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vg4.460 d operating instructions for specialist installation engineers gas burners 2-29 en de fr 4200 1032 6200 it nl 4200 1032 6300 4200 1032 6100 02/2011 art nr 4200 1032 6400a

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overview contents overview operation contents 2 important information 2 burner description 3 operation safety operation 4 automatic combustion control unit 5-7 terminal allocation chart connection socket 8-9 mb-zrdle gas train 10 burner assembly gas train assembly 11-12 checking the combustion components 13 electrical/gas connection 14 testing before start up 14 adjustment data 15 air regulation 16 setting the mb-zrdle gas train 17 pre-adjustment without flame 18-19 setting the flame 20-22 saving the adjustment values in the display 23 maintenance 24-25 troubleshooting 26-27 fault diagnosis menu operating statistics menu 28-29 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 cm2 per additional kw 2.0 cm2 ch qf [kw x 6 cm2 but at least 150 cm2 variations may arise as a result of local regulations 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 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 d assembly commissioning servicing 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 important information vg4.460 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 vg4.460 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 typeapproval 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 2 02/2011 art nr 4200 1032 6400a

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overview burner description en a1 a4 f6 k1 m1 t1 y10 3 5 6 control and safety unit display air pressure switch auxiliary motor supply relay blower motor igniter air flap servomotor adjusting screw for dimension y housing 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 02/2011 art nr 4200 1032 6400a 3

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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 2nd 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 f4 f6 y12 y13 y14 1 gas pressure switch air pressure switch safety solenoid valve solenoid valve 1st stage solenoid valve 2nd stage 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 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 4 02/2011 art nr 4200 1032 6400a

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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 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 en moves the cursor upwards moves the cursor downwards pressing the causes unlocking button on the unit for 1 second the control unit to unlock the control unit to lock the statistics to be deleted red led flashes if a fault is present increases the marked value reduces the marked value modifies/confirms the value shown unlocks the control unit 9 seconds 2 seconds screen description screen description awaiting the heat request from the boiler opening the gas valve and safety time air flap is forced open for preventilation 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 02/2011 art nr 4200 1032 6400a 5

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operation tcg 2xx control unit 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 · menu for setting the servomotor 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 d burners · menu for setting adjusting the standard configurations · menu for storing the servomotor setpoints in the display · menu for setting industrial applications · menu for consulting faults · 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 · menu for statistical data 6 02/2011 art nr 4200 1032 6400a

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operation tcg 2xx control unit en 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 preventilation 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 2nd stage valve is reached 13:operation in 2nd stage 14:closing the air flap until the 2nd stage valve reaches the closed position 15:operation in 1st stage 16:regulator shutdown closure of the air flap to 0° 17:awaiting a new heating request 02/2011 art nr 4200 1032 6400a 7

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operation terminal allocation chart 230 volt connection burner motor solenoid valve l1 power supply earth earth igniter 2nd stage thermostat heating request connector terminal flame check air pressure switch remote unlocking fault display gas pressure switch connector terminal terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 earth neutral description burner motor phase connector terminal 20 st description 1 stage thermostat live t1 heating request signal option t2 flame monitoring signal earth live air pressure switch signal live live remote unlocking signal neutral signal fault live live live not used not used connector 4 2 6 21 22 23 24 25 26 27 28 29 30 31 32 33 19 11 10 20 21 8 34 1st stage solenoid valve live neutral earth live 2 nd stage solenoid valve live live l1 earth neutral earth earth igniter live earth neutral live for the 2nd stage thermostat signal t7 signal t8 5 t6/7/8 34 8 02/2011 art nr 4200 1032 6400a

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operation terminal allocation chart low voltage connections display-pc interface en terminal connector connector terminal air servomotor terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 description not used not used not used not used not used not used not used not used not used connector 30 27 28 29 16 17 display or pc interface terminal 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 description not used not used not used not used not used not used not used not used not used not used connector 14 33 32 15 air servomotor 02/2011 art nr 4200 1032 6400a 9

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operation mb-zrdle gas train setting the hydraulic brake setting the 2nd stage setting the 1st stage gas pressure switch solenoid valve coil filter cap connecting flange 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 1st 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 adjusting screw of the gas pressure regulator pbr 4 20 mbar 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 sealed screw locking screw 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 2nd 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 1st 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 10 02/2011 art nr 4200 1032 6400a

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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 en Øa 190-240 Øb 200-270 c m10 d 45° fitting the burner body · remove the cover 2 screws w · unscrew the two screws 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 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 on boilers with reverse firing minimum flame tube insertion depth a should be observed as per the boiler manufacturer s instructions exhaust gas evacuation system to avoid unpleasant noise emissions right-angled connectors should not be used on the flue gas side of the boiler 02/2011 art nr 4200 1032 6400a 11

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assembly gas manifold gas train assembly · check the correct position of the oring 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 12 02/2011 art nr 4200 1032 6400a

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assembly checking/adjusting the burner head checking the burner head · check the adjustment settings of the ionisation probe and of the ignition electrode as per the diagrams en 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 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 02/2011 art nr 4200 1032 6400a 13

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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 6.3 a specified by the draft combustion ordinance it is the responsibility of the fitter or his representative to obtain approval for the system at the same time as the burner is commissioned only the fitter or his representative can guarantee that the system meets applicable standards and regulations the fitter should be in possession of the corresponding official permit and should carry out the corresponding sealing tests and purge the system of air the burner motor has its own separate power supply no 3 fuse on the motor circuit 6 a gm connecting the gas train connect the gas train to the plugs on the burner black to black grey to grey 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 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 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 · · · · · ionisation current measurement to measure the ionisation current disconnect connector b10 and connect a multimeter with a measuring range of 0-100 µa the 2nd stage ionisation current must be at least 7 µa it is also possible to read the ionisation current on the display 14 02/2011 art nr 4200 1032 6400a

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commissioning adjustment data dimension y mm furnace pressure pf mbar 2,6 3,5 4 2,6 3,5 4 2,6 3,5 4 2d stage valve opening 17 20 30 17 20 30 17 20 30 gas valve setting gas head pressure pbr mbar 1 stage 2 stage mb 412 mb 407 g20 g25 g31 g20 g25 g31 2,3 5 3,2 6,3 4 7,9 3,6 12,1 4,8 15,6 2,3 9,2 5,2 17,2 7,1 21,8 3,4 12,5 0,7 5,2 0,7 5,7 0,5 4,8 2,2 8 2,2 9 1,8 7,6 2,7 10,5 3,1 11,5 2,3 9,8 burner power air flap setting ignit 1st stage 2nd stage 13 13 23 17 17 44 22 22 80 5 17 22 9 17 20 5 17 22 9 17 20 27 44 80 23 44 80 vg4.460 d d3/4 rp3/4 1st stage 2nd stage 150 220 180 350 220 430 105 180 220 125 180 220 250 350 430 220 350 430 40 40 40 40 40 40 40 40 40 mb 420 g25 1,3 4,7 1,7 8,5 2,1 10,9 en vg4.460 d d1 1/4-rp1 1/4 vg4.460 d d2 rp2 the adjustment values above are guide values and facilitate commissioning the factory settings are in bold set against a grey background the final settings are essential in ensuring that the burner functions as well as possible setting the gas pressure switch · remove the transparent cover · provisionally set to 15mbar setting the air pressure switch · remove the transparent cover · provisionally set to 1 mbar 02/2011 art nr 4200 1032 6400a 15

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