Page 1
03/2013 - Art. Nr. 4200 1032 7200A
VG4.460 DP
VG4.610 DP
Operating instructions
For specialist installation engineers
Gas burners ...........................................2-28
en
de, fr.....................................4200 1032 7000
it, nl ......................................4200 1032 7100
............................................. 4200 1032 6900
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03/2013 - Art. Nr. 4200 1032 7200A2
Overview
Contents
Declaration of conformity
for gas burners
We, certified company No. AQF030,
F-74106 ANNEMASSE Cedex, declare
under our sole responsibility that the
products
VG4.460 DP
VG4.610 DP
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
2009/142/EC Gas appliances
directive
2004/108/EC EMC directive
2006/ 95/EC Low voltage directive
92/ 42/EEC EEC Working
efficiency directive
Annemasse, 1st December 2010
M. SPONZA
Overview Contents....................................................................2
Important information................................................2
Burner description..................................................2-3
Operation Operation, safety operation.......................................4
Control and safety unit...........................................5-7
Terminal allocation chart,
connection socket..................................................8-9
MB-VEFgas train.....................................................10
Assembly Burner assembly, gas train assembly................11-12
Checking the combustion components...................13
Electrical/gas connection........................................14
Testing before commissioning ................................14
Commissioning Adjustment data .................................... ... ..............15
Air regulation...........................................................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
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.
Important information
VG4.460 DP and VG4.610 DP 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
VG4.460 DP and VG4.610 DP 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 aut hority 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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03/2013 - Art. Nr. 4200 1032 7200A 3
Overview
Burner description
A1 Control and safety unit
A4 Display
F6 Air pressure switch
K1 Auxiliary motor supply relay
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
10.2 3-pin connector (auxiliary motor
supply relay)
18 Cover
19 Release knob
20 Hood securing screw
113 Air intake box
en
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03/2013 - Art. Nr. 4200 1032 7200A4
Compact train
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
- 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
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).
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
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03/2013 - Art. Nr. 4200 1032 7200A 5
en
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
Operation
TCG 5xx control unit
The TCG 5xx 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
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).
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03/2013 - Art. Nr. 4200 1032 7200A6
• menu for setting the
servomotor,
• menu for storing the
servomotor setting
points in the display
• menu for consulting
faults
• menu for statistical data
Fonctionnement
Coffret de sécurité TCG 5xx
In parallel with its control and safety
functions, the TCG5xx 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
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 VG4.460 DP
and
VG4.610
DP 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
these menus are
available on request.
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03/2013 - Art. Nr. 4200 1032 7200A 7
en
Operation
TCG 5xx 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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03/2013 - Art. Nr. 4200 1032 7200A8
Operation
Terminal allocation chart
230 Volt connection
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 Description Connector Terminal Description Connector
1 Burner motor live
4
20 Minimum output thermostat live (T1)
19
2 Earth 21 Heating request signal (option T2)
3 Neutral 22 Flame monitoring signal
11
4 Solenoid valve live
2
23 Earth
5 Neutral 24 Live
6 Earth 25 Air pressure switch signal
10
7 Solenoid valve live 26 Live
8 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 Control thermostat live
T6/7/8
18 Signal T7
19 Signal T8
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03/2013 - Art. Nr. 4200 1032 7200A 9
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Operation
Terminal allocation chart
Low voltage connections
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
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03/2013 - Art. Nr. 4200 1032 7200A10
Operation
MB-VEF gas train
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 54
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
11 Connection for pressure pipe pBr,
R1/8
12 Outlet flange
13 Pressure take-off pipe pBr
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03/2013 - Art. Nr. 4200 1032 7200A 11
Ø a Ø b c d
190-240 200-270 M10 45°
en
Assembly
Burner assembly
Preparing the boiler front
• Prepare the burner mounting plate/
boiler door in accordance with the
diagram.
• Establish the internal diameter a of
190-240 mm.
• To mount the burner head bracket, drill
four M10 holes (drill diameter 200 to
270 mm) as shown in the diagram
opposite.
Burner head assembly
• Screw the bolts into the burner fixing
plate/boiler door and position the
insulation material. For a drill hole of
< 270 mm, elongated slots should be
cut to the required dimensions.
• Remove the combustion components
from the head
• Attach the burner head with 4 nuts
(ref. 4). At this point, check that the
gas connection flange is correctly
positioned (on the left or right).
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.
The furnace pressure take-off pipe pF
must not be clogged.
Exhaust gas evacuation system
To avoid unpleasant noise emissions,
right-angled connectors should not be
used on the flue gas side of the boiler.
Fitting the burner body
• Remove the cover (2 screws W).
• Unscrew the two screws Z on the
burner body completely.
• Bring the burner body into contact after
having swivelled it at least 15° to the
left.
• Engage the two screws Z on the body
into the two lugs provided.
• Tighten the 2 screws.
For assembly in the position with
the volute facing upwards, unclip
the display, turn it over 180°, and
refit it.
On boilers with reverse firing, minimum
flame tube insertion depth A should be
observed as per the boiler
manufacturer's instructions.
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03/2013 - Art. Nr. 4200 1032 7200A12
Gas train assembly
• Check the correct position of the
O-ring B in the gas connecting flange
C.
• 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.
• Connect the power cable to the gas
train.
Assembly
Gas manifold
Pressure take-off pipes
Connecting pressure take-off pipes
pF and pL
• Connect the furnace pressure take-off
pL on the burner body 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 body 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.
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03/2013 - Art. Nr. 4200 1032 7200A 13
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Checking the burner head
• Check the adjustment settings of the
ionisation probe and of the ignition
electrode as per the diagrams.
Setting to liquid gas operation
• Remove the gas diffuser 5 and the
turbulator 2.
• Remove adaptor 3.
• Fit the adaptor 6 (supplied with the
housing) on the gas burner head.
• Turn the gas diffuser 5 180° and refit it.
• Refit the turbulator 2 and the 3 spacers
4, using the 3 new screws 1 provided.
Assembly
Checking/adjusting the burner head
Check the radial position of the flame
tube
After untightening the three mounting
screws S, it is possible to change the
position of the flame tube using the lever
H. Nitrogen oxide emissions may be
affected by the radial position of the
flame tube
• To be set at the start to position 1.
Fitting the combustion components
• Check that the O-Ring J1 is in the
correct position in the gas elbow.
• Insert the combustion components
into the head, tighten the mounting
screw X using an Allen key, then
tighten the lock nut using an openended spanner.
• Thread the ionisation cable IK and the
ignition cables ZK into the grommets
R and S.
• Remove the cover.
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03/2013 - Art. Nr. 4200 1032 7200A14
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.
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
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).
Assembly
Gas connection
Electrical connection
Checks before commissioning
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
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.
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, pressu re
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.
• 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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03/2013 - Art. Nr. 4200 1032 7200A 15
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Commissioning
Adjustment data
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 15 mbar.
Setting the air pressure switch
• Remove the transparent cover.
• Provisionally set to 1 mbar.
Mini. Maxi. Ignition Mini. Maxi. G20 G25 G20 G25 G31 G20 G25 G31
100 200 15 2
5525 - -
1,2 / 0 1,4 / 0 1,2 / 0 1,7 / -0,5 1,7 / 0 1,5 / 0
200 300 20 3 20 20 40 - -
1,2 / 0 1,5 / 0 1,2 / 0 1,7 / 0 2 / 0 1 ,5 / 0
300 4 00 30 4 20 30 90 - - 1,2 / 0 1,5 / 0 1,2 / 0 1,7 / 0 2 / 0 1,5 / 0
186 371 30 3 7 13 15 40 1,5 / -0,3
1,7 / -0,5 1,4 / 0
1,5 / 0 1,5 / -0,5
1,5 / 0 1,7 / 0,5 1 ,5 / 0
224 446 30 4 2 13 20 52
1,5 / -0 ,3 1,7 / -0,5 1,4 / 0 1,5 / 0 1,5 / -0,5 1,5 / 0 1,7 / 0,5 1,5 / 0
260 521 40 4 7
13 21 90 1,5 / -0,3 1,7 / -0,5 1,4 / 0
1,5 / 0 1,5 / -0,5
1,5 / 0 1,7 / 0,5 1 ,5 / 0
Furnace
pressure
pF
(m bar)
MB-VEF420 MB-VEF412
Gas valve setting
Screw V / Screw N
VG 4.460
DP
VG 4.610
DP
A ir flap se tting
MB-VEF40
7
Burner
power
Dimension
Y
(mm)
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03/2013 - Art. Nr. 4200 1032 7200A16
Commissioning
Air regulation
Gas valve adjustment
Air regulation
Combustion air is regulated at two
points:
• on the pressure side, using the gap
between the turbulator and the burner
tube.
• on the vacuum side, by the air flap
driven by servomotor Y10.
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 CO2 turn upwards on the
scale.
- For less CO
2
turn downwards on the
scale.
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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.
Important
At this point, no setting position for the
servomotor has been defined, therefore
the burner cannot be started under
these conditions.
• For the next step, press any
button.
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
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 VG4.460 DP).
The following positions for the
air flap are presented:
- 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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03/2013 - Art. Nr. 4200 1032 7200A18
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
2
value.
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 com ply with
the requirements for flue gas ducts.
Risk of deflagration
Continuously check CO, CO
2
and soot emissions when
adjusting. Optimise
combustion values if CO is
present. The CO level must
not exceed 50 ppm.
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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en
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
Pre-ventilation
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.
If the flame is detected
Flame stabilisation
The control unit awaits the
regulation authorisation.
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03/2013 - Art. Nr. 4200 1032 7200A20
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
2
, soot test). If necessary, adjust screw N on the valve
(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 th e
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.
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 regu l a to r 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.
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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en
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 pr esetting 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.
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 ma ximum power) is
shown by the cursor.
The lower cell shows the intensity of the signal. The display range is from 0 µA to 13 µA. A good
quality signal is above 8µA.
The following limit values are valid:
• When checking an unwanted flame: the signal must be < 0.7µA
• During the safety time: the signal must be > 1.0µA
• During operation: the signal must be > 8µA
The cell at the bottom right displays the current operating time of the burner.
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03/2013 - Art. Nr. 4200 1032 7200A22
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
• 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.
Setting the air pressure switch
• Install a pressure measuring device.
To do this, install a T union in the air
tube.
• Set the burner to its maximum
operating power.
• Set the switch-off point to
approximately 15% below the switchoff pressure read.
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. A back-up copy of the values is therefore stored in
the display.
In order to visualize them, press the button , the screen opposite
is displayed. Using the button select the menu "Save
adjustment values" and confirm with the button .
The screen opposite appears. The adjustment data have been
stored in the display.
At this point, it is possible to exit the menu in one of two ways:
- positioning the cursor on the symbol and confirm with the
button.
- using the symbol.
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03/2013 - Art. Nr. 4200 1032 7200A 23
en
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
Servicing
Maintenance
Burner and boiler servicing must on ly
be carried out by a professional
heating engineer trained in these
operations. 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.
Checking the combustion
components
• Remove the burner hood.
• Remove the two screws W from the
cover.
• Remove the combustion components.
• Check the ignition electrodes and the
ignition cables; replace if necessary.
• Clean the turbulator.
• Check adjustments and settings
during assembly.
Removing the plate
• To do this, unscrew but do not remove
the 2 screws
X
securing the motor plate.
• Turn the plate (bayonet system),
carefully remove it and hang it in the
maintenance position (see
illustration).
• Clean the housing, fan wheel and
recirculation unit, and check that they
are not damaged.
• If necessary to clean it, remove the air
recycler; to do so, remove the screw Z
then unclip it.
• Clean the turbine and check it is not
damaged.
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.
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03/2013 - Art. Nr. 4200 1032 7200A24
Servicing
Maintenance
Replacing the flame tube
For this operation, it is necessary to
either open the furnace gate or remove
the burner.
- Variant 1 - Access via the furnace gate
• Remove the burner head
• Loosen the 3 securing screws S on the
flame tube support by 1 to 2 turns.
(Allen 3).
• Open the combustion chamber door.
• Take out the flame tube, check it,
clean it and, if it is deformed, replace
it.
• Proceed in the reverse order for
refitting.
• Fill in the space between the furnace
gate and the burner tube with fireresistant material.
• Close the furnace gate.
- Variant 2 - Removing the burner
• Remove the burner head.
• Loosen the electrical connections.
• Loosen the burner housing (2 M8
screws) and remove. Do not damage
electrical cables.
• Unscrew the burner head and then
proceed as under variant 1.
• Proceed in the reverse order for
refitting.
The flame tube may be 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 box
First check that the air flap is in the
closed position (0°), before
removing it (2 screws V).
• Unscrew the three securing screws T
in the base of the housing by a few
turns.
• Shift the air intake box 113 to the right
to release the screws (bayonet).
• Remove the air intake box, clean it and
refit it in reverse order.
• Check that the air flap and the
servomotor are correctly positioned.
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 abov e
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.
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.
Symbol Observation Cause Corrective action
Burner does not start after
thermostatic closure.
No malfunction indicated on the
control and safety unit.
Drop in supply voltage or power
failure.
Control unit malfunction.
Check the cause of the drop in
voltage or the power failure.
Replace the control unit.
No heat requested. Thermostats defective or
incorrectly adjusted
Adjust the thermostats, replace if
necessary.
The burner starts briefly when
switched on, then switches off and
the red indicator light comes on.
The control unit has intentionall y
been manually locked.
Unlock the unit.
Burner does not start. Air pressure switch: not in rest
position.
Incorrect adjustment
Contact welded
Readjust the pressure switch.
Check the wiring.
Replace the pressure switch.
Burner does not start.
Gas pressure normal
Insufficient gas pressure.
Gas pressure switch wrongly set or
defective
Check the gas lines.
Clean the filter.
Check the gas pressure switch or
replace the compact gas unit.
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03/2013 - Art. Nr. 4200 1032 7200A26
Symbol Observation Cause Corrective action
Burner blower starts up.
Burner does not start.
Air pressure switch: Contact does
not close.
Readjust the pressure switch.
Check the wiring.
Replace the pressure switch.
Burner blower starts up.
Burner does not start.
Flaring during pre-ventilation or
pre-ignition.
Check the valve. Check flame
monitoring.
The burner starts, the ignition
switches on, then failure
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
No ignition sparks.
Electrode(s) short-circuited.
Ignition cable(s) damaged or
defective.
Igniter defective.
Control and safety unit
Solenoid valves do not open.
Valves jamming.
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.
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.
The burner switches off during
operation.
Air pressure switch: contact opens
during start-up or during operation.
Flame failure during operation.
Adjust or replace the pressure
switch.
Check the ionisation probe circuit
Check or replace the control and
safety unit.
Servomotor fault Clogging of the air flap
Locking of the air flap
Internal fault with the servomotor
Replace the servomotor
Servicing
Troubleshooting
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03/2013 - Art. Nr. 4200 1032 7200A 27
en
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
Page 28
03/2013 - Art. Nr. 4200 1032 7200A28
- 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
Servicing
Operating statistics menu
- 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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03/2013 - Art. Nr. 4200 1032 7200A 29
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03/2013 - Art. Nr. 4200 1032 7200A30
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03/2013 - Art. Nr. 4200 1032 7200A32
Made in EU.
Non contractual document..
www.elco.net
Hotline
ELCO Austria GmbH
Aredstr.16-18
2544 Leobersdorf
+43 (0)810-
400010
ELCO Belgium n.v./s.a.
Industrielaan 61
1070 Anderlecht
+32 (0)2-
4631902
ELCOTHERM AG
Sarganserstrasse 100
7324 Vilters
+41 (0)848 808
808
ELCO GmbH
Dreieichstr.10
64546 Mörfelden-Walldorf
+49 (0)180-
3526180
ELCO Italia S.p.A.
Via Roma 64
31023 Resana (TV)
+39 (0)800-
087887
ELCO Burners B.V.
Amsterdamsestraatweg 27
1411 AW Naarden
+31(0)35-
6957350
OOO «Ariston Thermo RUS LLC»
Bolshaya Novodmitrovskaya
St.bld.14/1 office 626
127015 Moscow -Russia
+7 495 213
0300#4128
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