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vectron g 05.700 modulo vectron g 05.1000 modulo operating instructions for the authorised specialist gas burners 2-31 en ersatzteilliste spare parts list pièces de rechange wisselstukkenlijst art nr 13 019 525 elektro und hydraulikschema electric and hydraulic diagrams schémas électr et hydraulique elektr en hydraulische schema 09/2005 art nr 13 019 526a art nr 13 018 839

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overview contents overview contents declaration of conformity 2 important notes 3 description of burner scope of delivery optional accessories 4 technical data power graphs 5 gas valve selection 6 dimensional drawings and measurements 7 gas valve assembly 8 hydraulics diagrams 9 control panel 10 overview of combustion control unit mpa22 function description 11 display and operating unit 12 programme structure 13 assembly burner head burner housing 14 gas valve assembly 15 checking/setting mixer unit for natural gas/propane gas 16 gas supply electrical supply 17 start-up default settings 18 burner head gas and air pressure switch settings gas pressure regulator 19 checks before start-up 20 control unit auto-test 20 adjustment mode 21-25 access 21 parameters menu 21-22 cold adjustment menu 23 hot adjustment menu 24-25 operating mode 26 info mode 27 voice mode 28 maintenance 28-29 burner-specific adjustment settings of the mpa 22 30 troubleshooting 31 declaration of conformity for gas burners we ceb of 18 rue des bûchillons ville-la-grand f-74106 annemasse cedex declare under our sole responsibility that the products vectron g 05.700 modulo vectron g 05.1000 modulo conform to the following standards en 60335 en 50081 en 50082 en 676 in accordance with the stipulations of the european directives 90 396 eec gas device guidelines 89 336 eec emc directive 73 23 eec low voltage directive 92 42 eec working efficiency directive these products bear the ce marking ville-la-grand 01 january 2005 j haep 2 09/2005 art nr 13 019 526a

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overview important notes important instructions the g 05.700/1000 modulo burners are designed to burn natural gas or propane gas in category ii 2 ell 3p 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 design and function of the burners meet standard en676 assembly start-up and maintenance must be carried out only by authorised specialists and all applicable guidelines and regulations complied with gas pipes and fittings must likewise be installed in compliance with all applicable guidelines and regulations e.g dvgw-trgi 1986/96 trf 1988 din 4756 only dvgw-tested and -approved sealing materials should be used connections should be leak-tested using non-corrosive foam-producing materials or similar gas piping should be vented before start-up under no circumstances should venting be carried out over the furnace repair work to switches limiters control and safety units and other individual items of safety equipment must be carried out by the relevant manufacturer or his representatives the replacement of original parts must be carried out by specialist staff basic regulations the following standards should be observed in order to ensure safe environmentally sound and energy-saving operation din 4705 calculation of flue dimensions en 676 forced-draught gas burners en 226 connection to heating systems of vaporising-fuel-oil and forced-draught gas burners vde 0116 electrical equipment for furnace systems en 60335-1 safety of electrical equipment for domestic use and similar purposes vde 0722 electrical equipment for non-electrically powered heating devices installation location the burner must not be used in rooms with aggressive vapours e.g hair spray perchlorethelen carbon tetrachloride high levels of dust or high air humidity e.g washhouses an air inlet must be present ­ up to 50 kw 150 cm² ­ for every further kw +2 cm² variations may arise as a result of local regulations the guarantee does not cover damage resulting from · inappropriate use · incorrect installation and/or initial start-up on the part of the buyer or any third party including the fitting of non-original parts · operation of the system at excessive pressure final delivery and instructions for use the combustion system manufacturer must supply the operator 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 heating unit and 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 it is advisable to enter into a maintenance contract in order to ensure trouble-free running en 09/2005 art nr 13 019 526a 3

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overview description of burner burner description the g 05.700/1000 modulo burners are low emission modulating gas burners with a monoblock type electronic connection they are suitable for use with all heat generators in accordance with din 4702/en 303 within the respective performance range scope of delivery the burner is supplied in three packaging units · burner housing with operating instructions flow diagram spare parts list combustion chamber board · burner head with flange seal and fixing screws · gas valve assembly with gas throttle module dmv gas valve with built-in pocket filter or with external filter connection parts screws seals ­ ­ ­ ­ ­ ­ ­ ­ ­ optional accessories separate air intake box air intake silencer gas stop valve thermal safety cut-out valve compensator power regulator potentiometer test burner pressure gauge a1 a4 b10 f6 f12 k1 m1 t1 y10 7 8 13 113 combustion control unit display and operating unit ionisation bridge air pressure switch protective motor relay motor contactor burner motor ignition transformer concealed servomotor air flap control panel blast tube burner cover air box 4 09/2005 art nr 13 019 526a

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overview technical data power graphs type description burner power operating mode fuel gas valve gas connection gas flow pressure burner motor 2800 ¹/min combustion control unit/flame sensor power consumption protection level ambient temperature max ignition transformer air flap drive gas throttle drive burner tube-Ø x insertion depth mm air pressure switch burner weight incl gas valve kg ce mark 1312 aq 0924 °c w 1800 ip 41 60° c ebi-m 2 x 7.5 kv servomotor ste 4.5 q5.51/6-02r runtime aspprox 40 sec with adjustment travel of 90° servomotor ste 4.5 170 x 215 kn 325 km kl 435 lgw 10 a 2 100 kg 1312 aq 0925 m bar 230/400 v 50 hz 1.1 kw kw g 05.700 modulo 140-700 g 05.1000 modulo 170-1040 two-stage sliding/modulating natural gas ll e hi 8.83-10.35 kwh/m3 or propane gas f hi 25.89 kwh/m3 dmvse 512-t rp 1 1/2 dmvse 520-t rp 2 dmvse 512-t rp 1 1/2 20-100 230/400 v 50 hz 1.5 kw mpa 22/ionisation/alternative ird probe 2000 dmvse 520-t rp 2 dmvse 525-r rp 2 dmvse 5065-r dn 65 en note on type designation g 05 700 modulo natural gas/propane gas size power rating modulating with electronic connection mbar 10 8 6 4 2 kn normal burner head length km medium burner head length kl long burner head length dapa 100 80 60 40 20 0 g 05.700 modulo mbar 10 8 6 4 2 dapa 100 80 60 40 20 0 g 05.1000 modulo 0 100 300 500 700 900 1100 kw 335 0 100 300 500 700 900 1100 kw 530 1040 power graph when selecting the burner and gas valves the boiler efficiency must be taken into account power graphs are expressed as burner power relative to furnace pressure this corresponds to the maximum value in accordance with en676 measured on the test blast tube calculation of the burner power qn hk qf burner power kw qn krated boiler power kw hk boiler efficiency qf 09/2005 art nr 13 019 526a 5

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overview gas valve selection the gas pressure loss specified in the table is to be added on to the combustion chamber pressure in mbar n.b the calculated gas flow pressure is to be complied with at the gas valve inlet to calculate the gas flow pressure required at the transfer station the resistance of the burner supply conduit including valves ball valve tas additional filter or counter must also be taken into account g 05.700 modulo burner power dmv512-t rp1,1/2 dmv520-t rp 2 dmv512-t rp1,1/2 dmv520-t rp 2 dmv512-t rp1,1/2 propane gas hi=25.89kwh/m³ natural gas e hi 10.365 kwh/m3 kw 550 600 650 700 16 19 22 26 15 15 18 21 natural gas ll hi 8.83 kwh/m3 gas pressure loss from gas valve inlet 17 21 24 28 15 16 19 22 15 15 17 20 g 05.1000 modulo burner power dmv512-t rp1,1/2 dmv520-t rp 2 dmv525-r rp 2 dmv5065-r dn65 dmv520-t rp 2 dmv525-r rp 2 dmv5065-r dn65 dmv512-t rp1,1/2 propane gas hi=25.89kwh/m³ natural gas e hi 10.365 kwh/m³ kw 550 600 650 700 750 800 850 900 950 1000 17 20 23 27 31 35 40 44 49 55 15 15 15 17 20 23 26 29 32 36 15 15 15 15 18 20 23 25 28 31 natural gas ll hi 8.83 kwh/m³ gas pressure loss from gas valve inlet 15 15 15 15 18 20 23 25 28 31 15 17 20 24 27 31 35 39 44 48 15 15 17 20 23 26 29 33 37 41 15 15 17 20 23 26 29 33 37 41 15 15 16 18 21 24 27 30 34 38 1 example for burner g 05.1000 modulo · system data gas type natural gas e gas flow pressure 20 mbar n.b at gas valve inlet required burner power 700 kw combustion chamber pressure with boiler rated load 2.5 mbar · condition working point must be within the burner s permissible field of work · selected gas valve dmv 520-t · checking the selection ­ gas pressure loss from table 17 mbar ­ combustion chamber pressure 2.5 mbar total 19.5 mbar ­ hence gas flow pressure 20 mbar >19.5 mbar ðselection of dmv520-t correct ­ ­ ­ ­ 6 09/2005 art nr 13 019 526a

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overview dimensional drawings and measurements g 05.700/1000 modulo with dmv se gas valve km kl kn en km kl kn km kl kn space requirements there should be a space of no less than 0.60 m on each side of the burner for maintenance purposes gas valve assembly the valve assembly can be fitted on the left or the right 09/2005 art nr 13 019 526a 7

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overview gas valve assembly the gas valve assembly consists of ­ a gas throttle controlled by a servomotor ­ a dmv-se gas valve ­ a gas filter pocket filter or external filter ­ a thermally triggered safety cut-off valve and a gas ball valve are to be provided by the manufacturer dmv se 512 520 with pocket filter dmv se gas valve 1 electrical connection of the solenoid valves din 43650 2 electrical connection of the gas pressure switch din 43650 3 gas pressure switch 4 gas inlet flange 5 pocket filter under cover 6 gas pressure adjusting screw pbr 8 gas pressure measuring nipple g1/8 9 pipe filter dmv se 525 with pipe filter installation position vertical with upwards facing magnet description technical data the compact gas valve dmv se 512,520 is a compact unit with 2 class a solenoid valves class a servo-pressure regulator pocket filter and pressure switch for the dmv se 525 5065 types the tube filter is installed externally ­ pressure switch gw a5 adjustment range 5 50 mbar ­ magnetic valve v1/v2 quick opening/quick closing ­ servo-pressure regulator can be adjusted via a spindle dmv se 5065 with pipe filter ­ max operating overpressure 500 mbar ­ inlet pressure range pe 15-500 mbar ­ voltage/frequency 230 v/50-60 hz 8 09/2005 art nr 13 019 526a

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overview hydraulics diagram en 09/2005 art nr 13 019 526a 9

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overview control panel function a2 a4 a4.1 standardised position for fitting three-point regulator display and operating unit mounting location with clips for removing the display and operating unit flame signal measuring bridge concealed fuse b10 f10 s1/h10 main switch 0 off 1 on operating light in switch lights up s2 s3 operating mode selector switch auto/manual n manual increase of burner power manual reduction of burner power all control elements are visible externally a removable transparent cover clipped to the burner cover gives access to the monitoring and control elements for setting and operating the burner the control panel contains the switching circuit cut-out to remove the cover press in one or both sides gently and pull out at the same time to replace the cover position the two clips at the appropriate openings and push in n.b mmain switch of the control panel the only operates the control voltage before working in the control area of the burner disconnect it fully from the mains incl burner motor ac connection 10 09/2005 art nr 13 019 526a

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overview combustion control unit mpa22 function description in addition to the function of a gas combustion control unit the mpa 22 combustion control unit also realises power modulation of the burner via the actuation of air flaps and gas throttle in an electronic connection the electronic connection controls the opening of the gas throttle proportional to the air flap along a curve based on 10 adjustment points during start up the adjustment points are defined based on the measurement values of the exhaust gas analysis this guarantees optimal combustion across the entire performance modulation of the burner with adjustment point p0 a separate ignition load can be defined for the burner the thresholds for the normal range are defined with adjustment points bu and bo lower operasssting point and upper operating point in addition other optional functions such as leak checks reventilation or waiting times can be activated the combustion control unit is operated via a display and operating unit ¬ en ¬ ¬ ¬ ¬ 1 2 3 4 5 6 7 additional propane gas valve ¬ safety gas valve y15 main gas valve y13 burner motor m1 ignition transformer t1 power 230v-50hz gw max bridge connector safety chain inlet ¬ 8 9 10 11 12 13 14 gw min f4 gw vps ¬ air pressure switch f6 15 16 air servomotor y10 display and operating unit connection a e-bus connection ¬ power regulator connection 4p boiler control panel connection 7p option 17 light sensor ¬ 18 flame monitor uv/ion ¬ pulse counter ¬ gas servomotor y11 19 ¬ 09/2005 art nr 13 019 526a 11

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overview combustion control unit mpa 22 display and operating unit display button · access to info mode t 5 s · access to voice mode t 5 s · return to next highest program level · activating a function · confirming a value · moving the cursor anti-clockwise · increasing the marked value · moving the cursor clockwise · reducing the marked value · unlocking the combustion control unit · red light diode flashes in the event of a fault current values and operating statuses are displayed via the display and operating unit by activating certain keys it is possible to switch to info mode operating mode or voice mode in addition to adjustment mode 12 09/2005 art nr 13 019 526a

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overview combustion control unit mpa 22 program structure voice mode adjustment mode enter access code parameter adjustment t>5 s cold adjustment hot adjustment temperature controller on set key data p9/p1/p0 burner start-up burner burns in ignition setting setting for points p0 to p9 adjustment of upper/lower threshold points ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ebus address reventilation time waiting time pulses per l/m³ rest pos air flap delete error list check for leaks valve 1 check time valve 2 check time address regulation · · · · · francais english deutsch italiano nederlands calculation of characteristics curve points p2 p8 en start burner via boiler regulator for hot adjustment operation at bu lower operating point back to operating display operating mode info mode ready for operation t<5 s temperature controller on start-up errors counters parameters settings check air pressure switch pre-ventilation safety time · · · · · · error error error error error error 0 1 2 3 4 5 · fuel consumption m · total operating time hours · successful · · · · · · · · · · · burner starts stabilization time ebus address rest pos air check for leaks reventilation error list software automatic control unit version date product no · · · · · · · · · · · fuel value value value value value value value value value value p0 p1 p2 p3 p4 p5 p6 p7 p8 p9 operation 09/2005 art nr 13 019 526a 13

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assembly burner head burner housing boiler door preparation · prepare the burner plate/boiler doors as per the drawing · stipulate interior diameter Ø 195 mm · four m10 holes 220-260 mm diameter circle are required as indicated in the accompanying diagram fitting the burner head · screw m10 stay bolts into the burner plate/boiler door and add the insulation if the bolt circle is <260 cut slots to the required size · fix the burner head with 4 hexagonal nuts m10 Øa 195 Øb 220-260 de c d 45° m10 blast tube installation depth on boilers with reverse firing or on three-pass boilers the blast tube installation depth must be complied with for correct operation the following standards are to be reconciled with the boiler manufacturer s specifications ­ boiler in reverse firing chamber dimension a boiler front to reverse edge of second pass 80-190 mm insertion depth ­ three-pass boiler -20 to +90 mm insertion depth fitting the burner housing · dismantle the mixing unit before fitting the burner housing · undo the fixing screw m10 counter nut and allen screw on the side of the unit opposite the gas connection and withdraw the mixing unit if the burner housing hangs below the burner head axis proceed as follows · unscrew and remove the two lower nuts on the burner housing and unscrew the two upper nuts as far as possible 14 · place the burner housing sloping diagonally forwards and fit the two upper bolts into the two slots in the burner head flange · press the burner housing against the burner head flange and tighten the 4 nuts the housing can be mounted above the axis of the burner head if required in this case the procedure must be reversed no other positions for the burner housing are possible 09/2005 art nr 13 019 526a

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assembly gas valve assembly assembly gas valve assembly · press the gas throttle module 5 against the burner head and tighten the 4 nuts then secure the gas connection pipe 3 to the gas throttle module check that o-ring 6 and flat gasket 4 are in the correct position · secure gas valve 2 so that the solenoids of dmv se are positioned vertically over the gas valve · fit the supplied gas pressure tube 7 between the gas throttle module and dmv se · if available secure external filter 1 · note the direction of the flow · fit a thermally triggered safety valve and a gas ball valve provided by manufacturer before the gas valve the gas m if the position ofenclosedtrain is angled use the right-angled pressure release pipe with screw connection if the gas valve is changed the applicable guidelines and regulations must be observed all connections should be leak-tested using foam-producing or similar materials caption 1 external filter 2 gas valve 3 gas connection pipe 4 flat gasket between gas connection pipe and gas throttle module 5 gas throttle module 6 o-ring between gas throttle module and burner head flange 7 gas pressure tube 1 2 3 4 5 6 en 7 09/2005 art nr 13 019 526a 15

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