p. 1

vg 04.570 v operating instructions for the authorized specialist gas burners 2-20 en de fr 4200 1028 3500 it nl 4200 1028 3600 4200 1028 3900 04/2010 art nr 4200 1028 3700a

[close]

p. 2

overview contents overview page contents 2 important notes 2 burner description 3 compact valve assembly mbvef operating function safety function control unit options of connection layout plant connection base 4 5 6 7 8 declaration of conformity for forced-draught gas burners we factory certified with nr aqf030 f-74106 annemasse cedex declare under our sole responsibility that the products vg 04.570 v conform to the following standards en 50165 en 55014 en 60335 en 60555-2 en 60555-3 en 676 belgian royal order of 2004/01/08 in accordance with the stipulations of directives 2009 142 /ec gas devices 2004 108 /ec emc directive 2006 95 /ec low-voltage devices directive 92 42 /eec working efficiency directive 97 23 /eec pressure equipment directive these products bear the ce marking annemasse march 2nd 2010 m sponza function installation burner assembly 9 checking setting 10 burner head for natural gas propane gas 10 gas supply electrical supply 11 pre-startup check 11 burner adjustment data 12 airflow control 13-15 burner adjustment 16 gas pressure switch air pressure 17 checking for correct functioning 17 maintenance 18 troubleshooting 19 frequency converter fault analysis 20 startup servicing description of burner the burner vg 04.570 v is a modulating burner in a monoblock configuration within its corresponding power range it is suitable for use with all heat generators designed to conform to en303 for any other use the agreement of elco must be asked for the special design of the burner head with internal fume recirculation permits highly efficient combustion while ensuring minimum emissions of nitrogen oxide important notes the design and function of this burner both conform to en 676 standards all installation initial-startup and maintenance work must be carried out by authorised service engineers who should observe all relevant guidelines directives and specifications the installation of the gas conduits and valve assemblies should likewise be carried out in conformity with the applicable directives and regulations e.g dvgw-trgi 1986/96 trf 1988 din 4756 all seals and sealing material used must be dvgw argb-kvbg for belgium tested and approved check seals and connection points for possible leaks with a suitable noncorrosive foam product bleed the gas conduit before using for the first time do not bleed via the furnace servicing work on switches limiting devices and control units along with other safety devices must be carried out by the supplier of each individual item or by its authorised service engineers original parts may only be replaced by an authorised service engineer scope of delivery · the burner assembly is supplied in three separate packages · burner with operating instructions flow diagram spare parts list boiler-room information sheet · burner head flange gasket and fixing screws · gas-valve assembly the following standards should be observed in order to ensure safe environmentally sound and energy-saving operation en 676 forced-draught gas burner en 60335-2 safety of electrical devices designed for domestic use gas conduits and valve assemblies must be installed in accordance with dvgw-tvr trgi gas place of installation the burner must not be operated in the presence of corrosive fumes e.g hairspray tetrachloroethylene or carbon tetrachloride large amounts of dust or high levels of air humidity e.g in laundry rooms ensure that a ventilation inlet of the following characteristics is provided de up to 50kw 150cm2 for each additional kw 2,0cm2 ch up to 33kw 200 cm2 for each additional kw 6,0cm2 rules may vary according to local legislation we can accept no warranty liability whatsoever for loss damage or injury caused by any of the following unauthorised use incorrect installation and/or initial startup on the part of the buyer or any third party including the fitting of nonoriginal parts handover and operating instructions the person engaged to install the firing system must provide the user with operation and maintenance instructions no later than at the moment in which the unit is handed over for use these instructions should be displayed in a prominent location at the point of installation of the heating unit and should include the address and telephone number of the nearest customer service centre advice to the user have the system professionally serviced at least once a year it is recommended to enter into a maintenance contract in order to ensure trouble-free running 2 04/2010 art nr 4200 1028 3700a

[close]

p. 3

overview burner description en a1 a4 b1 f6 k1 m1 t1 y10 1 3 4 6 7 7.1 8 13 14 113 pf pg pl control unit translucent cover ionisation bridge air-pressure switch motor relay electric motor ignition transformer servomotor for air control frequency converter for speed control hanging facility for servicing position cable clamp for electrical connection burner tube electrical connection 7-pole electrical connection 4-pole temperature controller gas valve assembly connection flange reset button cover air intake cover measuring nipple for furnace pressure gas pressure measuring nipple air pressure measuring nipple 04/2010 art nr 4200 1028 3700a 3

[close]

p. 4

function compact valve assembly mbvef 1 2 3 4 5 6 7 8 9 10 11 12 13 the mbvef compact gas valve assembly is a combination of filter gas air regulator valves and pressure switches fine 0.8mm mesh filter gwa5 pressure switch servo pressure regulator unit with adjustable v ratio correction of zero value n and furnace pressure connection v1 and v2 fast-opening and closing magnetic valves input pressure pe 20-100 mbar voltage frequency 230v 50-60hz 14 15 16 17 18 electrical connection for gas pressure switch din 43650 electrical connection for magnetic valves din 43650 gas pressure switch input flange pressure measuring nipple r1/8 ahead of filter both sides filter under cover type plate connection for air pressure pipe pl r1/8 setting screw for v ratio pressure measuring nipple pe ahead of valve 1 both sides gas pressure measuring nipple m4 after valve 2 setting screw for zero value n connection for furnace pressure take-off pipe pf r1/8 connection for gas pressure take-off pipe pg r1/8 output flange pressure measuring nipple pa after valve 1 both sides v1 and v2 valve operation indicator pressure release pipes gas-pressure switch adjustment · remove transparent cover adjustment is carried out by turning the adjustment screw with circular scale and index · adjust provisionally to minimum setting burner vg 04.570 v gas vef 407 412 pres s ures gas g20 20 25 gas g25 20 25 gas g20 50 100 gas g25 50 100 gas g31 37 50 gas g20 300 gas g25 300 gas g31 148 vnvnvnvnvn bold print f actory supply 420 1,25 0 1,5 0 1,5 0 2,4 -0,5 1,9 0 4 04/2010 art nr 4200 1028 3700a

[close]

p. 5

function operating function safety function function description control thermostat indicates heat requirement the operating program of the control system starts up if the air pressure switch contact is in its idle position and is receiving a signal from the gas pressure switch indicating that there is sufficient pressure burner motor running pre-ventilation time 54 s during the pre-ventilation period fan pressure is monitored the furnace is monitored for flame signals after the pre-ventilation period has expired the ignition system is activated the main valve and safety valve are opened burner start-up monitoring the flame is monitored by an ionisation probe the insulated probe is fitted to the gas head and leads through the turbulator to the flame zone note that the probe must not be allowed to come into electrical contact with earthed grounded components if a short circuit occurs between the probe and the burner the burner switches to malfunction mode when the burner is in operation there is an ionised zone within the gas flame which allows a rectified current to flow from the probe to the burner the ionisation current must not drop below 8 µa safety functions if no flame appears when the burner starts up release of gas a safety period of up to three seconds elapses before the burner shuts down and the gas valve closes if the flame goes out during operation the gas supply cuts out within one second and the control unit triggers an emergency shutdown if there is insufficient air during the preventilation phase the burner will not start and an emergency shutdown takes place an emergency shutdown likewise takes place if there is insufficient air during operation the burner will not start if the gas supply is insufficient if the gas supply drops during operation the gas valve closes and the burner shuts down this does not result in an emergency shutdown the burner restarts automatically when gas pressure returns to its correct level en compact valve assembly low gas-level protection low air-level protection solenoid valve burner safety valve thermally triggered safety shutoff valve installed onsite 106 filter 108 gas ball valve installed onsite 119 measuring point for gas pressure 119.1measuring point for air pressure pf furnace pressure pg gas pressure pl air pressure 04/2010 art nr 4200 1028 3700a f4 f6 y13 y15 1 note fire regulations normally stipulate that gas-fired devices must be fitted with a thermally-triggered shutoff valve 5

[close]

p. 6

function control unit sg 513 press button r for less than 9 seconds leads to the sg 513 oil-fired unit controls and monitors the forced-draught burner the microprocessor-controlled program sequence ensures the maximum consistency of the time periods involved regardless of fluctuations in the power-supply voltage or ambient temperature the design of the control unit protects it from the effects of brownouts whenever the supply voltage drops below its rated minimum level the control unit shuts down even if no malfunction signal has been emitted the control unit switches itself back on again once the voltage has returned to normal levels information system the built-in visual information system keeps you up-to-date regarding the causes of any safety shutdown the most recent cause of a malfunction is logged and the information can be reconstructed on startup of the system even if there has been a power failure in the meantime in the event of a malfunction occurring the led indicator in the reset button r lights up and stays permanently lit until the fault has been acknowledged i.e until the error has been cleared or the control unit fault has been dealt with the light pauses every ten seconds to emit a blink-code designed to indicate the cause of the malfunction it is possible using the display program available as an accessory to obtain further in-depth information on the system s operating and malfunction procedures locking and unlocking the system the control unit can be locked corresponding to a malfunction and unlocked cleared by pressing the reset button r provided the system is connected to the power supply if the button is pressed during normal or startup mode the device goes into malfunction mode if the button is pressed with the system in malfunction mode the control unit is unblocked 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 unblocking or blocking of the control unit between 9 and delete the 13 seconds statistics of the control unit more than 13 seconds no effect on control unit blink-code cause of malfunction no flame signal at end of safety time unauthorised flame detected during the pre-ventilation/pre-ignition time air-pressure switch contact fails to close within defined time period air-pressure switch contact opens at startup or during operation air-pressure switch not in rest position e.g due to fused contact flame goes out during operation code ­ manual safety shutdown refer also to locking procedure note short light signal long light signal pause required input signals output signals temper controller air-pressure switch 1 2 3 4 activation of control unit motor and sm testing of air pressure end of pre-ventilation activation of transformer and end of pre-ventilation phase burner motor 5 6 7 0 10 gas valve regulation ignition transf flame monitor tlw tlk tr tvz ts tv2 servomotor sm fault unblocking activation of gas valve flame check activation of sm and release gas valve 2d stage followed by burner operation regulator shutdown burner stopped malfunction mode waiting period of air-pressure switch opening time of servomotor and discharge of pre-ventilation shutting time of servomotor pre-ignition time safety valve minimum time between fuel valve 1 and 2 6 04/2010 art nr 4200 1028 3700a

[close]

p. 7

function options of connection different slots are available for external devices e.g operating-hour counter using the sockets underneath the control unit proceed as follows · use a small screwdriver to snap off the plastic cover over the corresponding plug socket · insert the cable towards the retainer outlet see illustrations en remote reset fault warning light operating-hour counter power supply 230v permanent ventilation power regulator 04/2010 art nr 4200 1028 3700a 7

[close]

p. 8

function layout plant connection base terminal plug no terminal plug no plug no terminal plug no terminal malfunction display air-pressure switch solenoid valves i+ii flame check remote control operating-hour counter gas pressure switch actuator ignition burner motor power supply l1 terminal 1 2 3 4 5 6 7 9 10 11 12 15 16 17 18 19 20 21 22 23 24 25 26 27 28 description terminal a of control unit terminal 9 of control unit neutral terminal b of control unit terminal 4 of control unit terminal 7 of control unit terminal t2 at wiel plug 7p terminal 9 of control unit via bridge or temperature control regulator terminal 4 of control unit earth ground neutral terminal 2 of control unit neutral terminal 8 of control unit terminal 9 of control unit terminal b5 at wiel plug 4p and terminal 4 of sm-plug full-load earth ground neutral terminal 5 of control unit and terminal b4 at wiel plug 7p low-load terminal 5 of control unit and terminal b4 at wiel plug 7p low-load counter terminal b5 at wiel plug 4p and terminal 4 of sm-plug counter full-load neutral phase phase earth ground neutral terminal 29 30 31 32 33 34 35 36 37 38 39 40 41 42 48 49 50 51 52 54 55 56 description terminal 3 of control unit neutral terminal t7 at wiel plug 4p 1 of sm-plug terminal c of control unit 2 of sm-plug terminal t1 at wiel plug 7p 3 of sm-plug terminal b5 at wiel plug 4p 4 of sm-plug and phase of valve 2 terminal b4 at wiel plug 7p 5 of sm-plug and phase of valve 1 terminal 5 of control unit neutral 6 of sm-plug terminal 3 of control unit terminal 4 of control unit 8 of sm-plug terminal t8 at wiel plug 4p terminal 9 of sm-plug phase earth ground neutral terminal t8 at wiel plug 4p terminal t6 at wiel plug 4p terminal t7 at wiel plug 4p 1 of sm-plug terminal t2 at wiel plug 7p via gas pressure switch terminal 9 of control unit phase earth ground neutral 8 04/2010 art nr 4200 1028 3700a contin ventilation ignition

[close]

p. 9

installation burner assembly fitting the burner head · prepare the burner s casing/boiler door as per the drawing · establish the internal diameter a at Ø 155 mm · to secure the burner head flange 4 m10 drillings drilling diameter 180 270mm are required as per the drawing · screw the m10 stay bolts into the burner s casing/boiler door and apply the insulation material with a slot diameter 270 mm elongated slots should be cut to the required dimensions · secure the burner head using 4 m10 hexagon nuts en Ø a mm 155 Ø b mm 180 to 270 c m10 d 45° fitting the burner housing · loosen the two screws on the burner housing as far as possible · set front of the burner housing at a slant and insert the two screws into both eyelets on the burner head flange · push the burner housing onto the burner head flange and screw both screws tightly · where required the housing can be fitted over the burner head axis other burner housing positions are not possible burner installation depth and brickwork on boilers without a cooled front wall unless the boiler manufacturer indicates otherwise brickwork 5 as shown in the illustration is required the brickwork must not protrude beyond the leading edge of the flame tube and should have a minimum conical angle of 60° the space between the brickwork and burner should be filled with an elastic nonflammable insulation material 6 on boilers with reverse firing minimum insertion depth a of the burner tube should be observed as per the instructions of the boiler manufacturer installation of valve assembly mbvef · check the correct position of the · o-ring in the gas connecting flange · install the gas connection pipe to the left or the right of the burner housing · secure the valve assembly in such a way that the trip coils of the mbvef are positioned absolutely perpendicular above the gas valves · note the direction of flow · fit a thermally activated safety valve and a gas ball valve installed on site in front of the gas valve assembly 04/2010 art nr 4200 1028 3700a 9

[close]

p. 10

installation checking setting burner head for natural gas propane gas check the burner head · check adjustment settings of ionisation probe 1 and ignition electrode 2 as per specifications given · check the clearance between twist ring 6 to the burner head conversion to propane gas operation · remove gas diffusor 3 and turbulator 4 · turn the cover plate 5 by 180° so that the slots in the turbulator are closed · refit turbulator 4 and gas diffusor 3 label points to gas pipe adjust the radial flame tube position after releasing the three s fixing screws the flame tube position can be adjusted using the h lever nitrogen emissions can be affected by the flame tube position basic setting for scale value 1 fitting burner head · place o-ring j in the groove of the gas connection flange o-ring is located in the gas flue of the burner housing · install the burner head · secure cover 3 screws s in twist and lock · insert the ionisation probe from the terminal box into the support · connect ignition cable to ignition transformer 10 04/2010 art nr 4200 1028 3700a

[close]

p. 11

installation gas supply electrical supply pre-startup check installation of pf and pl pressure release cables · release cable clamp 4 · insert the two c cables and the pf and pl pressure release cables into the cable clamp · secure the cable clamp to the equipment plate · tighten the pf and pl cable screws on the gas cover and valve · tighten the nuts by hand · check for leaks en general regulations applying to gas supply · the gas-valve assembly must be connected to the gas supply network by an authorised service engineer · the cross-section of the gas conduit should be of a size designed to guarantee that the gas flow pressure does not drop below the specified level the act of startup places the system under the joint responsibility of the user and the fitter engaged to carry out installation or the latter s corresponding legal representative only the authorised fitter can guarantee that the system conforms to relevant standards and regulations the fitter should be in possession of the corresponding official permit and should carry out the corresponding leak tests and purging of the system all electrical installation and connection work must be carried out by a suitably qualified service engineer vde and evu rgie-arei for belgium rules and regulations must be observed when doing so electrical connection · check to ensure that the power supply is as specified 230 v 50 hz burner fuse rating 10a electrical plug connection the electrical plug-and-socket connection burner and heat generator boiler are linked via one 7p and one 4p plug-and-socket connection the connection cable is fed through the connection clamp and secured insert connection cable for gas valve through the clamp and into the gas valve in belgium relay kit no 13013508 must be used pre-startup check the following tests and checks must be carried out before the burner is used for the first time operating specifications of the boiler manufacturer adjustment of temperature controller pressure regulator limiting device safety switch gas input pressure min 20mbar flow pressure correct sealing of gas-bearing elements purging of fuel-bearing conduits unobstructed exhaust conduits sufficient supply of fresh air testing of burner program sequence before releasing gas for first time · close ball valve upstream of gas valve assembly · if gas pressure upstream of valve assembly is insufficient bypass the gas pressure switch terminal 2 and 3 if necessary shutting down the power supply to the burner · activate the boiler to start up the burner and check the program sequence · the blower runs 04/2010 art nr 4200 1028 3700a pre-ventilation time 54s pre-ignition time 3s open solenoid valves safety period 3s fault shutdown after expire of safety period with blocking of control unit fault indicator lamp lights up · shut off power to burner by disconnecting electrical supply and remove any bypass connection fitted to the gas pressure switch · reconnect electrical power supply · press button r to reset control unit · · · · · 11

[close]

p. 12

startup burner adjustment data f re quencycon tro llerdi sp laylow lo a d h z 40 40 40 41 f u ll lo a d h z 48,5 51 55 55 b u rn erpowert yp e low lo a d 140 160 180 200 f u lllo a d 410 470 540 570 dim y m m a i r-fl apopeninglow -l oadcam iv 20 20 20 25 full -l o a d ca m i 45 50 60 60 v g 04.570 v 20 30 30 40 the above adjustment data correspond to the default settings pre-delivery adjustment settings appear within a black rectangle these settings allow the burner to be run in normal operation but always carry out a careful check of adjustment settings as individual plant conditions may require certain corrections adjusting the gas pressure switch · remove transparent cover · provisionally adjust air-pressure switch to minimum setting adjusting the air-pressure switch · remove transparent cover · provisionally adjust air-pressure switch to minimum setting 12 04/2010 art nr 4200 1028 3700a

[close]

p. 13

startup airflow control the combustion air is regulated at two points · on the pressure side by means of the opening gap between the turbulator and burner tube · on the suction side by means of the air flap actuated by servomotor y10 · air regulated by fan speed setting via frequency converter en airflow control in the burner head has an effect on the air quantity as well as on the mixing zone and the air pressure in the burner tube turn adjustment screw a clockwise increased airflow anticlockwise reduced airflow · adjust dimension y corresponding to table of settings suction-side airflow regulation is carried out using an air flap this is actuated by servomotor y10 the position of the air flap is determined by adjusting cams i iv servomotor y10 1 four adjustable red cams 2 marking to indicate cam setting relative to scale no 4 s adjust screws for cams 4 three scales divided between 0 and 160° 5 air-flap setting indicator 6 removable plug-and-socket connection cam function cam function i full-load ii air shut-off iii firing load iv low-load two interconnected cams cam iv can be set at a value above or below cam iii adjustment · remove hood · temporarily set the cams according to the boiler output capacity and the table values using s screws the angle should be read based on the scale and the marking 2 on each cam 04/2010 art nr 4200 1028 3700a 13

[close]

p. 14

startup airflow control air regulation air regulated via fan speed the fan speed is controlled via the frequency converter depending on the position of the air damper the minimum and maximum fan speed are set via the lsp and hsp parameters as a frequency 50 hz 2800 u/min depending on the reduced position of the air damper the frequencies set within the lsp and hsp parameters are not fully obtained during operation during operation the actual frequency is shown in the display of the frequency converter example in order to obtain an operating frequency of 55 hz at full load and an air damper position of 60° the hsp parameter must be set at around 80 hz precautions for this reason the difference between operation of the fan speed and the setting value of the lsp and hsp parameters must be observed in the setting table the operating speed of the fan must not exceed 55 hz setting the starting frequency to suppress start-up fluctuations when starting the burner the speed for the burner start period is automatically raised the starting frequency is set via parameter sp2 setting the lsp and hsp parameters the lsp and hsp parameters are preset in the factory but can be altered to do this proceed as follows mode button switches between the control/programming modes the mode button is only accessible with the door open four 7-segment displays esc button exits a menu or parameter or aborts the displayed value to return to the previous value in the memory stop/reset button stops the motor could be hidden by door if function disabled allows to reset a fault door jog dial acts as a potentiometer in local mode for navigation when turned clockwise or counterclockwise and selection validation when pushed run button starts running if the function is configured could be hidden by door if function disabled caption turn button press button rdy ref menus mon see table on next page conf see table on next page 14 04/2010 art nr 4200 1028 3700a

[close]

p. 15

startup airflow control · monitoring menu mon to select a parameter for purpose of monitoring to change the default displayed value during operation select a parameter using and press for more than 2 seconds en · configuration mode conf to alter a parameter abstract of parameters list atv12 usually on commissoning only parameters hsp lsp and sp2 have to be altered menu conf sub-menu parameter acc dec lsp hsp ncr sub-menu i-odrcdrcdrcdrcdrcdrcdrcdrcdrcdrcdrc funfunfunfunfunfunfunfltfltparameter bfr npr uns ncr frs nsp tfr ctt pfl sfr nrd stt adc pss pss cli spl spl flr tht stt adc ps2 sp2 cli lsp hsp ith standard motor frequency rated motor power rated motor voltage rated motor frequency maximum value for hsp switching frequency motor noise reduction freewheel stop assignment no dc injection low speed high speed with «catch on the fly» function motor thermal current lel 50 0.75 230 2.9 50 2900 85.0 pump 20 12 yes nst no l3h 48 3.5 31.4 80.0 yes 2.9 hz kw v a hz min-1 hz hz function acceleration deceleration low speed high speed rated motor current factory setting 3.0 3.0 31.4 80.0 2.9 unit s s hz hz a full a hz hz a 04/2010 art nr 4200 1028 3700a 15

[close]