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vectron g 02.120 modulo vectron g 02.160 modulo vectron g 02.210 modulo operating instructions for specialist installation engineers gas burners 2-26 spare parts list 13 022 424 electric and hydraulic diagrams13 022 317 12/2008 art nr 13 023 168c

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general information contents page contents important notes 2 technical data power graphs 3 dimensions burner description 4 mbc se gas train 5 mpa22 safety unit general information operating description 6 display and operating unit 7 program structure 8 assembly burner assembly 9 checking the burner head 10 adjusting the burner head in liquid gas mode 10 gauge glass/flue cooling 10 electrical connection 11 commissioning burner adjustment data 12 burner head position 13 gas pressure switch/air pressure switch pre-setting gas pressure regulator pre-setting 13 ionisation current measurement 13 checks before start-up 14 safety unit auto-test 14 accessing setting mode 15 setting mode 16-19 gas pressure switch/air pressure switch setting function check 20 operating mode 21 information mode/language mode 22 specific setting values of the mpa 22 23 servicing maintenance 24 troubleshooting 25 general information important information vectron g 02.120/160/210 modulo burners are desired for the low-pollutant combustion of natural gas and liquid gas the design and function of the burners meet standard en 676 assembly start-up and maintenance must be carried out only by authorised specialists and all applicable guidelines and regulations complied with description of burner the vectron g 02.120/160/210 modulo burners are single unit modulating gas burners with an electronic cam they are suitable for use with all heat generators complying with en 303 or for use by hot air generators complying with din4794 or din30967 or en621 within their respective performance range any other type of application requires the approval of elco the special construction of the burner head with internal recirculation of exhaust gases means that combustion is very low in nitric oxide when burning natural gas the requirements of the 1st bimschv german clean air act and lrv swiss air quality directive are met nox emission values of <80 mg kwh are achieved with natural gas fuel under test conditions complying with en 676 emission values may differ depending on combustion chamber dimensions combustion chamber load and the firing system three-pass boilers u-fired boilers the conditions for the measuring equipment tolerances humidity and fuel oil sulphur content must be observed for warranty values to be obtained scope of delivery every burner is supplied in an individual package which includes the following components 1 gas connection flange 1 compact gas train with gas filter 1 burner flange with insulation 1 1 bag containing mounting parts bag containing technical documentation declaration of conformity for gas burners we as the factory certified with no aqf030 18 rue des bûchillons ville-la-grand f-74106 annemasse cedex declare under our sole responsibility that the products vectron g 02.120 modulo vectron g 02.160 modulo vectron g 02.210 modulo conform to the following standards en 50165 en 60335 en 60555-2 en 60555-3 en 55014 en 676 these products bear the ce mark in accordance with the stipulations of the following european directives 90/396/eec gas appliances directive 89/336/eec emc directive 73 23/eec low-voltage devices directive 92 42/eec directive efficiency rating these products bear the ce marking annemasse 01 march 2007 j haep the following standards should be observed in order to ensure safe environmentally sound and energy-efficient operation en 676 forced-draught gas burners en 226 connection to heating systems of vaporisingfuel-oil and forced-draught gas burners en 60335-1 safety of electrical appliances for domestic use guidelines switzerland the following swiss directives and installation guidelines must be observed ssige g1 gas directive gas installations form cfst 1942 liquified gas directive 2nd section cantonal authority guidelines e.g guidelines for pilot valves fire protection valves installation site the burner must not be used in rooms with aggressive vapours e.g hair spray perchloroethylene 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 50kw 150 cm2 for each 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 warranties shall not cover any damage caused by the following unauthorised use incorrect installation and/or repair undertaken by the buyer or any third party including the fitting of other brand parts final delivery and instructions for use the supplier of the heating system must provide the user on receipt of the system with the system operating manual and maintenance instructions 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 note for the user the system should be inspected by a specialist at least once a year it is advisable to take out a maintenance contract to guarantee regular servicing 2 12/2008 art nr 13 023 168c

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overview technical data power graphs g 02.120 modulo g 02.160 modulo g 02.210 modulo 30-120 40-160 40-210 natural gas e hu 9.45 kwh m3 natural gas ll hu 8.13 kwh m3 liquid gas f hu 24.44 kwh m3 1312 bq 4069 as per en 676 emissions class 3 for natural gas nox 80 mg/kwh for liquid gas nox 140 mg/kwh under test conditions mbc 300 se rp 3/4 natural gas e and ll 20-300 mbar liquid gas f 37-148 mbar air flap with sad 1.2 servomotor baffle plate in the burner head setting range 0.5 5 mbar 1:4 1:4 1:5 230 v 50 hz operation 160 w operation 250 w operation 260 w 22.5 160 w 2,850 rpm 130 w 2,900 rpm ip 21 mpa 22 ionisation sensor ebi-m 1 x 11 kv 62 64 65 burner power fuel ce number type check gas train gas connection gas input pressure air regulation i air regulation ii air pressure switch regulating ratio voltage power consumption weight electric motor protection control and safety unit flame monitor ignition transformer sound pressure level in accordance with din2715 key min max kw approx kg dba the regulating ratio is a median value and may vary according to system design g natural gas/liquid gas 02 size 120 output value in kw modulo modulating with electronic cam kn normal burner head length kl long burner head length mbar 3 2,5 2 1,5 1 0,5 0 kw dapa 30 25 20 15 10 5 0 0 30 g 02.120 modulo mbar dapa 30 25 20 15 10 5 0 g 02.160 modulo dapa 30 25 20 15 10 5 0 0 g 02.210 modulo mbar 3 2,5 2 1,5 1 0,5 210 40 80 120 160 200 kw 0 40 80 120 160 200 40 80 120 160 200 0 kw 12/2008 art nr 13 023 168c power graphs the power graph shows burner output as a function of combustion chamber pressure they correspond to the maximum en 676-compliant values as measured at the test combustion chamber the efficiency of the boiler should be taken into account when selecting a burner calculating burner power qn qf k qf burner output kw qn rated boiler output kw k boiler efficiency 3

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overview dimensions description of burner Øa Øb 120 135 150 180 c m8 d 45° a 60 c 173 d 144 f 466 g 233 rp 3/4 y10 a1 a4 b1 f6 m1 t1 y11 2 3 4 5 6 8 9 10 10.1 16 18 19 20 113 119 air flap servomotor automatic combustion control unit display ionisation bridge air pressure switch blower motor ignition transformer gas servomotor burner flange gas restricting piece for gas train connection flange liquid gas stop housing equipment plate fastener burner tube clamp for gas train connection cables 7 pin plug 4 pin plug gas train connecting flange burner hood release knob hood securing screw tx25 air intake box air pressure take-off nipple 4 12/2008 art nr 13 023 168c

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general information mb cse gas train the gas train consists of a gas connection flange 1 with o-ring a gas throttle 2 controlled by a servomotor a gas connection pipe 3 a mbc-se gas valve train with gas filter 4 mini filter mbc se gas valve 1 electrical connection of solenoid valves din 43650 2 electrical connection of gas pressure switch din 43650 3 gas pressure switch 4 gas inlet flange 5 mini filter under cover 6 gas pressure adjustment screw pbr 8 gas pressure measurement nipple g1/8 inter-valve pressure 9 gas pressure measurement nipple g1/8 outlet pressure pbr 10 gas pressure measurement nipple g1/8 inlet pressure pbr assembly location vertical with the coils facing upwards where the lines are vertical the coils must be horizontal description technical data the mbc se gas compact valve train is a compact unit with 2 class a solenoid valves a class a servo pressure controller a mini filter and a pressure switch gw a5 pressure monitor setting range 5 50 mbar solenoid valve v1/v2 fast-opening fast-closing adjustable servo pressure controller max operating pressure 500 mbar inlet pressure range 15-500 mbar voltage/frequency 230 v 50-60 hz pressure controller setting the outlet pressure is set via adjustment screw 6 12/2008 art nr 13 023 168c 5

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general information mpa22 safety unit function description in addition to functioning as a gas control and safety unit the mpa safety unit also guarantees the modulation of the burner power by actuating the air valve and the gas throttle via an electronic connection the electronic connection enables the gas throttle opening to be controlled in proportion to the air valve along a curve based on one of 10 setting points during start-up the setting points are established using the values measured during the combustion analysis this procedure guarantees optimal combustion over the entire power modulation of the burner with setting point p0 a separate burner ignition load can be defined the limit values of the control range are established via setting points bu and bo in addition further optional functions such as leak checks postventilation or waiting times can be activated the safety unit is operated via a display 1 2 3 4 5 6 7 additional valve for liquid gas or external gas valve safety gas valve y15 main gas valve y13 burner motor m1 ignition transformer t1 output 230 v ­ 50 hz gw max bridge plug safety chain input 8 9 10 11 12 13 14 15 gas min pressure switch f4 gas pressure switch vps leak checker air pressure switch f6 16 17 18 19 display and operating unit a e-bus connection output regulator 4p connection boiler connector panel 7p connection option cell flame detector ird/ion pulse counter gas servomotor y11 air servomotor y10 12/2008 art nr 13 023 168c 6

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general information mpa22 safety unit display display · access to information mode t 5 s · access to language mode t 5 s · return to next higher program level · activating a function · confirming a value · moving the cursor in an anticlockwise direction · increasing the marked value · moving the cursor in a clockwise direction · reducing the marked value · resetting the safety unit · red led flashes if a fault is present operating values are shown in real time on the display by pressing certain buttons it is also possible to switch from setting mode to information mode operating mode or language mode 12/2008 art nr 13 023 168c 7

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general information mpa 22 safety unit program structure setting mode operating mode enter the access code operational program setting temperature regulator in operation setting parameters temperature regulator in operation start-up setting the reference data p9/p1/p0 starting the burner the burner operates in the ignition position adjust points p0 to p9 ebus address postventilationtime waiting time pulse per l/m³ air valve rest pos erase memory leak checks test timevalve 1 test timevalve 2 control address checking the air pressure switch calculation of characteristic points preventilation adjust limit points low regulation setting high regulation setting safety time start up the burner using the boiler regulator for warm adjustment stabilisation time operating on low ctrl setting return to operating display operation information mode language mode t<5 s t>5 s lockout info parameter general · · · · · · lockout n-0 lockout n-1 lockout n-2 lockout n-3 lockout n-4 lockout n-5 · fuel consumption m³ · operating time total hrs · number of successful starts ebus address air valve closed leak check postventilation memory content software version date · safety unit product -number · · · · · · · · · · · · · · · · · fuel gas point p0 point p1 point p2 point p3 point p4 point p5 point p6 point p7 point p8 point p9 · · · · · francais english deutsch italiano nederlands 8 12/2008 art nr 13 023 168c

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assembly burner assembly burner assembly burner flange 3 is equipped with elongated slots and can be used with a hole circle diameter of 150 180 mm these dimensions comply with en 226 sliding pipe bracket 2 on the burner pipe makes it possible to adjust the installed depth of the burner head to the geometry of the combustion chamber concerned the installed depth remains the same during fitting and removal the burner is secured to the connecting flange and therefore to the boiler via pipe bracket 2 this completely seals off the combustion chamber installation · secure connecting flange 3 to the boiler using screws 4 · fit pipe bracket 2 to the burner pipe and secure using screw 1 tighten screw 1 to a maximum torque of 6 nm · turn the burner slightly guide it into the flange and secure using screw 5 removal · loosen screw 5 · turn the burner out of the bayonet socket and pull it out of the flange burner tube installation depth and brickwork surround for boilers without a cooled front wall a brickwork surround 5 as shown in the diagram is required unless otherwise indicated by the boiler manufacturer the brickwork must not protrude beyond the leading edge of the burner tube and should have a maximum conical angle of 60° the space between the brickwork and burner tube should be filled with an elastic non-flammable 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 gas train assembly · check that ring seal j1 is present and correctly fitted to the flange only for burners g02.160 210 · mount the gas restricting piece 4 supplied with the housing · mount the gas train facing left or right · route the connection cable for the gas train through clamp 7 and fit it to the gas train general regulations applying to the gas connection · the gas train must be connected to the gas mains only 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 gas ball valve not supplied must be fitted upstream of the gas train · in germany a thermally triggered shut-off valve not supplied must be fitted as specified by the draft combustion ordinance it is assumed that the system obtains approval at the responsibility of the installer or his representative at the same time as the burner is commissioned only the authorised fitter can guarantee that the system complies with relevant standards and regulations the fitter should be in possession of the corresponding official permit and should carry out the corresponding leak checks and purge the system of air 12/2008 art nr 13 023 168c 9

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assembly checking the burner head adjusting the burner head in liquid gas mode gauge glass/flue cooling checking the burner head · remove the three screws w from the cover · remove the cover · loosen lock nut e on the gas pipe bracket · loosen the retaining bolt · remove the combustion head · when fitting the burner head ensure that o-ring j2 is correctly positioned v-g 02.120 v-g 02.160/210 checking the burner head · check the adjustment of the ionisation sensor and the ignition electrode as shown in the illustration adjusting the burner head in liquid gas mode by default the burner head is set to operate on natural gas to operate on liquid gas the burner head must be converted as follows to operate on liquid gas it is also necessary to program a postventilation time of 20 seconds see page 15 g 02.120 burner · remove stabilising gas stop 3 and baffle plate 4 · fit adaptor 5 supplied with the housing · refit baffle plate 4 without stabilising gas stop 3 g 02.160/210 burner · remove stabilising gas stop 3 and baffle plate 4 · fit adaptor 5 supplied with the housing · refit baffle plate 4 and stabilising gas stop 3 vg 02.120 inspection glass cooling the burner housing can be equipped with an r1/8 connection to support a line for cooling the inspection glass of the boiler · to do this drill through boss 6 and cut an 1/8 thread · use accessories article no 12 056 459 for the threaded union and connection hose exhaust system to avoid unfavourable noise emissions right-angled connectors should not be used on the flue gas side of the boiler g 02.160/210 10 12/2008 art nr 13 023 168c

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assembly electrical connection all electrical installation and connection work must only 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 that the supply voltage corresponds to the specified operating voltage of 230 v 50 hz boiler fuse rating 10 a it must be possible to isolate the burner from the mains using an omnipolar isolating switch complying with applicable standards the burner and boiler are connected via one 7 pin and one 4 pin plug connection the diameter of the cables connected to these plugs must be between 8.3 and 11 mm electrical connection prior to any maintenance of connectors to the gas and air servomotors display or the e-bus connector the burner must be unplugged from the 7 pin plug gas train connection · connect the gas train to the plugs on the burner black to black grey to grey gas safety valve power supply connection · the gas safety valve not supplied is connected to connection 1 on the safety unit see page 6 gas throttle servomotor connection · carefully connect the connector plugs between the burner and the gas throttle servomotor as per the diagram provided incorrectly positioning the plug can cause irreparable damage to the electrical components in the servomotor connection of the burner to the boiler · plug the 4 pin and 7 pin plug for the boiler control panel into the corresponding sockets of the burner safety unit 12/2008 art nr 13 023 168c 11

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commissioning burner adjustment data setting table natural gas burner vg02.120m vg02.160m vg02.210m gas throttle opening pressure air flap position dimension furnace controller y pressure ignition ignition setting pbr mm mbar low-load full-load load low-load full-load load low-load full-load mbar p0 ° p1 ° p9 ° p0 ° p1 ° p9 ° 40 80 20 0 5 5 27 11 11 28 13,5 40 55 55 60 60 60 60 110 160 150 160 170 180 195 30 5 15 5 10 15 35 0 0 0 0 0 0 0 5 5 8 5 5 5 5 5 5 8 5 5 5 5 42,5 90 40 90 90 90 90 11 16 15,6 16 16 16 16 11 16 15,6 16 16 16 16 41,6 65 41,6 65 65 65 65 13,5 13 13 13 13 13 13 burner power kw only for burner g02.210 · in the case of operation at low gas pressures it is compulsory to remove the gas restricting piece 4 of the gas inlet setting table liquid gas burner power kw gas throttle opening pressure air flap position dimension furnace controller burner y pressure ignition ignition setting pbr mm mbar low-load full-load load low-load full-load load low-load full-load mbar p0 ° p1 ° p9 ° p0 ° p1 ° p9 ° 40 80 20 0 5 5 31 0 0 18 19,5 v40 110 25 0 5 5 54 0 0 31 19,5 g02.120m 50 140 5 0 5 5 39,5 0 0 28,5 13 v60 155 15 0 10 10 55 9 9 31,2 13 g02.160m 70 170 5 0 16 16 85 13 13 40,6 13 70 180 10 0 16 16 85 13 13 40,6 13 v70 190 15 0 16 16 85 13 13 40,6 13 g02.210m 70 200 35 0 16 16 85 13 13 40,6 13 the above setting data correspond to the default settings the factory settings appear on a grey background within a black box these adjustment values are normally suitable for commissioning the burner always check the adjustment values on a case by case basis individual plant conditions may require certain corrections 12 12/2008 art nr 13 023 168c

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commissioning position of the burner head gas pressure switch air pressure switch /pressure controller setting position of the burner head dimension y is adjusted by turning screw a adjust the settings of the burner head in accordance with the table page 12 operation during starting and combustion may be affected by the burner head settings air pressure switch adjustment · remove the transparent cover · provisionally adjust the air pressure switch to minimum setting setting the gas pressure switch · remove the transparent cover · set the setting scale to 5 mbar natural gas and liquid gas the gas pressure switch is built into the valves the safety gas valve y15 is actuated 1 second before the safety time the gas pressure switch must switch within this time if there is insufficient gas pressure the burner start will be interrupted and a waiting time of 2 minutes will start this waiting time is followed by a further start attempt the waiting time can only be reset by interrupting the power supply to the burner waiting times 3 x 2 min then 1 hour pressure controller setting the gas pressure controller is set at 10 mbar in the factory check the gas pressure after the first burner start measuring point at gas train outlet flange and if necessary correct gas pressure pbr at adjustment screw s in accordance with the table page 12 after start up no further changes should be made ionisation current measurement to measure the ionisation current remove measuring bridge b1 and connect a multimeter with a measuring range of 0-100 µa the monitoring current must be at least 8 µa 12/2008 art nr 13 023 168c 13

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commissioning checks before start-up self-testing of the safety unit checks before start-up the following must be checked before initial start-up · correct assembly of the burner in accordance with these instructions · correct preliminary adjustment of the burner in accordance with the values in the adjustment table · combustion head setting · the heat generator must be assembled and ready to operate the operating instructions of the heat generator manufacturer must be complied with · all electrical connections must be correctly installed · the heat generator and heating system are supplied with sufficient water circulators are operational · the temperature controller pressure controller and protection devices for low water and other safety equipment and any existing limiting devices must be correctly connected and in working order · conduits for combustion gases must be unobstructed and the air supply if applicable must be operational · an adequate supply of fresh air must be guaranteed · the heat recovery system must be installed · minimum required gas pressure according to the gas valve assembly table must be supplied · fuel lines must be assembled by a professional and they must be checked for leaks and purged of air · a standard measuring point must be available for analysis of combustion gases conduits for combustion gases to this point must be airtight to avoid external air influencing the measurements starting the burner risk of air blast during adjustment continuously check emissions of co co2 and soot optimise combustion values if co is present the level of co must not exceed 50 ppm perform the first settings with the manual gas valve closed do not open the valve unless stated in the start up instructions · activate the boiler controller to start the burner safety unit test air gas self-testing of the safety unit switch on the burner the safety unit runs a self-test if the safety unit has not yet been programmed the display will then show unit deprogrammed self-testing of the safety unit and of the air and gas stepper servomotors loading 0 100 the displays loads the values stored in the safety unit unit deprogrammed the safety unit has not yet been programmed 14 12/2008 art nr 13 023 168c

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commissioning access to the setting mode parameter menu programming of additional functions access to the setting mode is only possible when the burner is stopped display unit deprogrammed or thermostatic cut-off for this purpose reduce the temperature at the boiler controller or remove bridge plug 7 to activate the setting mode it is also possible to enter an access code precautions the setting mode is activated via the access code and the burner setting must only be adjusted by a technician adequately qualified and authorised to handle the mpa 22 the access code is located on an information plate affixed to the mpa22 safety unit during the setting procedure a time-out of 30 minutes will be activated if no buttons are pressed this time may be reset by pressing the keypad after this time has expired the boiler stops so that it cannot run until the setting procedure is completed in setting mode all safety functions are activated flame failure air pressure switch failure or a fault in the stepper motor control will lead to a fault or safety disconnection unit configuration code access to the setting mode · press and hold button and after 0.5 seconds press button or · enter the access code numbers with buttons · confirm each number with · if a number is entered incorrectly button program parameter setting allows you to return to the level above after entering the correct code three menus will appear for selection parameter for programming of additional functions program for presetting the burner during initial start-up settings for partial programming e.g after thermostatic cut-off during adjustment or during subsequent correction of the adjustment values e-bus address 03h parameter the parameter menu item is accessed via the setting mode it allows the various additional functions and function parameters to be set e-bus address 03h standard address factory setting this parameter is required to establish communication with a pc other addresses are possible f3h 73h 33h 13h access to the next parameter confirm next with button this parameter enables a postventilation time to be set setting range 0 s no postventilation up to 240 s postventilation 0-240 secs 000s next previous end stop 0-100 min 000 min next previous this parameter enables a waiting time between a standard disconnection and a new burner start to be set setting range 0 min no waiting time up to 100 min impuls 1-255 l m3 200 next previous this parameter indicates the number of pulses that the gas counter sends to the safety unit for one cubic meter of gas consumed setting range 1 1 pulse 1m3 to 255 255 pulse 1m3 12/2008 art nr 13 023 168c 15

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