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n6.2400 g-ef3 n6.2900 g-ef3 n7.3600 g-ef3 n7.4500 g-ef3 operating instructions for specialist installation engineers gas burners 2-23 en de fr 4200 1030 7400 it nl 4200 1032 0500 4200 1031 7900 10/2010 art nr 4200 1030 7300a

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overview contents contents 2 important information 2 burner description 3 operation gas start-up mode gas operating mode 4 general safety functions 4 fuel-air compound control 5 electronic burner controller etamatic oem 6 gas valve vgd with skp actuator 7 gas valve mbc-se 7 assembly boiler lining for g-ef3 burner burner assembly 8 gas connection 9 checking assembling the combustion components10 gas connection electrical connection 11 checks before commissioning 11 commissioning burner power adjusting sequence 12 electrical actuator stm 40/schimpf 13 flame sensor 14 gas pressure switch air pressure switch 15 gas valves and instruments group description 16 basic construction 17-19 servicing maintenance 20-21 exhaust gas test trouble shooting instructions 22-23 overview declaration of conformity for gas burners we elco burners gmbh herbertliebsch-straße 4a 01796 pirna germany declare under our sole responsibility that the products n6.2400 g-ef3 n6.2900 g-ef3 n7.3600 g-ef3 n7.4500 g-ef3 conform to the following standards en 50165 en 12953-7 en 12952-8 en 61000-6-2 en 61000-6-4 en 676 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 2009/142/ec gas appliances directive 97/23/ec pressure equipment directive pirna 26th may 2010 d hoffmann 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 n6 and n7 g-ef3 burners are designed for the low-polluant combustion of natural gas the design and function of the burners meet standard en 676 they are suitable for use with all heat generators complying with standard 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 n6 and n7 g-ef3 burners are modulating electronic 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 body with integrated switch cabinet flange seal and securing screws operating instructions circuit diagram and spare parts list combustion head compact gas train with integrated or external filter the following standards should be observed in order to ensure safe environmentally sound and energy-efficient operation en 226 connection of fuel oil and 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 cm 2 but at least 200cm 2 variations may arise as a result of local regulations 2 10/2010 art nr 4200 1030 7300a

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overview burner description 2 5 6 7 8 10 11 13 19 f6 m1 y10 y11 power controller option housing gas inlet flange gas damper burner flame tube integrated electrical cabinet burner fixing flange air intake box hoisting eyes air pressure switch blower motor actuator for air damper actuator for gas damper en 10/2010 art nr 4200 1030 7300a 3

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operation gas start-up mode gas operating mode general safety functions gas start-up mode as soon as the furnace system is required to supply heat the burner control circuit will close and the program flow started when the program has come to its end the burner will be turned on an automatic test is made for the tightness of the gas valves prior to each burner start the air damper is in its closed position when the burner is out of operation the electric actuator will open the closed air damper to its full-load position so that the burner will ventilate the furnace and the exhaust hoods with the specified air rate shortly after the pre-ventilation process has been started the lack-of-air cut-out must change over to operating position within a certain time i.e the minimum air pressure setting must be reached and maintained until the burner is turned off after the expiry of the preset pre-ventilation time the air damper and the gas control damper are set to their partial-load positions the ignition transformer is activated after the pre-ignition time the main gas valves are open and the gas comes out from injectors where it is mixed in the combustion head with air coming from the fan the ignition of the gas air mixture is done directly by a high voltage spark on a gas injector during the safety time a stable flame is formed and is monitored by a uv photocell the ignition is stopped before the end of the safety time and the burner operates at its minimum power the start-up programme is completed gas operating mode after flame formation the burner will shortly remain in the separately set ignition load und is then run at minimum output.this brings the burner to its operating position the controller will now automatically control the burner between its partial-load and full-load positions depending on the heat demand the output controller will actuate the electronic compound controller which in turn will control the actuators of the gas control damper and air control dampers and increase or decrease the flow rates according to a specific program the stepless control makes it possible to operate the burner at any desired stage between its partial-load and full-load positions for turning off the burner this must always be in its partial-load position the air damper will be closed when the burner is in its off position so as to prevent cold air from flowing through the furnace chamber heat exchanger and chimney the interior cooling losses will be greatly minimised attention si des volets de fermeture sont installés dans les conduits d évacuation des fumées ils doivent absolument être totalement ouverts sous peine de faire naître un risque élevé de détonation lente voire d explosion a cet effet il est possible de s assurer de l ouverture du volet de fermeture en intégrant un contact d ouverture du volet dans la chaîne de sécurité du générateur de chaleur general safety functions in case a flame does not develop when starting the burner fuel release the burner controller will shut off at the end of the safety period shut-off on trouble a shut-off on trouble will also occur in the case of flame failure during operation air flow failure during the preventilation phase and pressure failure during the whole period of burner operation any failure of the flame signal at the end of the safety period and a flame signal during the pre-ventilation phase external light control will result in a shut-off on trouble with the automatic furnace controller being locked the 4 trouble is indicated by the trouble signal lamp lighting up the automatic furnace controller can be unlocked immediately after a shut-off on trouble by pressing the unlocking key the program unit will return to its starting position and proceed with the restart of the burner a voltage failure will result in a regular shut-off of the burner after voltage recovery the burner can be automatically restarted unless another interlock is active e.g one caused by the safety circuit in any case the fuel oil supply will be immediately stopped upon occurrence of a trouble 10/2010 art nr 4200 1030 7300a when using the burner control system electronic compound control all operational and fault messages may be indicated in plain text on an optionally available operating and display module.

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operation fuel-air compound control fuel-air compound control this compound pneumatic control system with precision-adjustment capability has been designed to allow the fuel and air flow rates to be steadily varied in sliding mode for an adjustment of the fuel-air ratio over the whole control range in the stepless control mode the load will be controlled at any point within the control range depending on the heat demand electronic compound control the air flap and the gas flap are each fitted with a servomotor that controls the position of these servo components at the factory the air curve of the compound controller is configured in such a way that the air flap is closed at the minimum setting and open at the maximum setting as part of burner commissioning the servo components for the fuel and air are assigned permanently defined positions in relation to burner output during burner operation the servo components move into these positions with great accuracy this precision is a fundamental prerequisite for permanently ensuring low-emission combustion the gas pressure should be corrected at the gas pressure regulator if necessary please note the gas outlet pressure gas regulating pressure must always be less than the gas inlet pressure but higher than the total pressure loss of the system proceed in accordance with the commissioning instructions for the electronic compound control system when making gradual adjustments to the load points fuel flow rate air flow rate where possible a combustion measurement should be carried out at each point equipment option speed control the burners can be equipped with a speed controller as an option during long burner operating periods in the partial load range in particular the reduction in blower speed helps to conserve electrical energy and reduce noise emissions from the burner blower itself the speed of the blower is measured by a namur sensor and controlled to the programmed reference value for the current output level equipment option o2 control co control to improve the efficiency of the system the combustion manager can be equipped with residual oxygen or co control co control available only with the use of a lamtec burner controller the residual oxygen is measured in the flue gas of the heating system by an o2 measuring probe with zirconium oxide sensor and sent to the combustion manager as a correction factor thanks to o2 control it is possible to eliminate variations in ambient conditions e.g combustion air temperature and humidity calorific value fluctuations etc and significantly reduce the air surplus required for calibration reference value deviations are controlled by corrections to the blower speed or the air flap position with the use of co control only possible with gas operation the co content is measured in addition to the residual oxygen the air surplus is reduced to the co edge by a correction to the blower speed or the air flap position the correction factors are determined in a systemspecific learning process and stored temporarily in the combustion manager this makes it possible to maximise the system s heating efficiency across the entire output range and optimally manage the combustion process for further information please refer to the manufacturer s documentation for the electronic combustion manager en gas air 1a 1b 2 3 4 gas damper with actuator air damper with actuator burner boiler combustion air fan 10/2010 art nr 4200 1030 7300a 5

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operation electronic burner controller etamatic oem description the electronic burner controller is a programmable automatic combustion control unit with an integrated electronic coupled controller there may be additional functions depending on the equipment and model technical data operating voltage 230 vac frequency 50 60 hz power consumption ca 50 va ambient temperature during operation 0-60°c storage -25-60°c mode of operation:continuous operation reset load fault history up load fault history down manual operation on off display change compound o2 flame intensity general safety interlock circuit gas safety interlock circuit burner on gas pressure min air pressure switch fuel selection flame signal control release gas pressure max air damper fan fuel valve re-circulation damper re-circulation fan ignition transformer ignition valve gas valve 1 gas line gas valve 2 burner side fan on key to the process sequence charts t1 wait for gas safety interlock circuit air pressure monitor min scan t2 time for pressure build-up in the gas test line only with leakage test activated t3 servo drive running time t4 re-circulation damper delay t5 aeration time t6 t9 t10 t11 t12 6 transformer pre-energise time safety period operating phase control mode time for pressure relief in the gas test line t13 any 2 sec 30-60 sec 0-t5 30-999 sec adjustable 3 sec 3 sec any any 3 sec t16 t17 t18 t14 t15 post-ventilation time control elements at base load after-burning time flame extinguishing check leakage test gas valve 2 triac selftest 0-999 sec adjustable 0-20 sec adjustable 5 sec 30 sec 10/2010 art nr 4200 1030 7300a

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o per i at on g as val vg dwih sk p act or ve t uat g as val m b c ve se 1 2 3 4 5 6 7 8 gas ball valve filter under the cover gas manometer with push button upstream test burner with push button option actuator skp 15 actuator skp 25 gas main valve vgd gas manometer with push button downstream option en technical data input pressure 360 mbar max ambient temperature -15 to +50°c voltage 230 v 50 hz max protection rating ip 54 1 2 3 4 5 8 gas ball valve filter under the cover gas manometer with push button upstream test burner with push button option compact gas train safety valve main valve gas manometer with push button downstream option technical data input pressure 360 mbar max ambient temperature -15 to +50°c voltage 230 v 50 hz max absorbed output in operation 250 w max protection rating ip 54 10/2010 art nr 4200 1030 7300a 7

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assembly boiler lining for g-ef3 burner burner assembly boiler lining the burner lining must be installed rightangled to the burner tube possible trimming work bevelling rounding as required for reverse boilers for example should done at a diameter not below 70 of the combustion chamber diameter the space between the flame pipe of the burner and the boiler lining should be lined with heat resistant material such as cerafelt this space is not allowed to be lined with brickwork d see dimensioned drawings d1 see dimensioned drawings df combustion chamber diameter t1 80 mm t depth of boiler lining option extensions see technical data note for reverse flow boilers for reverse flow boilers the dimension t1 is only a recommended value depending on type of boiler the burner head must stand at least 50 mm ahead the opening for flue gas turning back burner assembly · take the burner tube delivered in a separate box · fit it on burner body · remove cover · tighten the 2 fixing screws s1 · lift the burner using the 2 hoisting eyes 19 see page 3 and fasten to the boiler · tighten the 4 fixing screws s2 · place cover back on 8 10/2010 art nr 4200 1030 7300a

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assembly gas connection gas connection the gas lines and valves and instruments group should be installed and taken into operation in accordance with the applicable engineering standards and regulations the connection between the gas distribution network and the gas ramp must be done by authorised persons the section of the pipings must be calculated so that the loss of load doesn t exceed 5 of the distribution pressure a quarter turn manual valve not supplied must be provided for upstream of the gas ramp and the filter the filter must be installed on a horizontal nozzle with the cover in the vertical position to enable cleaning the threaded unions used must be in conformity with present standards tapered male thread straight female thread with sealing provided in the thread provide for sufficient space to access the gas pressure switch adjustment gas properties prior to any installation work make sure to obtain the following data from the gas supply company 1 type of gas 2 calorific value h un=kw/m³ kj/m³ 3 maximum co2 content of exhaust gas 4 gas connection pressure and rest pressure type of gas test prior to mounting the burner to the gas feed line check the available type of gas and burner type against the data given on the burner nameplate attached to burner be sure the description of the burner and the type of gas are the same as indicated on the nameplate gas connection pressure a minimum connection pressure must be available upstream of the burner gas valve to ensure the proper functioning of the burner for the installation of the valves and instruments group take care to observe the mounting instructions supplied by their manufacturers these are packed with the equipment the gas line installed to the burner must be dimensioned in accordance with the throughput rate and the available pressure for selecting the nominal bore dn of the gas valves and instruments group care should be taken to observe the flue resistance of the boiler and the gas pressure loss of the burner and valves and instruments group caution the absence of impurities and foreign bodies must be checked before installation and commissioning of the gas ramp the lever valves and unions gas valves and instruments group the gas valves and instruments group can be connected directly to the gas feed line take care to observe the correct order of installation and direction of flow arrow on housing check the valves and instruments and connection pieces for absence of dirt particles and foreign matter before installation and initial operation to provide effective conditions for startup make sure the distance between the burner and the gas stop valve is as short as possible leak test the gas line upstream of the burner gas valves and instruments group must be installed in accordance with the applicable regulations checked for absence of leaks vented and certified accordingly by the gas installation company the screwed unions and flanged joints must be checked for proper tightness by making a pressure test the leak test must be made under pressure using approved foaming agents which do not cause corrosion for steam boiler furnaces the result of the leak test must be duly certified venting caution prior to taking the burner into operation or after any repair work make sure to vent the complete gas feed line and the gas valves and instruments group into the open atmosphere e.g by means of a hose taking care to avoid any hazards in no case should the gas line be vented into the heating or furnace chambers make use of a test burner to check the gas-carrying spaces are free from an inflammable gas mixture support the valves and instruments group must be supported with a telescopic jacking member or similar during and after installation e.g on filter and valve joint it is recommended to provide an easytodisconnect joint with planar sealing faces to facilitate repair work on the boiler furnace and allow the boiler door to be swivelled out if required en 10/2010 art nr 4200 1030 7300a 9

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assembly checking assembling the combustion components burner n6 g-ef3 n7.3600 g-ef3 n7.4500 g-ef3 a 35 45 45 b 40 15 10 assembling the combustion components · check that the o-ring j1 is in the correct position in the gas elbow · check the adjustment settings of the ignition electrode as per the diagrams · insert the combustion components into the head tighten the mounting screws s3 · connect the ignition cable zk on the combustion head · connect the ignition cable zk on the ignition transformator t1 important if there is a change to the type of gas used for example h or e natural gas g20 to l or ll gas g25 or vice versa the burner settings should be completely overhauled it is not necessary to modify the combustion head in any way 10 10/2010 art nr 4200 1030 7300a

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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 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 10 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 en electrical connection it must be possible to disconnect the burner from the mains using an omnipolar shutdown device complying with the standards in force burner motor connection the burner is delivered for a power supply of 400v 50hz of triphase current with neutral and earth connect the burner motor cable to the terminals in the electrical cabinet check the direction of rotation of the ventilation motor manually with the burner contactor connecting the gas train connect the gas train to the plugs on the burner 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 · 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 10/2010 art nr 4200 1030 7300a 11

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commissioning burner power adjusting sequence see also operating instructions for control unit etamatic oem supplier lamtec adjusting sequence short description gas pressure setting vgd gas train vgd · remove protection cap on skp25 · set gas pressure pbr using screw s1 hidden by the cap · check setting position of the index in relation with the scale x gas train mbc · set gas pressure pbr using screw s2 caution gas output pressure regulator output pressure must be adjusted lower than the input pressure but higher than the total gas pressure loss of the heating plant mbc 12 10/2010 art nr 4200 1030 7300a

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commissioning electrical actuator stm 40/electrical actuator schimpf the stm 40 servomotor is used in conjunction with various electronic compound control systems priority with products supplied by lamtec etamatic etamatic oem vms fms with some types of burner the motor is also used as a servomotor for other servo components independently of the compound control system e.g nozzle linkage safety adjustment please refer to the appropriate section of the operating instructions the electrical diagram for the burner shows how to establish the servomotor s electrical connection observe the documentation issued by the manufacturer technical data voltage frequency angle of rotation running time torque static holding moment dimensions a xbxc potentiometer integrated 230 v ac 50 hz 90° 40 sec for 90° 15 nm 8 nm 93 mm x 144 mm x 149 mm 5 k en 10/2010 art nr 4200 1030 7300a 13

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commissioning flame sensor the flame sensor is a component of the flame monitoring system in interaction with the automatic combustion control unit it suppresses stray flame during burner start-up and monitors the presence of flame during burner operation the flame sensor is an optical sensor that monitors light radiation in the ultraviolet spectrum emitted by the flame for the electrical connection please refer to the electrical diagram and the supplementary information for the individual flame sensors contained in the manufacturer s documentation n.b the flame sensors must be regularly inspected for dirt and cleaned as necessary the sensor windows of the optical flame sensors must be kept free of dust the ionisation rods must be checked for burn-up and replaced if necessary 14 10/2010 art nr 4200 1030 7300a

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commissioning gas pressure switch air pressure switch gas pressure switch a5 gas pressure switch gw a5/a6 the gas pressure switch is designed to monitor the gas flow pressure it can be used for monitoring either falling pressure minimum or rising pressure maximum specified for equipment according to trd 604 the types gw a5/a6 may be used as pressure switches of specific design according to vdtÜv leaflet pressure 100/1 for application in furnace systems complying with trd 604 the setpoint switching point may be selected by means of a setting disk with scale technical data type of gas gases according to dvgw worksheet g 260/1 gas families 1 2 3 degree of protection ip 54 ambient temperature -15°c to +50°c mounting position any operating pressure up to gw 50/150 a5a6 500 mbar gw 500 a5/a6 600 mbar max gas pressure switch · remove the protective cover · at the rated output measure the gas flow pressure and calculate the switch-off pressure by increasing by approximately 20 no more than 30 under any circumstances · adjust the graduated disc to the desired switch-off pressure opposite the arrow the graduations are approximate values · operate the burner at minimum power if the max gas pressure switch switches off the burner increase the adjustment value but not to more than 130 of the flow pressure at the rated output certification the pressure switch has been tested in accordance with din 3398 part 2 and is registered by ce/din-dvgw it has been registered in other important gas consumption countries important once the pressure switches have been set they must be protected to prevent settings from being altered for example this can be done by placing a spot of varnish on at least one of the screws on the equipment s protective cover en gas pressure switch a6 setting the min gas pressure switch /tightness controller gas pressure switch · remove the protective cover · at the rated output measure the gas flow pressure and calculate the switch-off pressure by reducing by 50 · adjust the graduated disc to the desired switch-off pressure opposite the arrow the graduations are approximate values · refit and screw down the protective cover air pressure switch the air pressure switch is provided for monitoring the pressure of the combustion air fan the pressure switch dungs lgw has been designed for switching on off or over an electric circuit in the case of changes of the actual pressure levels from the setpoint setting the pressure switch lgw can be used as overpressure vacuum or differential pressure monitor for air and nonaggressive gases but not for gases according to dvgw worksheet g 260/l determining the differential preflushing pressure and adjusting the differential pressure switch · burner in the pre-aeration phase · measure pressure on test connection 2 · measure vacuum on test connection 3 · add the measured pressures · set the scale to 90 of the calculated value switch function test · test buttons are provided to check the switch functions for proper operation with safety cut-out and interlock the burner is normally run in partial-load condition when testing the safety functions on pressing button 4 the vacuum will be removed which causes the differential pressure to drop below the required level if it is necessary to test the pressure switch functions under full-load conditions this may be done by pressing button 1 10/2010 art nr 4200 1030 7300a 15

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