
requirements for gas burning appliances

Gas lines

When installing the gas lines and trains,
the general directives and guidelines, as
well as the following national regulations,
must be observed:
CH: - G1 instruction text from SSIGE

- EKAS form no. 1942,
liquefied gas directive, part 2

- Cantonal authority guidelines (e.g.
directives for the pilot valve)

DE: - DVGW-TVR/TRGI

Installation location

The burner must not be used in rooms with
aggressive vapours (e.g. hair spray,
tetrachloroethylene, carbon tetrachloride),
high levels of dust or high air humidity (e.g.
laundry rooms).
If no connection to an air exhaust system is
provided for the air supply, there must be a
supply air inlet measuring:
DE: up to 50 kW: 150 cm

2

per additional kW: : + 2.0 cm

2

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

150 cm2.
Variations may arise as a result of local
regulations.

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Overview

Burner description

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

(Maintenance)

7 Combustion chamber pressure

take-off pipe
8 Burner tube
10 7-pin connector

10.1 4-pin connector
18 Cover
19 Release knob
20 Hood securing screw
113 Air intake box

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Operation

Safety function

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

- the combustion chamber is monitored
to detect any 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 2

nd

stage ionisation current must be

at least 7 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 the gas pressure recovers a
sufficient value, burner starts again.

During the regulator shutdown

- The control thermostat interrupts the
heat request.

- The gas valves close

- The flame goes out

- The burner is ready for operation

Compact train

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 (mark 1).

F4 Gas pressure switch
F6 Air pressure switch
Y12 Safety solenoid valve
Y13 Solenoid valve, 1st stage
Y14 Solenoid valve, 2nd stage
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

Combustion Control ltd

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Operation

TCG 2xx control unit



The TCG 2xx 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

… causes …

... 1 second ... the control unit to

unlock.

... 2 seconds ... the control unit to

lock.

... 9 seconds ... the statistics to

be deleted

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).

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.

Screen Description Screen Description

Awaiting the heat request from

the boiler

Opening the gas valve and

safety time

Air flap is forced open for pre-

ventilation.

Flame is present, awaiting
authorisation of regulation

Pre-ventilation

Burner in operation. The lower

cell shows the strength of the

signal and the operating time of

the burner.

Closing the air flap to the ignition

position, pre-ignition

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Combustion Control ltd

02/2011 - Art. Nr. 4200 1027 9501B6

Operation

TCG 2xx control unit

• menu for setting the
servomotor,

• menu for storing the
servomotor setpoints in
the display

• menu for consulting
faults

• menu for statistical data

In parallel with its control and safety
functions, the TCH2xx control unit
allows the following to be set:
(see illustration)

- the position of the air flap during
ignition

- the position of the air flap during the
1st stage

- the opening position of the stage 2
valve (for switching from 1st to 2nd
stage)

- the position of the air flap during the
2nd stage

- the closing position of the stage 2 air
flap (for switching from 2nd to 1st
stage).

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 7
menus:
(The menu on the bottom right is not
activated in VG3.290 D and VG3.360 D
burners)

• menu for setting/
adjusting the standard
configurations.

• menu for setting
industrial applications

• menu for manual control

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 this menu are available
on request.

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Operation

TCG 2xx control unit

Operating cycle phases:

1: No voltage
2: Powering up, no heat request
3: Checking the air flap is closed
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: End of pre-ventilation
8: Air flap closes to the ignition position
9: Switching on the igniter, unauthorised

flame monitoring
10:Starting the burner: Opening of the

solenoid valve, flame formation,

safety time: max. 3 s.
11:Awaiting regulator release
12:Opening the air flap, until the opening

position of the 2

nd

stage valve is

reached
13:Operation in 2

nd

stage

14:Closing the air flap, until the 2

nd

stage valve reaches the closed

position
15:Operation in 1

st

stage

16:Regulator shutdown, closure of the

air flap to 0°
17:Awaiting a new heating request

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Earth

Flame check

Fault
display

Air
pressure
switch

Igniter

Burner motor

Connector

Terminal

Terminal

Connector

Remote
unlocking

L1 power
supply

Solenoid valve

2nd stage
thermostat

Heating
request

Earth

Gas
pressure
switch

Operation

Terminal allocation chart
230 Volt connection

Terminal Description Connector Terminal Description Connector

1 Burner motor phase

4

20 1st stage thermostat live (T1)

19

2 Earth 21 Heating request signal (option T2)

3 Neutral 22 Flame monitoring signal

11

41st stage solenoid valve live

2

23 Earth

5 Neutral 24 Live

6 Earth 25 Air pressure switch signal

10

7 Live 26 Live

82

nd

stage solenoid valve live 27 Live

20

9 Live L1

6

28 Remote unlocking signal

10 Earth 29 Neutral

21

11 Neutral 30 Signal fault live

12 Earth 31 Live

8

13 Earth 32 Live

14 Igniter live

5

33 Not used

34

15 Earth 34 Not used

16 Neutral

17 Live for the 2

nd

stage thermostat

T6/7/8

18 Signal T7

19 Signal T8

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Display-PC interface

Air servomotor

Connector

Terminal

Terminal

Connector

Terminal Description Connector Terminal Description Connector

1 not used

30

18 not used

14

2 not used 19 not used
3 not used 20 not used
4 not used

27
28
29

21 not used
5 not used 22 not used
6 not used 23 not used
7 not used 24 not used

33

8 not used 25 not used
9 not used 26 not used

32

10

Display or PC interface

16

/

17

27 not used

11 28

Air servomotor

15

12 29
13 30
14 31
15 32
16 33
17

Operation

Terminal allocation chart
Low voltage connections

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Setting the hydraulic brake

Setting the 2nd stage

Setting the 1st stage

Gas pressure
switch

Solenoid valve
coil

Filter ca p

Connecting
flange

Adjusting screw of
the gas pressure
regulator

pBr (4 - 20 mbar)

Locking
screw

Sealed
screw

Operation

MB-ZRDLE gas train

MBZRDLE... B01S.. (dual-stage)

Compact unit consisting of:
filter, adjustable pressure switch, non­adjustable rapid opening and closing
safety valve, adjustable pressure
regulator, main valve (first and second
stage) with adjustable throughput and
hydraulic brake, plus rapid closing.
Default setting:

- Flow rate 1

st

stage and 2nd stage, set

to maximum.

- Ignition flow rate and pressure
regulator set to minimum.

Technical data

Input pressure 360 mbar max.
Ambient temperature -15 to +70 C°
Voltage 230 V/ 50 Hz
Absorbed output 60 VA
Protection level IP 54
Gas connection 3/4" Rp or 1" 1/4 Rp
Assembly position:

- Vertical with coil facing upwards

- Horizontal with coil hidden

Pressure regulator setting

The adjusting screw has a path of 60
turns for adjusting the output pressure.
Three turns clockwise or anticlockwise
increases or reduces pressure by
1 mbar respectively.
At commissioning:

• Turn the screw at least 10 turns
clockwise (+)

• Then fine tune the adjustment (more or
less pressure)

• Checking the gas pressure on the
pressure tap 119pBr.

Setting the ignition throughput

• Unscrew plastic cap B.

• Turn it over and use it as a tool for
turning the adjusting screw (three
turns to adjust from minimum to
maximum throughput)

• Reduce the ignition throughput by
turning the screw clockwise, reduce it
by turning it anti-clockwise.

Adjusting the nominal flow rate

• Unscrew the locking screw (the sealed
screw must not, however, be
unscrewed)

Setting the gas throughput for
the 2

nd

stage

• Reduce nominal gas throughput by

turning adjusting knob C, anti­clockwise (located on the upper
section of the solenoid coil). Turning
clockwise increases throughput.

Setting the gas throughput for
the 1

st

stage

By hand (not tool).

• Reduce gas throughput by turning ring
D clockwise (located on the lower
section of the solenoid coil). Turn anti­clockwise to increase gas throughput.

Combustion Control ltd