elco N6.2400 G-V User manual

10/2010 - Art. Nr. 4200 1032 1300A
N6.2400 G-V
N6.2900 G-V
N7.3600 G-V
N7.4500 G-V
de, fr ..................................... 4200 1032 1400
it, nl ...................................... 4200 1032 1500
............................................. 4200 1032 0000
Operating instructions
For specialist installation engineers
Gas burners ........................................... 2-25 e
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10/2010 - Art. Nr. 4200 1032 1300A2
Overview
Contents
Overview Contents.................................................................... 2
Important information................................................2
Burner description..................................................... 3
Operation Gas start-up mode, gas operating mode ..................4
General safety functions........................................... 4
Equipment options.................................................... 5
Automatic furnace controller LFL 1.../LGK................ 6
Gas valve VGD with SKP actuator............................ 7
Gas valve MBC-VEF................................................. 7
Assembly Boiler lining for G-V burner, burner assembly ...........8
Gas connection.........................................................9
Gas manifold, Pressure take-off pipes.................... 10
Checking, assembling the combustion components11
Gas connection, Electrical connection.................... 12
Checks before commissioning................................ 12
Commissioning Working cycle test, Firing........................................ 13
Safety unit settings and checks .............................. 13
Actuator, Limit switch setting .................................. 14
Flame sensor .......................................................... 15
Gas pressure switch, air pressure switch ............... 16
Gas valves and instruments group
Description.............................................................. 17
Basic construction.............................................. 17-19
Gas valve leakage controller................................... 20
Servicing Maintenance ..................................................... 21-22
Exhaust gas test, trouble shooting instructions.. 23-24
Operating trouble .................................................... 25
Important information
N6 and N7 G-V burners are designed for the
low-polluant combustion of natural gas. The
design and function of the burners meet
standard EN 676. They are suitable for use
with all heat generators complying with
standard within their respective performance
range. Any other type of application requires
the approval of ELCO.
Installation, start-up and maintenance must
only be carried out by authorised specialists
and all applicable guidelines and regulations
must be complied with.
Burner description
N6 and N7 G-V burners are modulating
pneumatic fully automatic monoblock
devices. Emissions values may differ,
depending on combustion chamber
dimensions, combustion chamber load and
the firing system (three-pass boilers, boilers
with reverse firing). For specifying warranty
values, the conditions for the measuring
equipment, tolerances and humidity must be
observed.
Packaging
The burner is supplied packaged in three
boxes on a pallet:
- Burner body with:
- integrated switch cabinet
- flange seal and securing screws
- operating instructions, circuit diagram
and spare parts list
- Combustion head
- Compact gas train with integrated or
external filter
The following standards should be observed
in order to ensure safe, environmentally
sound and energy-efficient operation:
EN 226
Connection of fuel oil and forced-draught gas
burners to a heat generator
EN 60335-1, -2-102
Specification for safety of household and
similar electrical appliances, particular
requirements for gas burning appliances
Gas lines
When installing the gas lines and trains, the
general directives and guidelines, as well as
the following national regulations, must be
observed:
CH: - G1 instruction text from SSIGE
- EKAS form no. 1942,
liquefied gas directive, part 2
- Cantonal authority guidelines
(e.g. directives for the pilot valve)
DE: - DVGW-TVR/TRGI
Installation location
The burner must not be used in rooms with
aggressive vapours (e.g. hair spray,
tetrachloroethylene, carbon tetrachloride),
high levels of dust or high air humidity (e.g.
laundry rooms).
If no connection to an air exhaust system is
provided for the air supply, there must be a
supply air inlet measuring:
DE: up to 50 kW: 150 cm2
per additional kW: : + 2.0 cm2
CH: QF [kW] x 6= ...cm2; but at least
200cm2.
Variations may arise as a result of local
regulations.
We accept no responsibility for damage
arising from:
- inappropriate use.
- incorrect installation and/or repair on the
part of the buyer or any third party,
including the fitting of non-original parts.
Final delivery and instructions for use
The firing system fitter must supply the
operator of the system with operating and
maintenance instructions on or before final
delivery. These instructions should be
displayed in a prominent location at the point
of installation of the heat generator, They
should include the address and telephone
number of the nearest customer service
centre.
Notes for the operator
The system should be inspected by a
specialist at least once a year. Depending on
the type of installation, shorter maintenance
intervals may be necessary! It is advisable to
take out a maintenance contract to guarantee
regular servicing.
Declaration of conformity
for gas burners
We,
Elco Burners GmbH, Herbert-
Liebsch-Straße 4a, 01796 Pirna,
Germany,
declare under our sole responsibility
that the products
N6.2400 G-V
N6.2900 G-V
N7.3600 G-V
N7.4500 G-V
conform to the following standards
EN 50165
EN 12953-7
EN 12952-8
EN 61000-6-2
EN 61000-6-4
EN 676
These products bear the CE mark in
accordance with the stipulations of the
following directives
2006/42 /EC Machinery directive
2004/108/EC EMC directive
2006/95/EC Low voltage directive
2009/142/EC Gas appliances
Directive
97/23/EC Pressure Equipment
Directive
Pirna, 26th May 2010
D. HOFFMANN

10/2010 - Art. Nr. 4200 1032 1300A 3
Overview
Burner description
2 Power controller (option)
5 Housing
6 Gas inlet flange
7 Gas damper (manual adjustment)
8 Burner flame tube
10 Integrated electrical cabinet
11 Burner fixing flange
13 Air intake box
19 Hoisting eyes
F6 Air pressure switch
M1 Blower motor
Y10 Actuator for air damper
pF Furnace pressure take-off tube
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10/2010 - Art. Nr. 4200 1032 1300A4
Gas start-up mode
As soon as the furnace system is
required to supply heat, the burner
control circuit will close and the program
flow started. When the program has
come to its end, the burner will be turned
on.
An automatic test is made for the
tightness of the gas valves prior to
each burner start.
The air damper is in its closed
position when the burner is out of
operation.
The electric actuator will open the closed
air damper to its full-load position so that
the burner will ventilate the furnace and
the exhaust hoods with the specified air
rate. Shortly after the pre-ventilation
process has been started the lack-of-air
cut-out must change over to operating
position within a certain time, i.e. the
minimum air pressure setting must be
reached and maintained until the burner
is turned off. At the end of the specified
pre-ventilation time the air damper will
be moved into its partial-load position in
a linked control concept with the gas
damper.
The ignition transformer is activated.
After the pre-ignition time, the main gas
valves are open and the gas comes out
from injectors where it is mixed in the
combustion head with air coming from
the fan. The ignition of the gas air
mixture is done directly by a high voltage
spark on a gas injector. During the
safety time, a stable flame is formed and
is monitored by an ionisation sensor.
The ignition is stopped before the end of
the safety time and the burner operates
at its minimum power. The start-up
programme is completed.
Gas operating mode
After the flame has developed the load
regulator will be enabled which brings
the burner into its operating position.
The load regulator will now control the
burner automatically between its partial-
load and full-load stages. Depending on
the heat demand, the electric actuator of
the compound control system will be fed
with the OPEN or CLOSE command via
the regulator and thus increase or
decrease the gas and air flow rates. This
compound control system will vary the
positions of the gas control valve and air
damper and thus regulate the gas flow
rate in a linked concept with the air flow
rate. The burner can either be controlled
by a 2-stage sliding or, if a respective
controller is provided, a stepless control
concept. The stepless control will allow
the burner to be operated at any desired
stage between its partial-load and full-
load positions.
The air damper will be closed when the
burner is out of operation and will thus
prevent cold air flowing through the
burner chamber, heat exchanger and
chimney. The interior cooling losses will
thus be greatly minimized.
Attention:
If there are shut-off dampers in the flue
gas tract they must be complete open.
Otherwise there will be a high danger of
low-speed detonation or explosion! The
open-position of the shut-off damper can
be assured by the integration of the
opening contact of the shut-off damper
in the safety chain of the heat generator.
General safety functions
In case a flame does not develop when
starting the burner (fuel release), the
burner controller will shut off at the end
of the safety period (shut-off on trouble).
A shut-off on trouble will also occur in
the case of flame failure during
operation, air flow failure during the pre-
ventilation phase and pressure failure
during the whole period of burner
operation. Any failure of the flame signal
at the end of the safety period and a
flame signal during the pre-ventilation
phase (external light control) will result in
a shut-off on trouble with the automatic
furnace controller being locked.
The trouble is indicated by the trouble
signal lamp lighting up. The automatic
furnace controller can be unlocked
immediately after a shut-off on trouble
by pressing the unlocking key. The
program unit will return to its starting
position and proceed with the restart of
the burner.
A voltage failure will result in a regular
shut-off of the burner. After voltage
recovery, the burner can be
automatically restarted unless another
interlock is active, e.g. one caused by
the safety circuit. In any case, the fuel oil
supply will be immediately stopped upon
occurrence of a trouble.
The control unit will stop at the same
time causing also the trouble location
indicator to stop. The symbols will
indicate the kind of trouble.
Operation
Gas start-up mode
Gas operating mode
General safety functions
Full load
Operating position
Load regulator
Release
Partial load
Ignition/Gas valves
Gas control:
2-stage sliding Stepless
ON OFF
ON OFF
Full load
Operating position
Load regulator
Release
Start load
Partial load
Ignition/Gas valves

10/2010 - Art. Nr. 4200 1032 1300A 5
Operation
Equipment options
Please note!
The gas outlet pressure (gas regulating
pressure) must always be less than the
gas inlet pressure but higher than the
total pressure loss of the system.
Equipment option: speed control
The burners can be equipped with a
speed controller as an option.
During long burner operating periods in
the partial load range in particular, the
reduction in blower speed helps to
conserve electrical energy and reduce
noise emissions from the burner blower
itself.
The speed of the blower is measured by
a Namur sensor and controlled to the
programmed reference value for the
current output level.
Equipment option:
O2control / CO control
To improve the efficiency of the system,
the combustion manager can be
equipped with residual oxygen or CO
control (CO control available only with
the use of a Lamtec burner controller).
The residual oxygen is measured in the
flue gas of the heating system by an O2
measuring probe with zirconium oxide
sensor and sent to the combustion
manager as a correction factor. Thanks
to O
2control, it is possible to eliminate
variations in ambient conditions (e.g.
combustion air temperature and
humidity, calorific value fluctuations,
etc.) and significantly reduce the air
surplus required for calibration.
Reference value deviations are
controlled by corrections to the blower
speed or the air flap position. With the
use of CO control (only possible with gas
operation), the CO content is measured
in addition to the residual oxygen. The
air surplus is reduced to the “CO edge”
by a correction to the blower speed or
the air flap position. The correction
factors are determined in a system-
specific “learning process” and stored
temporarily in the combustion manager.
This makes it possible to maximise the
system's heating efficiency across the
entire output range and optimally
manage the combustion process. For
further information, please refer to the
manufacturer's documentation for the
electronic combustion manager.
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10/2010 - Art. Nr. 4200 1032 1300A6
Functional diagram
LFL 1.../LGK...
A = Starting type interval
A-B= Flame development interval
B = Burner has reached operating
position
B-C= Burner operation
(heat generation)
C-D= regular shut-off
t1 Pre-ventilating time
t2 Safety time
t3 Pre-ignition time
t4 Fuel valve enable
t5 Load regulator enable
t6 post ventilation time
t7 start delay interval for ventilation
motor
t11 „OPEN“ run time of air damper
t12 „CLOSE“ run time of air damper
t13 Permissible afterburn time
R = Temperature or pressure
controller
M = Fan motor
Z = Ignition transformer
BV= Fuel valve(s)
LR= Load regulator
LK= Air damper
RV= Steadily adjustable fuel valve
FS= Signal of flame
O peration
Autom atic furnace contro ller LFL 1.../LG K ...
The LFL 1…/LGK... type controller is designed
to control and monitor burners working
according to a stepwise or modulating
principle. A detailed functional
description with technical data and
project planning information with respect
to the automatic combustion controllers
can be found in the annex and in the
documents:
LFL 1...-7451/LGK...

10/2010 - Art. Nr. 4200 1032 1300A 7
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O peration
G as valve VG D with SKP actuator
G as valve M BC-VEF
Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +50°C
Voltage 230 V/ 50 Hz max.
Protection rating IP 54
1 Gas ball valve (option)
2 Filter (under the cover)
3 Gas manometer with push button
(upstream) (option)
4 Test burner with push button
(option)
5 Actuator SKP 15
6 Actuator SKP 75
7 Gas main valve VGD..
8 Gas manometer with push button
(downstream) (option)
Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +50°C
Voltage 230 V/ 50 Hz max.
Absorbed output (in operation)
250 W max
Protection rating IP 54
1 Gas ball valve (option)
2 Filter (under the cover)
3 Gas manometer with push button
(upstream) (option)
4 Test burner with push button
(option)
5 Compact gas train (safety valve +
main valve)
8 Gas manometer with push button
(downstream) (option)

10/2010 - Art. Nr. 4200 1032 1300A8
D = see dimensioned drawings
D1 = see dimensioned drawings
DF = combustion chamber diameter
T1 > 80 mm
T = depth of boiler lining
(option: extensions: see technical data)
Note for reverse flow boilers!
For reverse flow boilers the dimension
T1 is only a recommended value.
Depending on type of boiler the burner
head must stand at least 50 mm ahead
the opening for flue gas turning back.
Burner assembly
• Take the burner tube (delivered in a
separate box).
• Fit it on burner body.
• Remove cover.
• Tighten the 2 fixing screws S1.
• Lift the burner, using the 2 hoisting
eyes 19 (see page 3) and fasten to the
boiler.
• Tighten the 4 fixing screws S2.
• Place cover back on.
Assembly
Boiler lining for G-V burner
Burner assembly
Boiler lining
The burner lining must be installed right-
angled to the burner tube. Possible
trimming work (bevelling, rounding) as
required for reverse boilers, for example,
should done at a diameter not below
70% of the combustion chamber
diameter. The space between the flame
pipe of the burner and the boiler lining
should be lined with heat resistant
material, such as Cerafelt.
This space is not allowed to be lined
with brickwork

10/2010 - Art. Nr. 4200 1032 1300A 9
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Assembly
Gas connection
Gas connection
The gas lines and valves and
instruments group should be installed
and taken into operation in accordance
with the applicable engineering
standards and regulations.
The connection between the gas
distribution network and the gas ramp
must be done by authorised persons.
The section of the pipings must be
calculated so that the loss of load
doesn’t exceed 5% of the distribution
pressure.
A quarter turn manual valve (not
supplied) must be provided for upstream
of the gas ramp and the filter.
The filter must be installed on a
horizontal nozzle with the cover in the
vertical position to enable cleaning.
The threaded unions used must be in
conformity with present standards
(tapered male thread, straight female
thread with sealing provided in the
thread).
Provide for sufficient space to access
the gas pressure switch adjustment.
Gas properties
Prior to any installation work make sure
to obtain the following data from the gas
supply company:
1. type of gas
2. calorific value Hun=kW/m³ (kJ/m³)
3. maximum CO2content of exhaust gas
4. gas connection pressure and rest
pressure
Type of gas test
Prior to mounting the burner to the gas
feed line check the available type of gas
and burner type against the data given
on the burner nameplate (attached to
burner). Be sure the description of the
burner and the type of gas are the same
as indicated on the nameplate.
Gas connection pressure
A minimum connection pressure must
be available upstream of the burner gas
valve to ensure the proper functioning of
the burner.
For the installation of the valves and
instruments group take care to observe
the mounting instructions supplied by
their manufacturers (these are packed
with the equipment).
The gas line installed to the burner must
be dimensioned in accordance with the
throughput rate and the available
pressure.
For selecting the nominal bore „DN“ of
the gas valves and instruments group
care should be taken to observe the
flue resistance of the boiler and the
gas pressure loss of the burner and
valves and instruments group.
Caution!
The absence of impurities and foreign
bodies must be checked before
installation and commissioning of the
gas ramp, the lever valves and unions.
Gas valves and instruments group
The gas valves and instruments group
can be connected directly to the gas
feed line. Take care to observe the
correct order of installation and
direction of flow (arrow on housing).
Check the valves and instruments and
connection pieces for absence of dirt
particles and foreign matter before
installation and initial operation. To
provide effective conditions for start-
up make sure the distance between
the burner and the gas stop valve is
as short as possible.
Leak test
The gas line upstream of the burner gas
valves and instruments group must be
installed in accordance with the
applicable regulations, checked for
absence of leaks, vented and certified
accordingly by the gas installation
company. The screwed unions and
flanged joints must be checked for
proper tightness (by making a pressure
test). The leak test must be made under
pressure using approved foaming
agents which do not cause corrosion.
For steam boiler furnaces the result of
the leak test must be duly certified.
Venting
Caution! Prior to taking the burner into
operation or after any repair work make
sure to vent the complete gas feed line
and the gas valves and instruments
group into the open atmosphere (e.g. by
means of a hose) taking care to avoid
any hazards.
In no case should the gas line be
vented into the heating or furnace
chambers. Make use of a test burner to
check the gas-carrying spaces are free
from an inflammable gas mixture.
Support
The valves and instruments group must
be supported with a telescopic jacking
member or similar during and after
installation (e.g. on filter and valve).
Joint
It is recommended to provide an easyto-
disconnect joint (with planar sealing
faces) to facilitate repair work on the
boiler (furnace) and allow the boiler door
to be swivelled out if required.

10/2010 - Art. Nr. 4200 1032 1300A10
Gas train assembly
• Check the correct position of the
O-ring in the gas connecting flange.
• Secure the gas train on the burner
head so that the gas train coils are in
the upper vertical position.
• Pay attention to the direction of
circulation.
• Connect the power cable to the gas
train.
Connecting pressure take-off pipes
pF and pL
• Connect the furnace pressure take-off
tube pL on the burner body and the
union pL on the gas train using the
tube pL (blue), shorten the tube
depending on the assembly scenario.
• Connect the furnace pressure take-off
tube pF on the burner body and the
union pF on the gas train using the
tube pF, shorten the tube depending
on the assembly scenario.
• Manually screw in the unions (max.
5Nm) and check tightness.
pBr (pG) = Gas pressure take-off tube
pF = Furnace pressure take-off tube
pL = Air pressure take-off tube
D = Setting screw (air surplus)
R = Setting screw (ratio Gas/Air)
Setting index of
the ratio RSetting
index of the
Dvalue
Assembly
Gas manifold
Pressure take-off pipes

10/2010 - Art. Nr. 4200 1032 1300A 11
Assembly
Checking / assembling the combustion components
Assembling the combustion
components
• Check that the O-Ring J1 is in the
correct position in the gas elbow.
• Check the adjustment settings of the
ignition electrode as per the diagrams.
• Insert the combustion components
into the head, tighten the mounting
screws S3.
• Connect the ignition cable ZK on the
combustion head.
• Connect the ignition cable ZK on the
ignition transformator T1.
Important
If there is a change to the type of gas
used, for example H or E natural gas
(G20) to L or LL gas (G25) or vice versa,
the burner settings should be
completely overhauled.
It is not necessary to modify the
combustion head in any way.
en
Burner A B
N6.2400 G-V 19 203
N6.2900 G-V 0185
N7.3600 G-V 50 234,5
N7.4500 G-V 100

10/2010 - Art. Nr. 4200 1032 1300A12
Assembly
Gas connection
Electrical connection
Checks before commissioning
Checks before commissioning
The following must be checked before
initial commissioning:
• That the burner is assembled in
accordance with the instructions given
here.
• That the burner is pre-set in
accordance with the values in the
adjustment table.
• Setting the combustion components.
• The heat generator must be ready for
operation, and the operating
regulations for the heat generator
must be observed.
• All electrical connections must be
correct.
• The heat generator and heating
system must be filled with water and
the circulating pumps must be in
operation.
• The temperature regulator, pressure
regulator, low water detectors and any
other safety or limiting devices that
might be fitted must be connected and
operational.
• The exhaust gas duct must be
unobstructed and the secondary air
system, if available, must be
operational.
• An adequate supply of fresh air must
be guaranteed.
• The heat request must be available.
• Sufficient gas pressure must be
available.
• The fuel supply lines must be
assembled correctly, checked for
leaks and bled.
• A standard-compliant measuring point
must be available, the exhaust gas
duct up to the measuring point must
be free of leaks to prevent anomalies
in the measurement results.
General regulations applying to the
gas connection
• The gas train must only be connected
to the gas mains by a recognised
specialist.
• The cross-section of the gas line
should be of a size designed to
guarantee that the gas flow pressure
does not drop below the specified
level.
• A manual shut-off valve (not supplied)
must be fitted upstream of the gas
train.
• In Germany, a thermally triggered
shut-off valve (to be installed by the
customer side) must be fitted as
specified by the draft combustion
ordinance.
It is the responsibility of the fitter or his
representative to obtain approval for the
system at the same time as the burner is
commissioned. Only the fitter or his
representative can guarantee that the
system meets applicable standards and
regulations. The fitter should be in
possession of the corresponding official
permit, and should carry out the
corresponding sealing tests and purge
the system of air.
All electrical installation and
connection work must only be carried
out by a suitably qualified electrician.
The applicable guidelines and
directives must be observed,
as well as the electrical circuit
diagram supplied with the
burner!
Electrical connection
• Check to ensure that the power supply
is as specified (230V, 50 Hz single
phase with neutral and earth)
Boiler fuse: 10 A
Electrical connection
It must be possible to disconnect the
burner from the mains using an
omnipolar shutdown device complying
with the standards in force.
Burner motor connection
The burner is delivered for a power
supply of 400V - 50Hz of triphase
current with neutral and earth.
Connect the burner motor cable to the
terminals in the electrical cabinet.
Check the direction of rotation of the
ventilation motor manually with the
burner contactor.
Connecting the gas train
Connect the gas train to the plugs on the
burner.

10/2010 - Art. Nr. 4200 1032 1300A 13
Commissioning
Working cycle test
Firing
Safety unit settings and checks
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- Pre-ventilation,
- Return to ignition position,
- Ignition of electrodes,
- Valves open,
- Burner stops due to lack of gas
pressure or control unit locks because
flame is extinguished.
- If unsure, redo the above test.
The unit can only be fired once this very
important operating sequence check
has been performed.
Firing
Warning:
The burner may be only fired when
all the requirements listed in
previous sections have been met.
• Connect a microammeter (scale 0 -
100 µA DC).
• Open the quarter-turn hand-operated
fuel valve.
• Close the thermostatic circuit.
The leak tester is charged. After running
the test (30 s), the control unit
programme will relaunch. After pre-
ventilation, the burner comes on and
operates at minimum power.
• Check the following:
- the combustion
- the overall leak tightness of the gas
train using foam designed for this
purpose.
No leaks should be detected.
• Measure the gas flow shown on the
counter.
• Slowly increase the power to nominal
output, controlling the combustion
throughout. If necessary, adjust the
combustion by adjusting the
Pair:Pgas pressure ratio ( ,
Screw R).
• Adjust the servomotor control cam I
(Nominal output) to limit the maximum
opening of the air flap to the position
reached for nominal output.
• Slowly reduce the power to the
nominal output required, checking the
combustion values throughout; if
necessary, at minimum power, adjust
the combustion via parallel shifting of
the characteristic ( , Screw D).
• Adjust servomotor control cam III
(Minimum output) to limit the minimum
opening of the air flap possible during
operation to the position reached for
minimum output.
•Precautions: On principle, the
nominal output must only be modified
by adjusting the Pair:Pgas pressure
ratio ( , Screw R), and the
minimum output must only be
modified by offsetting in parallel to the
characteristic e ( , Screw D).
• After any modification to the minimum
output settings, check the combustion
at nominal output and adjust if
necessary.
• After any modification to the nominal
output settings, check the combustion
at minimum output and adjust if
necessary.
• To complete the adjustment process,
restart the burner and check the
power and the combustion. If
necessary carry out adjustments as
described above.
• Check the leaktightness of the gas
train.
• No leakage should be detected.
• Check the safety devices.
• Setting and checking the safety
devices
Gas pressure switch
• Set it to the minimum distribution
pressure.
• The burner operates at minimum
output.
• Slowly close the 90° manual shut-off
valve.
• The burner must stop due to a lack of
gas pressure.
• Open the 90° manual shut-off valve.
• The burner restarts automatically.
• The pressure switch is set.
• Fix and screw on the cover.
Air pressure switch
• See the paragraph entitled
"Determining the differential pre-
ventilation pressure and setting the
differential pressure switch" (page
16).
Leak testing device VPS:
• Open pa on the device.
• Restart the burner. After 30s the tester
should enter safety mode (red light
on).
• Reclose pa.
• o Unlock the tester safety catch by
pressing the red indicator.
The test cycle is relaunched.
The burner will be working.
• Check the leaktightness.
• Disconnect the measurement devices.
• Re-close the pressure tap.
• Reset the unit.
The burner will be working.
• Check:
- the seal between the flange and the
boiler front,
- the opening of the control circuit
(limiter and safety),
- the current on the motor relay.
• Check the combustion under actual
working conditions (doors closed,
cover in place, etc.) and check all
circuits for possible leaks.
• Establish a measurement protocol.
• Start-up automatic operation.
• Provide all the data required for proper
operation. (Inform the boiler room
operator).
• Place the boiler plate in a visible
location.
Important!
Before firing, to ensure the gas train
operates correctly, the position of the
gas flap must be checked. The table
below shows the recommended setting
depending on the burner.
• If a correction is necessary, proceed
as follows:
• Loosen screw S.
• Manually move lever Hto the
recommended position (setting
according to the table above).
• Lock into position using screw S on the
housing mounting bracket.
Pre-setting the SKP 75 according to
the table below: (these values are
given as a guide only)
Pre-setting the pressure switches on
the burner and the gas train
See the "Commissioning, Gas pressure
switch/air pressure switch" section.
Checking the operating sequence
• Open the quarter-turn hand-operated
fuel valve, then immediately close it
again.
• Switch the burner on.
• Select manual operation mode on the
control cabinet.
• Close the thermostatic circuit.
The VPS 504 S02 leak tightness test
device is switched on. After 30 s if the
test is validated, the amber light will
come on. The control unit is now
powered on.
The program should function in the
following way:
- Air flap opens to the servomotor
nominal output position,
Burner Setting (°)
50 mbar 300 mbar
N6.2400 G-V 90 45
N6.2900 G-V 90 45
N7.3600 G-V 45 45
N7.4500 G-V 45 45
Burner Gas pressure
[mbar]
Shift from
origin
(screw D)
Pressure
ratio
(screw R)
N6.2400 G-V 50 0,5...0,9 0,8
300 2,9...4,0 2,2...2,3
N6.2900 G-V 50 0,9 1,3...1,4
300 2,9...3,7 2,2...2,3
N7.3600 G-V 50
300
N7.4500 G-V 50
300

10/2010 - Art. Nr. 4200 1032 1300A14
Commissioning
Actuator
Limitsw itch setting
Description
The SQM actuator is intended for use
with two-stage sliding or modulating oil,
gas or dual-fuel burners. The reversible
actuator is fitted with a synchronous
motor which drives a shaft via a
gearbox. The shaft end carries a
coupling to drive the fuel and
combustion air controlling element.
The SQM actuator has been designed
for dual-wire control by controller or
switching units with change-over
contacts. Potentiometers can be
installed for a range of applications on
customer's request.
The 60 Hz frequency will reduce the
running times by approx. 17 %.
Limit switch factory setting
Cam VI controls minimum automatic
flow-rate following ignition. If not
requested, the flow remains unchanged.
The time-delay unit K6 in the control
cabinet must be set at ≅15 s.
Descrip-
tion Pre setting Function
I Max. power (air and gas)
II 0° Closed flaps (air and
gas)
III Firing air flow
IV - Not used
V - Cam Vgives minimum
regulation info; must be
set between values of
cam Iand VI
VI Set minimum air flow-
rate
VII Simultaneous switch-on
of nominal flow indicator
and hour counter (only
for operation hours
below nominal flow rate)
Set a few degrees below
the regulation flow-rate
value of Cam I.
The limit and auxiliary switches are set
by means of manually adjustable
latching cam plates. Scales are fitted
between the disks to facilitate the
selection of the switching points.
The cam plates are provided with a
small pointer for indicating the switching
point of a scale between the setting
ranges.
An additional scale fitted to the end of
the cam roller serves to indicate the
position of the actuator.
The drive unit may be disconnected from
the controlling element by changing over
a rocker arm mounted to the gearbox.
This will allow any desired position of the
controller plate to be selected by hand.
Drive and output will be coupled in the
vertical position of the rocker arm.
Positions
1 Terminals
2 Cam setting key
3 Scales for switching point setting
4 Rocker arm for uncoupling
5 Scale for actuator position
6 Actuator position indicator
7 Shaft end to fit a return
potentiometer
8 Power supply
Technical data SQM actuator
Voltage 230 V -15%
50 / 60 Hz
240 V +10%
50 / 60 Hz
Power input 9 VA
Max. contact load250 V 10 (3) A
Mounting positionas required
Ambient
temperature -20°C + 50°C
Protection
classification IP 54, DIN 40050
Weight 1,7 kg
SQM10/11 SQM20/21
Running time at
130° turning
angle 42 Sec. 66 Sec.
Torque 10 Nm 20 Nm
Important
Once the pressure switches have been
set, they must be protected to prevent
settings from being altered. For
example, this can be done by placing a
spot of varnish on at least one of the
screws on the equipment's protective
cover.
Once the burner has started up, its
safety systems must be checked to
ensure they are operating correctly.
Likewise, following start-up, it is
necessary to check that the boiler's
safety chain is operating correctly in
accordance with the regulations in force.
This check must be carried out with the
user's agreement.

10/2010 - Art. Nr. 4200 1032 1300A 15
Commissioning
Flame sensor
e
n
Ionisation monitoring
Detection of the flame using an
ionisation device. Flame detection is
achieved using the conductivity and the
rectification effect of the hot flame
gases. An alternating voltage is applied
to the sensor (in refractory material),
which is dipped into the flame. When a
flame is present, the current (ionisation
current) circulates and forms the flame
signal. This signal is transmitted to the
input of the flame signal amplifier. The
flame signal amplifier is designed to
react only to the continuity of the flame
signal. This eliminates the possibility for
confusion of a potential short-circuit
between the sensor electrode and earth
with a flame signal (as an alternating
current would be used in this scenario).
Use a microammeter to measure the
signal (take into account the
measurement range). This device is
placed between the control box and the
ionisation electrode. Make sure the
polarity of the device is observed (see
connection examples for the control box
LFL 1…/LGK...).
During ionisation monitoring, it is
important that the signal is transmitted
without wastage. The connection cable
must not lie adjacent to a multicore
cable. A soiled sensor electrode bracket
or faulty ceramics encourage leakage
currents, which reduce the flame signal.
The burner (as a counter electrode)
must be earthed in conformity with the
directives. If this is not the case, an
ionisation current cannot flow. Earthing
of the boiler only is often inadequate.
The ionisation current must be
monitored when the burner is set to
ensure combustion hygiene, i.e. when
switching from partial load to full load.
The ionisation current must not fall
below the minimum monitoring current
required. A large drop in the ionisation
current indicates either a lack or an
excess of air. These malfunctions must
be corrected using appropriate
methods. A consistently high ionisation
current indicates a stable flame and the
correct combustion hygiene.
Sensor currents
* See technical data for automatic
furnace controller LFL 1.../LGK...
Automatic
controller Minimum required Maximum possible
* LFL 1...
LGK... 6µA-µA
Recommended instrument range:
0 - 150µA

10/2010 - Art. Nr. 4200 1032 1300A16
Gas pressure switch A6
Gas pressure switch A5
Commissioning
Gas pressure switch
Air pressure switch
Determining the differential pre-
flushing pressure and adjusting the
differential pressure switch
• Burner in the pre-aeration phase.
• Measure pressure on test
connection (2).
• Measure vacuum on test
connection (3).
• Add the measured pressures.
• Set the scale to 90% of the calculated
value.
Switch function test
• Test buttons are provided to check the
switch functions for proper operation
(with safety cut-out and interlock). The
burner is normally run in partial-load
condition when testing the safety
functions. On pressing button (4) the
vacuum will be removed which causes
the differential pressure to drop below
the required level. If it is necessary to
test the pressure switch functions
under full-load conditions this may be
done by pressing button (1).
Technical data:
Type of gas:
Gases according to DVGW Worksheet
G 260/1, gas families 1, 2, 3
Degree of protection: IP 54
Ambient temperature: -15°C to +50°C
Mounting position: any
Operating pressure up to:
GW 50/150 A5A6 500 mbar
GW 500/ A5/A6 600 mbar
Gas pressure switch GW...A5/A6
The gas pressure switch is designed to
monitor the gas flow pressure. It can be
used for monitoring either falling
pressure (minimum) or rising pressure
(maximum, specified for equipment
according to TRD 604).
The types GW...A5/A6 may be used as
pressure switches of specific design
according to VdTÜV Leaflet "Pressure
100/1" for application in furnace systems
complying with TRD 604. The setpoint
(switching point) may be selected by
means of a setting disk with scale.
Air pressure switch
The air pressure switch is provided for
monitoring the pressure of the
combustion air fan.
The pressure switch „Dungs“ LGW...
has been designed for switching on, off
or over an electric circuit in the case of
changes of the actual pressure levels
from the setpoint setting. The pressure
switch LGW... can be used as
overpressure, vacuum or differential
pressure monitor for air and non-
aggressive gases but not for gases
according to DVGW Worksheet G 260/l.
Certification
The pressure switch has been tested in
accordance with DIN 3398 Part 2 and is
registered by CE/DIN-DVGW. It has
been registered in other important gas
consumption countries.
Important
Once the pressure switches have
been set, they must be protected to
prevent settings from being altered.
For example, this can be done by
placing a spot of varnish on at least
one of the screws on the equipment's
protective cover.
Setting the min. gas pressure switch
• Remove the protective cover.
• At the rated output, measure the gas
flow pressure and calculate the
switch-off pressure by reducing by
approximately 20%.
• Adjust the graduated disc to the
desired switch-off pressure opposite
the arrow (the graduations are
approximate values).
• Operate the burner at minimum power.
• Close the gas cut-off valve slowly to
obtain the desired switch-off pressure.
• Turn the graduated disc until the
burner switches off.
• Refit and screw down the protective
cover.
Max. gas pressure switch
• Remove the protective cover.
• At the rated output, measure the gas
flow pressure and calculate the
switch-off pressure by increasing by
approximately 20% (no more than
30% under any circumstances).
• Adjust the graduated disc to the
desired switch-off pressure opposite
the arrow (the graduations are
approximate values).
• Operate the burner at minimum power.
If the max. gas pressure switch
switches off the burner, increase the
adjustment value but not to more than
130% of the flow pressure at the rated
output.

10/2010 - Art. Nr. 4200 1032 1300A 17
e
n
Gas valves and instruments group
Description
Specifications for the design,
construction and safety features of gas
furnace systems in heating installations
are contained in DIN 4756 and TRD 412.
Heating installations with higher
operating pressures are subject to the
DVGW Worksheets G 460 and G 461.
The gas pipes must meet the
specifications of DVGW-TRGI in the
case of installations with operating
pressures up to 100 mbar or higher
than100 mbar.
Gas connection pressure
To ensure the proper functioning of the
burner, a minimum connection pressure
must be available.
The gas feed pipe to the burner must be
dimensioned according to the
throughput rate and the available
pressure.
The nominal bore (DN) of the gas valves
and instruments group must be selected
on the basis of the resistance of the
boiler on its flue-gas side and the gas
pressure loss of the burner and
valves and instruments group.
Gas valves and instruments group
The gas valves and instruments group
may be connected directly to the gas
supply line. Care should be taken to
install the valves and instrumentsin the
specified order and according to the
direction of flow(arrow on housing).
Prior to installation and operation, check
the valves and instruments and the
connecting elements for possible
accumulated dirt particles and foreign
matter. To ensure proper conditions
for start-up, the distance between the
burner and the gas shut-off valve
must be as low as possible.
On completion of installation the gas
valves and instruments group must be
subjected to a leak test in accordance
with DVGW Worksheet G 600 and G
490 in the furnace system.
Description
The gas valves and instruments groups
type VGD (screwed and flanged valves)
are provided for gas supply, main shut-
off, gas filtration and gas supply
pressure control and monitoring. They
can be used for all types of gases in the
gas families 1, 2 and 3 according to
Worksheet G 260/1. The valves and
instruments groups are constructed as
specified by EN 676 and DIN 4788, Part
2. All functional parts have been
checked by individual tests and
approved by a CE and DIN-DVGW
registration number.
A detailed description of the valves and
instruments used is contained in the
Technical Datasheet for the Gas Valves
and Instruments Groups Type VGD.
The premounted gas valves and
instruments group is subjected to a leak
test at the manufacturer's works.
For the installation and start-up of the
gas pipes take care to observe the rules
and regulations set forth by DVGW,
especially DVGW-TRGI and TRF.
Gas valves and instruments group type
VGD
Technical data:
Types of gas:
Gas types of gas families 1, 2 and 3
according to DVGW Worksheet
G 260/1
Max. inlet pressure:
500 mbar
Electrical connection: 230-240V, 50Hz
Protection classification: IP 54
Ambient temperature:
-15°C to +50°C

10/2010 - Art. Nr. 4200 1032 1300A18
100 Burner
101 Gas pressure take-off tube
102 Air pressure take-off tube
103 Furnace pressure take-off tube
120 Air flap
142 Filter
151 Gas double valve
VGD20/40+SKP15+SKP75
153 SKP75
154 SKP15
313 Min. gas pressure switch
314 Gas pressure switch for valve leak check or valve leak
checker
349 Actuator
Gas valves and instruments groups
Basic construction
The burner's scope of delivery may
include a gas train. In this case, the
burner and the gas train are issued with
a CE Declaration of Conformity. If the
gas train is not delivered with the burner,
the conformity of the burner is valid only
if the gas fittings and instruments and
the design of the gas train satisfy the
burner test specified by EN 676 and
meet the Pressure Equipment Directive.
Individual testing will be necessary
where this is not the case.
The gas train delivered has its own
documentation including operating
instructions and a spare parts list. There
follows a general description of the gas
train.
Gas trains with a double valve are
intended for the supply, main shut-off,
gas filtration, gas pressure regulation
and monitoring of the gas supply. They
are compatible for use with gases
conforming to the specifications of the
gas fittings and instruments. They are
built in accordance with EN 676. All
function parts have been individually
tested and awarded the CE marking and
number of the Notified Body. The
preassembled gas train is checked for
leaks in the factory.
Low- and high-pressure gas trains
If the outlet side of the regulator, i.e.
individual fittings and instruments
downstream of the gas pressure
regulator, has not been designed to be
compatible with the maximum supply
pressure that occurs in the event of a
fault, the gas train must be equipped
with a safety shut-off valve (SSV) and a
safety relief valve (SRV) in accordance
with EN 676. This equipment is
generally required for maximum supply
pressures of >360 mbar and > 500 mbar
respectively. These are known as
highpressure gas trains.
If all fittings and instruments of the gas
train have been designed/approved for
the maximum supply pressure that
occurs in the event of a fault, the gas
train is known as a low-pressure gas
train. This is the case, depending on
component selection, for maximum
supply pressures of 360 and 500 mbar.
Gas valves and instruments group
The gas trains must be dimensioned to
suit the throughput required and the
available gas pressure. The gas valves
and instruments group is defined on a
system-specific basis.
The following must be taken into
consideration:
• Burner output,
• Combustion chamber counterpressure,
• Gas pressure loss in the burner head,
• Gas pressure losses in the gas fittings
and instruments.
The total drop in gas pressure must
always be lower than the available gas
flow pressure.

10/2010 - Art. Nr. 4200 1032 1300A 19
Gas valves and instruments groups
Basic construction
Installation and mounting of the gas
filter
The gas filter may be installed in any
desired position. Take care only to
observe the direction of flow of the gas
(arrow on filter housing). Make sure
there is adequate clearance to facilitate
the removal of the cover and
replacement of the filter cartridge.
Filter replacement
The filter cartridge should be replaced
by a new one as soon as a high pressure
drop is noticed. If a new filter cartridge is
not at hand it will be possible to wash the
filter mat in 40°C water adding some
light-duty detergent. Allow the mat to dry
before reinstallation.
NOTE: For the installation of the filter
mat take care to observe the marking or
sticker.
e
n
Test burner
Depending on the country-specific
requirements, when installing steam
boilers it may be necessary to fit a test
burner to the gas train (e.g. in line with
directive TRD 412). This is used to vent
the gas pipes. The gas supply is
switched on by pressing the button (1).
The flow of gas brings in the required
amount of combustion air via the hole in
the body (3). The gas/air mixture is
routed towards the burner head (4) and
ignited manually at its opening. Gas is
supplied for as long as the button is
pressed and cut off when it is released.
Technical features:
• Types of gas:
Gas in accordance with sheet G 260/1
of the DVGW, gas families 1, 2, 3
• Ambient temperature: -15°C to +70°C
• Assembly position: vertical, facing
upwards
• Operating pressure up to: 500 mbar

10/2010 - Art. Nr. 4200 1032 1300A20
Gas valves and instruments group
Gas valve leakage controller
Leakage controller VPS 504 S02
Working principle :
Prior to each burner start-up, the
controller checks for possible leaks
between safety and main valves by
increasing distribution pressure.
Electrically, the leakage controller is
serially connected between the
thermostatic circuit and burner control
and safety unit.
Installation :
Directly on valve.
Program stages :
On stoppage, safety and main valves
are closed.
On thermostat stoppage, the leakage
controller is turned on and booster
increases distribution pressure by
20mbar.
After no more than 30 seconds
operation :
- If leakage test is OK; yellow light
comes on and current is released to
feed the burner’s control and safety
unit, which then starts its cycle.
- If leakage test is NOK; red light comes
on and no power is fed to the control
and safety unit.
Control cycles have to be restarted
manually. Change valve if defect
persists.
Setting :
The controller requires no on-site
setting.
Working test :
While controller is working :
• Open pa pressure take-off. Leak
caused prevents superpressure from
building up and safety unit locks after
30 seconds.
• Reclose pa pressure take-off.
• Release controller safety by pressing
red indicator light.
Leakage test restarts and, after 30
seconds, yellow indicator lights up and
powers up the control and safety unit,
which begins its cycle.
1 Wieland 7P socket
3 Filter element
4 O-ring Ø10.5x2.25
5 Fuse T6.3 250V Ø 5x20
6 Yellow indicator On :
Leakage test OK
7 Red indicator On :
Leakage test NOK
Manual clear
8 Spare fuses
9pa (p2) pressure take-off Ø 9
pe + 20mbar
10 pe (p1) pressure take-off Ø 9
i nlet pressure (distribution)