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vectron g 06.1600 modulo vectron g 06.2100 modulo operating instructions for the authorised specialist gas burners 2-35 en ersatzteilliste spare parts list pièces de rechange wisselstukkenlijst art nr 13 018 117 elektro und hydraulikschema electric and hydraulic diagrams schémas électr et hydraulique elektr en hydraulische schema 09/2005 art nr 13 019 527a art nr 13 018 839

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overview contents contents overview contents declaration of conformity 2 important notes 3 description of burner scope of delivery accessories 4 technical data power graphs 5 gas valve selection 6 dimensional drawings and measurements 7-9 gas valve assembly 10 hydraulics diagrams 11 control panel 12 overview of combustion control unit mpa22 operating description 13 display and operating unit 14 programme structure 15 assembly burner head burner housing 16 gas valve assembly 17 check mixing unit secondary air 18 setting mixing unit for natural gas/propane gas 19 gas supply electrical supply 20 start-up default adjustment settings 21 setting burner head position gas and air pressure switches 22 electrical supply 23 control unit auto-test 23 adjustment mode 24-27 access 24 parameters menu 24-25 cold adjustment menu 26 hot adjustment menu 27-28 operating mode 29 info mode 30 voice mode 30 notes 31 maintenance 32-33 burner-specific adjustment settings of the mpa 22 34 troubleshooting 35 declaration of conformity for gas burners we factory certified with nr aqf030 of 18 rue des bûchillons ville-la-grand f-74106 annemasse cedex declare under our sole responsibility that the products vectron g 06.1600 modulo vectron g 06.2100 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 2 may 2005 j haep 2 09/2005 art nr 13 019 527a

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overview important notes important instructions the vectron g 06.1600/2100 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 perchloroethylene 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 09/2005 art nr 13 019 527a 3

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overview description of burner burner description the vectron g 06.1600/2100 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 15 113 combustion control unit display and operating unit ionisation bridge air pressure switch motor protection relay motor contactor blower motor ignition transformer concealed air servomotor control panel blast tube cover air box 4 09/2005 art nr 13 019 527a

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overview technical data power graphs type description burner power ce number type check operating mode gas flow pressure mbar fuel gas valve gas connection burner motor 2900 ¹/min combustion control unit/flame sensor power consumption w protection level ignition transformer air flap drive gas throttle drive burner tube diameter x insertion depth mm air pressure switch burner weight incl gas valve kg ambient temperature max °c kw g 06.1600 modulo g 06.2100 modulo 230-1600 260-2100 1312 bm 3427 1312 bm3428 in accordance with en 676 emissions class 3 for natural gas nox 80mg/kwh for propane gas nox 140mg/kwh under test conditions two-stage sliding/modulating 20-100 natural gas ll e hi 8.83-10.35 kwh/m3 or propane gas f hi 25.89 kwh/m3 dmv 512-t dmv 520-t dmv 525-r dmv 5065-r dmv 520-t dmv 525-r dmv 5065-r rp 1 1/2 rp 2 rp 2 dn 65 rp 2 rp 2 dn 65 230/400 v 50 hz 2.2 kw 230/400 v 50 hz 2.7 kw mpa 22/ionisation/alternative ird probe 2500 3100 ip 41 ebi-m 2 x 7.5 kv servomotor ste 4.5 b03/12 runtime approx 40 sec with adjustment travel of 90° servomotor ste 4.5 227 x 270 kn 370 km kl 470 lgw 3 a 2 in total 120 kg 60° c note on type designation g natural gas/propane gas 06 size 1600 power rating modulo modulating with electronic connection mbar 12 10 8 6 4 2 dapa 120 100 80 60 40 20 0 200 0 260 kn normal burner head length km medium burner head length kl long burner head length dapa 120 100 80 60 40 20 g 06.1600 modulo g 06.2100 modulo mbar 12 10 8 6 4 2 0 200 500 230 800 0 1100 1400 1700 kw 1600 800 1400 0 2000 kw 2100 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 qf qn hk qf burner power kw qn rated boiler power kw hk boiler efficiency 09/2005 art nr 13 019 527a 5

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overview gas valve selection 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 06.1600 modulo burner power dmv512-t dmv520-t dmv525-r dmv5065-r dmv512-t dmv520-t dmv525-r dmv5065-r dmv512-t dmv520-t rp 1,1/2 rp 2 rp 2 dn65 rp 1,1/2 rp 2 rp 2 dn65 rp 1,1/2 rp 2 natural gas e hi 10.365 kwh/m³ kw 800 850 900 950 1000 1050 1100 1200 1300 1400 1500 1600 16 18 20 23 25 28 30 36 42 49 56 64 dmv520-t rp 2 15 15 16 18 20 22 24 29 34 39 45 51 15 15 15 15 16 18 20 24 28 32 37 42 dmv525-r rp 2 natural gas ll hi 8.83 kwh/m³ gas pressure loss from gas valve inlet 15 15 15 15 16 18 19 23 27 31 36 41 dmv5065-r dn65 21 24 27 30 33 37 40 48 56 65 75 85 18 20 23 25 28 31 34 40 47 55 63 72 15 15 15 16 17 19 21 25 29 34 39 44 dmv525-r rp 2 15 15 15 16 17 19 21 25 29 34 39 44 dmv5065-r dn65 8 8 9 11 12 13 14 17 20 23 26 30 7 8 9 10 11 12 13 16 19 22 25 28 dmv520-t rp 2 propane gas hi 25.89 kwh/m3 propane gas hi 25.89 kwh/m3 g 06.2100 modulo burner power dmv520-t rp 2 natural gas e hi 10.365 kwh/m3 kw 1100 1150 1200 1250 1300 1400 1500 1600 1700 1800 1900 2000 21 23 25 27 29 34 39 44 50 56 63 69 15 15 16 18 19 22 25 29 32 36 41 45 natural gas ll hi 8.83 kwh/m3 gas pressure loss from gas valve inlet 15 15 15 15 17 19 22 25 28 32 35 39 29 32 35 38 41 48 55 62 70 79 88 98 20 22 24 26 28 32 37 42 47 53 59 65 19 21 23 25 27 31 36 41 46 52 58 64 13 15 16 17 19 22 25 28 32 36 40 44 example for burner g 06.2100 modulo · system data gas type natural gas ll gas flow pressure 50 mbar n.b at gas valve inlet required burner power 1600 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 525-r · checking the selection ­ gas pressure loss from table 42 mbar ­ combustion chamber pressure 2.5 mbar total 44.5 mbar ­ hence gas flow pressure 50 mbar 44.5 mbar ðselection of dmv 525-r correct ­ ­ ­ ­ 6 09/2005 art nr 13 019 527a

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overview dimensional drawings and measurements g 06.1600/2100 modulo with dmv se 512 520 gas valve km kl kn km kl kn space requirements there should be a space of no less than 0.60 metre 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 527a 7

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overview dimensional drawings and measurements g 06.1600/2100 modulo with dmv se 525 gas valve km kl kn km kl kn space requirements there should be a space of no less than 0.60 metre on each side of the burner for maintenance purposes gas valve assembly the valve assembly can be fitted on the left or the right 8 09/2005 art nr 13 019 527a

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overview dimensional drawings and measurements g 06.1600/2100 modulo with dmv se 5065 gas valve km kl kn km kl kn space requirements there should be a space of no less than 0.60 metre 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 527a 9

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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 ­ solenoid 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 10 09/2005 art nr 13 019 527a

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overview hydraulics diagram 09/2005 art nr 13 019 527a 11

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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 operating mode selector switch auto/manual n manual increase of burner power manual reduction of burner power s3 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 also 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 12 09/2005 art nr 13 019 527a

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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 operating 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 ¬ ¬ ¬ ¬ ¬ 1 2 3 4 5 6 7 8 additional propane gas valve¬ 9 safety gas valve y15 10 main gas valve y13 11 burner motor m1 ignition transformer t1 power 230v-50hz gw max bridge connector safety chain inlet ¬ gw min f4 12 13 14 15 gw vps ¬ air pressure switch f6 light sensor¬ flame monitor uv/ion ¬ pulse counter¬ gas servomotor y11 air servomotor y10 16 17 18 19 ¬ display and operating unit connection a e-bus connection ¬ power regulator connection 4p boiler control panel connection 7p option 09/2005 art nr 13 019 527a 13

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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 14 09/2005 art nr 13 019 527a

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overview combustion control unit mpa 22 program structure voice mode adjustment mode enter access code hot adjustment temperature controller on set key data p9/p1/p0 burner start-up burner burns in ignition setting ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 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 parameter adjustment t>5 s cold adjustment · · · · · francais english deutsch italiano nederlands setting points p0 to p9 calculation of characteristics curve points p2 p8 adjustment of upper/lower sthreshold points start burner via boiler regulator for hot adjustment operation at bu lower operating point back to operating display operating mode info mode standby 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 m³ · total operating time hours successful · burner starts · · · · · · · · · · · stabilisation time ebus address rest pos air check for leaks reventilation error list software automatic control unit version date product no · · · · · · · · · · · fuel gas value p0 value p1 value p2 value p3 value p4 value p5 value p6 value p7 value p8 value p9 operation 09/2005 art nr 13 019 527a 15

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