elco N6.2400 GL-RZ3/LFL User manual

09/2011 - Art. Nr. 4200 1040 7900A
N6.2400 GL-RZ3/LFL
N6.2900 GL-RZ3/LFL
N7.3600 GL-RZ3/LFL
N7.4500 GL-RZ3/LFL
............................................. 4200 1035 0600
Operating instructions
For specialist installation engineers
Dual fuel burners
de ......................................... 4200 1035 0500
fr ........................................... 4200 1040 8000
it ........................................... 4200 1041 4900
nl .......................................... 4200 1041 5000

09/2011 - Art. Nr. 4200 1040 7900A2
General information
Contents
General information Contents ............................................................................................................................ 2
Important notes ................................................................................................................. 3
Burner description ............................................................................................................. 4
Installation General information regarding burner assembly ............................................................... 5
Boiler lining for GL-RZ3/LFL burner .................................................................................. 6
Burner assembly................................................................................................................ 7
Burner head setting data GL-RZ3/LFL .............................................................................. 8
Gas train
Gas train description .............................................................................................. 9
Basic design....................................................................................................... 10
Description of gas train with MBC... ..................................................................... 11
Description of Dungs MBC double gas valve... (gas multiblock).......................... 12
Changing MBC-300-700-1200 filter ..................................................................... 13
Setting MBC-300-700-1200-SE pressure regulating component ....................... 13
Setting MBC-1900-5000-SE pressure regulating component ............................. 14
Description of double gas valve VGD... with servomotors SKP ........................... 15
Gas filters ............................................................................................................ 16
Gas/air pressure switch...................................................................................... 17
Leakage controller, test burner............................................................................ 18
Hydraulics
General information regarding fuel oil system, fuel oil hydraulics diagram ......... 19
Fuel oil pressure switch ....................................................................................... 20
General information regarding fuel oil system ..................................................... 21
Pump...............................................................................................................22-25
Nozzle line 3-stage..........................................................................................26-27
Commissioning Control and safety unit LFL 1.../LGK... ............................................................................ 28
Electrical servomotor .................................................................................................. 29-30
Flame monitor, probe current measurement .............................................................31-32
Connecting the gas train, electrical connection, checks before commissioning.............. 33
Gas connection................................................................................................................ 34
Fuel-air coupler control.................................................................................................... 35
Design of switch cabinet door.......................................................................................... 36
Dual fuel load regulator ..............................................................................................37-38
Control ............................................................................................................................. 39
Preventilation................................................................................................................... 40
Fuel oil start-up mode, fuel oil operating mode ............................................................... 41
General safety functions.................................................................................................. 41
Gas start-up mode, gas operating mode ......................................................................... 42
General safety functions.................................................................................................. 42
Servicing Maintenance .............................................................................................................. 43-45
Checking, assembling the combustion components ....................................................... 45
Setting for ignition electrodes .......................................................................................... 46
Exhaust gas analysis..................................................................................................47-48
Diagnosing and remedying faults ...............................................................................49-50
Faults ............................................................................................................................. 51
Declaration of conformity ...........................................................................................52-53

09/2011 - Art. Nr. 4200 1040 7900A 3
Important information
Burners
N6 and N7 GL-RZ3/LFL are
designed for the combustion of natural
gas and light oil. The design and
function of the burners comply with
EN676 and EN 267. They are designed
for use with systems that are approved
for the use of burners in accordance with
EN 676 and EN 267.. To use the burner
with heat generators in conformity with
Pressure Equipment Directive 97/23/
EU, special burner components are
required (not supplied with standard
equipment). Before using the burner
with equipment of this type, the
equipment characteristics must be
checked. Burners that comply with
Pressure Equipment Directive 97/23/EU
come with a declaration of conformity to
this effect and are labelled on the identi-
fication plate. Any other type of applica-
tion requires the approval of ELCO. The
burner may only be used in accordance
with the instructions set out in this docu-
mentation and the relevant technical
data. If not used properly, it could cause
damage to property and the environ-
ment and personal injury. Furthermore,
the burner would no longer be CE com-
pliant. Installation, commissioning and
maintenance may only be carried out by
authorised specialists and all applicable
guidelines and regulations must be
complied with.
Burner description
The burners N6 and N7 GL-RZ3/LFL are
progressive, fully automatic mechanical
monoblock-type burners for gas and 3-
stage for fuel oil. Emissions rates may
differ, depending on combustion
chamber dimensions, combustion
chamber load and the furnace (three-
pass boilers, boilers with reverse firing).
For specifying warranty values, the con-
ditions for the measuring equipment, tol-
erances and humidity must be observed.
Scope of delivery
The burner is supplied packaged in
three boxes on a pallet:
- Burner with:
- integrated switch cabinet
- flange seal and securing screws
- operating instructions, circuit
diagram and spare parts list
- Burner head
- Compact gas train with gas filter
Before commissioning, a check must be
carried out to ensure that the product
delivered complies with the scope of
delivery.
The following standards should be
observed in order to ensure safe, envi-
ronmentally sound and energy-efficient
operation:
EN 226
Connection of fuel oil and forced-
draught gas burners with fan to a heat
generator
EN 60335-1, -2-102
Specification for safety of household
and similar electrical appliances, partic-
ular requirements for gas burning appli-
ances
DIN EN 60204-1
Safety of machinery. Electrical
equipment of machines
DIN EN 50156-1
Electrical equipment for furnaces
Gas lines
When installing the gas lines and trains,
the general directives and guidelines, as
well as the following national regula-
tions, must be observed:
CH: - SVGW-Gasleitsätze G1
- Vorschriften der kantonalen
Instanzen (SVGW Gas Direc-
tives G1 - Cantonal specifi-
cations) (e.g. fire authority
specifications)
DE: - DVGW-TVR/TRGI
Installation location
The burner must not be used in rooms
with aggressive vapours (e.g. hair spray,
tetrachloroethylene, carbon tetrachlo-
ride), high levels of dust or high air
humidity (e.g. laundry rooms). The limi-
tations of use set out in the technical
data must be complied with.
Adequate provision must be made for
the supply of combustion air. Given
standard conditions, the combustion air
requirement may be calculated as
follows:
Vl [Nm³/h] = QF [kW] *1.25 [Nm³/(h*kW)]
We can accept no warranty liability
whatsoever for loss, damage or injury
caused by any of the following:
- 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 furnace 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. It is
advisable to take out a maintenance
contract to guarantee regular servicing.
Warning:
When in operation, the burner produces
an electromagnetic field. In certain cir-
cumstances, this field could affect
medical implants (e.g. pacemakers).
Before working with the machine,
anyone who has a medical implant
should consult their doctor and the man-
ufacturer of the medical implant in order
to reduce the risk of serious or fatal
injury.
Transport \ packaging \ storage
Safety measures
The burner and accessories must be
transported and stored using suitable
lifting equipment, means of transport
and tools. The safety instructions must
be complied with.
Transport
Depending on the size and weight of
packaging, burners and accessories
must be transported manually or with the
use of suitable aids. The transport
instructions on the packaging must be
complied with. The burner must be
properly secured for transport. If
measures to secure the burner have not
been taken at the factory, suitable
measures to secure it during transporta-
tion must be taken.
Packaging
The burner and accessories are placed
on a wooden pallet and shrink-wrapped.
When unpacking the product, suitable
lifting equipment and tools must be used
to remove the screw connections and
clamping devices between the burner
and the packaging. Suitable protective
clothing must be worn (gloves, safety
shoes).
Storage
In order to protect the burner from envi-
ronmental influences, it must be placed
in a dry, locked room when stored tem-
porarily. For the maximum storage tem-
peratures, please refer to the technical
data sheet.
Disposal The current local leg-
islation must be
complied with without
fail.
General information
Important notes

09/2011 - Art. Nr. 4200 1040 7900A4
General information
Burner description
2 Load regulator (option)
5 Body
6 Gas inlet flange
8 Burner tube
10 Integrated switch cabinet
11 Burner fixing flange
13 Air intake box
14 Mechanical coupler
19 Hoisting eyes
20 Connector for inspection glass
cooling
F6 Air pressure switch
M1 Fan motor
Y10 Servomotor for air and gas flaps
102 Pump

09/2011 - Art. Nr. 4200 1040 7900A 5
Installation
General information regarding burner assembly
Tightening torques
During installation, commissioning and
maintenance, the following torques for
unions must be complied with.
Recommended tightening torques
Standard unions
M4 M5 M6 M8 M10 M12 M16 M20
2 6 10 25 48 85 210 415 Nm
N.B.:
In general, the correct tightening torques have been applied when the unions are
tightened hand-tight using a screwdriver (ISO 272) or angled Allen key.
Tightening torques for root connector for fan impeller
SM16 (Ø28)
No.: 1615
SM20 (Ø38 and 42)
No.: 2012
SM25 (Ø42 and 48)
No.: 2517
Bushing
20 30 50 Nm
N.B.:
For more information regarding installation/dismantling of the fan impeller, please
refer to the relevant chapter in the operating instructions.
Tightening torque for gas train flange connector
M16 / DN 65 - DN 125
Max. 50 Nm
N.B.:
The unions must be tightened crosswise. The union must be checked to ensure it
is tight. If it is not sufficiently tight, the fitting must be removed and checked (tight-
ening surfaces).

09/2011 - Art. Nr. 4200 1040 7900A6
Installation
Boiler lining for GL-RZ3/LFL burner
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
tube 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
Sealed area
must cover the
entire
circumference
Seal corners with
sealing tape
Warning!
Owing to the fibre diameter, the mineral
fibre tightness thermocord may cause
reversible mechanical irritation to the
eyes and skin. In the event of high dust
concentrations, the upper respiratory
tract may suffer mechanical irritation.
When working with the tightness ther-
mocord, the operator should wear loose-
fitting, long-sleeved clothing. In the
event of high fibre dust concentrations,
the operator should wear an FFP1 mask
and well-sealed protective goggles
(when carrying out overhead work too).

09/2011 - Art. Nr. 4200 1040 7900A 7
Burner assembly
• Remove cover.
• Take the flame tube (delivered in a
separate box).
• Fit it on the burner body.
• Tighten the 2 fixing screws S1.
• Fit the boiler seal to the burner.
• Raise the burner with the aid of
hoisting eyes 19 and fix it to the
boiler.*
• Tighten the 4 fastening screws S2
(comply with tightening torques).
• Place cover back on.
* Alternatively a forklift truck may be
used for fixing it if the burner is fixed
to the transport pallet supplied with it.
Provision must be made for adequate
transport safety. It may be necessary
to use suitable materials for transpor-
tation (lashing straps).
The burner boiler must be tested while in
operation to ensure it is leak-proof.
Every effort must be made to ensure that
exhaust gases cannot leak in harmful
amounts. Poorly sealed burner boiler
connections may result in combustion
problems
D = see dimensioned drawings
D1 = see dimensioned drawings
DF = combustion chamber diameter
T1 = 70 to 200 mm
T = standard muffle depth
(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 70 mm ahead
the opening for exhaust gas turning
back.
Installation
Burner assembly

09/2011 - Art. Nr. 4200 1040 7900A8
Installation
Burner head setting data GL-RZ3/LFL
Ø a Ø b Ø c d e f g
X
min max
N6.2400 320 270 240 29 121 60.5 380 148 137
N6.2900 320 270 240 29 121 60,5 380 148 137
N7.3600 320 270 240 40 150 60 425 202 182
N7.4500 340 270 240 30 150 60 425 195 130

09/2011 - Art. Nr. 4200 1040 7900A 9
Installation
Gas train
Gas train description
Gas train installation
To install the gas train supplied in the
burner, the unions and seals intended
for this must be used (supplied with the
product).
Warning: in order to prevent injury, heavy
gas train components should only be fitted
using suitable aids and lifting equipment
(crane, cable slings, assembly supports).
The max. tightening torques must be
complied with (see chapter on Installation/
tightening torques). The unions must be
tightened crosswise and evenly. The union
must be checked to ensure that it is tight.
For further information, please refer to the
chapter on commissioning the gas connec-
tion.
Gas valve group selection
The gas trains must be dimensioned to suit
the throughput required and the available
gas pressure. The gas valve group is
defined on a system-specific basis.
The following must be taken into consider-
ation:
• Burner output,
• Combustion chamber counterpressure,
• Gas pressure loss in the burner head,
• Gas pressure losses in the gas fittings.
The total drop in gas pressure must always
be lower than the available gas flow
pressure.
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 Con-
formity. If the gas train is not delivered with
the burner, the conformity of the burner is
valid only if the gas fittings 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 gas valve are
intended for the supply, main shut-off, gas fil-
tration, gas pressure regulation and monitor-
ing of the gas supply. They are compatible for
use with gases conforming to the specifica-
tions of the gas fittings. The design complies
with EN 676. All function parts have been
individually tested and awarded the CE mark
and number of the notified body. The prefitted
gas train is subjected to a leak test at the
manufacturer's works.
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 (SSOV) 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 high-pressure 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.

09/2011 - Art. Nr. 4200 1040 7900A10
Installation
Gas train
Basic design
100 Burner
101 Gas pressure impulse pipe
120 Air flap
141 Ball valve
142 Gas filter
144 Gas pressure regulator
145 Safety gate valve (SGV)
148 Safety relief valve (SRV)
150 Gas control butterfly
151 Double gas valve or 2 single valves
155 Ignition unit
313 Min. gas pressure switch
314 Gas pressure switch for checking valve tightness
349 Servomotor
Options in accordance with country-specific requirements:
143 Pressure gauge with pushbutton valve
147 Test burner with pushbutton valve
148 Compensator
154 Gas safety valve (additional)
313a Max. gas pressure switch
High pressure
100 Burner
101 Gas pressure impulse pipe
120 Air flap
141 Ball valve
142 Gas filter
150 Gas control butterfly
151 Double gas valve with integrated regulation
(Siemens VGD system shown)
155 Ignition unit
313 Min. gas pressure switch
314 Gas pressure switch for checking valve seals or valve
tightness control device
349 Servomotor
Options in accordance with country-specific requirements:
143 Pressure gauge with pushbutton valve
147 Test burner with pushbutton valve
148 Compensator
154 Gas safety valve (additional)
313a Max. gas pressure switch
Low pressure

09/2011 - Art. Nr. 4200 1040 7900A 11
Description
The gas trains with Dungs MBC ...
double gas valves MBC... are used for
gas supply, as the main isolation valve,
for gas filtering, gas pressure regulation
and monitoring of the gas supply. They
can be used for all gases in the 1, 2, 3
gas families in accordance with DVGW
worksheet G 260/1 and/or EN 437. The
design complies with EN 676. All the
functional components have been
tested individually and awarded the CE
mark and number of the Notified Body.
The premounted gas valve group is
subjected to a leak test at the manufac-
turer's works.
Minimum scope of delivery for
gas trains in accordance with
EN 676:
- 1 Ball valve
- 1 Gas filter
- 1 Double gas valve with spring 5-
80 mbar
- 1 Min. gas pressure switch
- 1 Leakage controller or 1 gas pressure
switch for valve leak test
Options:
- Springs for other outlet pressures
- Test burner with pushbutton valve
- Pressure gauge with pushbutton valve
- Compensator
- Max. gas pressure switch
- Gas meter
- Pipe parts and connection parts
- Ignition gas device
- Installation support
- High-pressure regulator with safety
shut-off valve (SSOV)
- Settling section with pulse lines for
high-pressure regulator
- Safety relief valve (SRV)
- Additional gas safety valve
Low and high-pressure gas trains
If the outlet side of the regulator, i.e.
individual fittings and instruments down-
stream 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 (SSOV) 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 respec-
tively. These are known as high-
pressure gas trains. If all gas train
fittings and equipment have been
designed and/or 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 valve group
The gas valve group is defined on a
system-specific basis.
The following must be taken into consid-
eration:
• Burner output
• Furnace counterpressure
• Gas pressure loss in the burner head
• Gas pressure losses in the gas fittings
The total drop in gas pressure must
always be lower than the available gas
flow pressure.
The section of the pipings must be cal-
culated so that the loss of load doesn’t
exceed 5% of the supply pressure.
Warning!
With burners that have the CE mark,
only the use of gas fittings that have
been approved on the basis of burner
type-testing is permitted.
If alternative gas fittings are used, the
burner must undergo individual testing
by the relevant testing body.
Subject to change without notice due
to ongoing technical developments.
Gas train with MBC
Technical data:
Types of gas:
Gas types of gas families 1, 2 and 3
according to DVGW Worksheet
G 260/1
Max. inlet pressure:
MBC700-1200 with CG15 ignition gas
fittings: 360 mbar
without ignition gas fittings: 360 mbar
MBC1900-5000 with CG15 ignition
gas fittings: 360 mbar
MBC1900-5000 with FRS 505/ MVD
505 ignition gas fittings: 500 mbar
without ignition gas fittings: 500 mbar
Elect. connection: AC 220-240 V,
50 Hz
Protection level: IP 54
Ambient temperature:
-15 °C to +60 °C
Installation
Gas train
Description of gas train with MBC...

09/2011 - Art. Nr. 4200 1040 7900A12
Technical data
Gas multiblock MBC-.../SE:
Type of gas:
Gases in accordance with DVGW
worksheet
G 260/1, gas families 1, 2, 3
Electrical data:
230 V -15% + 10%, other voltages on
request
50...60 Hz
Protection level: IP 54
Ambient temperature:
-15C to +60C
Installation position:
MBC-300-1200: magnet vertically
upright or magnet horizontal
MBC-1900-5000: magnet vertically
upright
Max. operating pressure:
MBC-300-1200: 360 mbar
MBC-1900-5000: 500 mbar
The MBC...SE gasmultibloc integrates
the filter, valves and servo pressure
regulator into one compact unit:
- Dirt trap: fine filter (MBC-300-1200
only)
- 2 solenoid valves up to 360 mbar in
accordance with DIN EN 161 Class A
Group 2 fast-closing, fast-opening
(MBC-300-1200)
- 2 solenoid valves up to 500 mbar in
accordance with DIN EN 161 Class A
Group 2 fast-closing, fast-opening
(MBC-300-1200)
- Servo-pressure regulation component
in accordance with DIN EN 88 Class A
Group 2, EN 12067-1
- Outlet pressure: 0 - 300 mbar (MBC-
300-1200), 4 - 300 mbar (MBC-1900-
5000)
- Sensitive adjustment of the outlet
pressure with the SE version for
optimum outlet pressure sensitivity
- Sensitive adjustment of the gas and
air pressure ratio with the VEF version
- Flanged connections with pipe
threads in accordance with ISO 7/1 or
NPT (MBC-300-1200)
- Flanged connections in accordance
with EN 1097-1 / ISO 7005 (MBC-
1900-5000)
1, 2, 3
Seal plug G 1/8
4, 5, optional
Connection system accessories (optional)
6, 7
Seal plug G 1/4
8, 9, optional
Seal plug G 1/2 (optional)
10
Impulse line pBr (integrated)
11
Breather plug G 1/8
Installation
Gas train
Description of Dungs MBC double gas valve... (gas multiblock)
Pressure switches
MBC-300/
700...
MBC-1200...
1, 2, 3, 4, 5
Seal plug G 1/8
MBC-...-SE 1900-5100
Pressure switches

09/2011 - Art. Nr. 4200 1040 7900A 13
Filter inspection must be carried out
at least once a year
Replace filter if p between pressure
port 1 and 2 > 10 mbar.
Replace filter if p between pressure
port 1 and 2 is twice as high as the last
measurement.
1. Interrupt gas supply: close ball valve.
2. Unscrew screws 1-2.
3. Replace fine-filter element 3.
4. Screw in and gently tighten screws 1-
2.
5. Carry out a function test
and a test to check the water tightness
pmax.= 360 mbar.
Space required for filter replacement:
MBC-300-...: 150 mm
MBC-700-...: 170 mm
MBC-1200-...: 230 mm
Adjusting the MBC-300-700-1200-SE
pressure regulating component
1. Open the slide.
2. Start the burner, correction of set
values possible while burner in
operation (fig. 1).
3. Check ignition safety of the burner.
4. If necessary repeat the setting steps.
Check intermediate values.
5. Apply a security seal to the adjusting
screw, see right.
Optimum combustion and ignition
safety must be ensured.
Security seal
After you have set the desired nominal
pressure value:
1. Close the slide.
2. Secure the slide in closed position
using the screw (fig. 3).
Installation
Gas train
Changing MBC-300-700-1200 filter
Setting the MBC-300-700-1200-SE pressure regulating component
3
12
1
Allen key no. 2.5
Open
2
Closed
3

09/2011 - Art. Nr. 4200 1040 7900A14
Installation
Gas train
Setting the MBC-1900-5000-SE pressure regulating component
Allen key no. 2.5
Adjusting the MBC-1900-5000-SE
pressure regulating component
1. Open the protective caps.
2. Start the burner, correction of set
values possible while burner in
operation (see figure).
3. Check ignition safety of the burner.
4. If necessary repeat the setting steps.
Check intermediate values.
5. Apply a security seal to the adjusting
screw (see below).
Optimum combustion and ignition
safety must be ensured.

09/2011 - Art. Nr. 4200 1040 7900A 15
Installation
Gas train
Description of double gas valves VGD... with servomotors SKP
VGD 20
VGD 40
SKP 15
SKP 25
SKP 75
Technical data
Double gas valves VGD with servo-
motors SKP:
Type of gas:
Gases in accordance with DVGW
worksheet
G 260/1, gas families 1, 2, 3 and
biogas (H2S-content 0.1 Vol.% max.),
H2
Electrical data:
220 V -15%...240 V +10%
100 V -15%...110 V +10%
50 to 60 Hz
Protection level: IP 54
Media temperature :-15°C to +60°C
Ambient temp.: -10°C to +60°C
Installation position:
Magnet vertically upright or on its side,
magnet horizontal
Max. operating pressure:
VGD20: 500 mbar
VGD40: 700 mbar (DN 40 and DN 50
to 1000 mbar)
Double gas valve VGD with
servomotors SKP
The combined servomotor and valve
perform the following functions:
• safety shut-off valve Class A Group 2
in accordance with EN 161 (SKP15...)
• safety shut-off valve Class A Group 2
in accordance with EN 161 with gas
pressure regulator (SKP25...,
SKP55..., SKP75...)
The electrohydraulically operated servo-
motors with valve are designed for
gases of families I to III and air, and are
intended mainly for use in gas-fired
furnaces.
They are slow-opening and fast-closing.
The servomotor can be combined as
desired with any of the valves and
nominal widths specified above.
The servomotor can be supplied with a
limit switch (closed position signalling).
Valve dimension information is provided
on the "Throughput diagram" in the
relevant valve datasheet.
The SKP25... operates as a constant-
pressure regulator with setpoint spring.
It is mainly intended for use with forced
draught burners
- with mechanical coupler;
- with electronic coupler.
The SKP75... operates as a constant-
ratio pressure regulator and regulates
gas pressure in proportion to the
pressure of the combustion air. This
keeps the gas/air ratio constant across
the entire load range. It is intended
mainly for use with modulating forced
draught gas burners with pneumatic
coupler.
System accessories available for the
double gas valve include the VPS 504
leak testing system and the GW...A5
pressure switch.

09/2011 - Art. Nr. 4200 1040 7900A16
Installation
Gas train
Gas filter
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 replace-
ment of the filter cartridge.
Filter replacement
The filter cartridge should be replaced
with 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.
Warning: when installing the filter mat,
comply with the marking or adhesive
label.

09/2011 - Art. Nr. 4200 1040 7900A 17
Installation
Gas train
Gas/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 part-load
condition when testing the safety func-
tions. 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
Protection level: IP 54
Ambient temp.: -15°C to +50°C
Installation 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 a specific construc-
tion according to VdTÜV leaflet
"Pressure 100/1" for application in
furnaces complying with TRD 604.
The setpoint (switching point) may be
selected by means of a setting disk with
vessel.
Air pressure switch
The air pressure switch is provided for
monitoring the pressure of the combustion
air fan.
Pressure switch LGW... is suitable for
switching an electrical circuit or for
switching it on or off if the actual pressure
values
are changing vis-a-vis the setpoint.
The pressure switch LGW... can be used
as overpressure, vacuum or differential
pressure switch 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 EN1854 and is CE/DIN-
DVGW-registered. It has been registered
in other important gas consumption coun-
tries.
N.B.(Gas and air pressure switches)
The pressure switches must be set in
accordance with the specifications.
Furthermore, each time they are set, a
function test must be carried out. Non-
compliance could result in personal
injury or damage to property!
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 shut-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 cir-
cumstances). 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.
Gas pressure switch A5
Gas pressure switch A6

09/2011 - Art. Nr. 4200 1040 7900A18
Gas train
Leakage controller
Test burner
1 Wieland 7P socket
3 Filter element
4 O-ring Ø10.5x2.25
5Fuse
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 switch Ø 9
pe + 20mbar
10 pe (p1) pressure switch Ø 9
inlet pressure (distribution)
Leakage controller VPS 504 S02
Working principle :
Prior to each burner start-up, the control-
ler checks for possible leaks between
safety and main valves by increasing
supply pressure.
Electrically, the leakage controller is
serially connected between the thermo-
static 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 supply pressure by 20 mbar.
After no more than 30 seconds
operation :
- the leakage test has been passed; the
yellow light comes on and current is
released to feed the burner’s control
and safety unit, which then starts its
program cycle.
- If the leakage test is not passed; the
red light comes on and the power
supply to the control and safety unit for
the burner is not released. Control
cycles have to be restarted manually.
Change valve if fault persists.
Setting :
The controller requires no on-site
setting.
Working test :
While controller is working :
• Open pa pressure switch. The precip-
itated leak prevents superpressure
from building up and safety unit locks.
• Reclose pa pressure switch.
• Release controller safety by pressing
red indicator light.
The leakage test is restarted; after 30
seconds, yellow indicator lights up and
powers up the burner's control and
safety unit, which then starts its program
cycle.
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 com-
bustion air via the hole in the burner tube
(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 data:
• Type of gas:
gases in accordance with DVGW
worksheet G 260/1, gas families 1, 2, 3
• Ambient temp.: -15°C to +70°C
• Installation position: vertical, facing
upwards
• Operating pressure to: 500 mbar

09/2011 - Art. Nr. 4200 1040 7900A 19
Installation
Hydraulics
General information regarding fuel oil system
Fuel oil hydraulics diagram
100 Burner
101 Fan
118 Nozzle
120 Air flap
143 Pressure gauge (optional)
175 Filter
176 Pump
178 Solenoid valve, supply line
349 Servomotor

09/2011 - Art. Nr. 4200 1040 7900A20
Installation
Hydraulics
Fuel oil pressure switch
Fuel oil pressure switch
Fuel oil pressure switches are used to
monitor burners to ensure that they do
not exceed or fall below specific fuel oil
pressures.
Depending on the burner variant,
pressure switches may be specified for
backflow only
or for backflow and the supply line. The
shut-off pressure in question is set
depending on the system parameters
(ring line pressure, fuel oil nozzle etc.).
Fuel oil pressure damping
To reduce fluctuations in fuel oil
pressure, a throttle screw (2) or a
capillary tube may be screwed into the
connection nozzle.
Adjustment of switching pressure
To adjust the switching pressure, the
adjustment button (1) can be pulled
upward and reinserted the opposite way
around.
Setting the fuel oil pressure switch
min.:
The shut-off pressure is the fuel oil
supply pressure at full load, minus
approx. 20%.
Setting the fuel oil pressure switch
max. (only for burners with a return
nozzle):
The shut-off pressure is the ring line
pressure with a full load plus approx.
2...3 bar.
The set shut-off pressure should also
take cognisance of the set switch differ-
ence.
When the setting procedure is complete,
the setting button must be returned to its
original orientation
for safety.
A seal must be applied to the pressure
switch to secure the setting (Item 4).
Switching difference
The switching difference may be set at
the limits of the pressure switch in
accordance with the values in the table.
To do this, the set screw must be rotated
in the adjusting screw (3) for the
switching point. 1 turn modifies the
switching difference by approx. 20% of
the total switching difference range.
Model Adjustment
range
Switching
difference
Application
DSB 158 F ... 0-25 bar 1.0... 7.5 bar Standard EN 267 supply line
and backflow