elco VG4.460 D User manual

02/2011 - Art. Nr. 4200 1032 6400A
VG4.460 D
en
de, fr..................................... 4200 1032 6200
it, nl ...................................... 4200 1032 6300
............................................. 4200 1032 6100
Operating instructions
For specialist installation engineers
Gas burners ........................................... 2-29

02/2011 - Art. Nr. 4200 1032 6400A2
Overview
Contents
Overview Contents.................................................................... 2
Important information ................................................ 2
Burner description..................................................... 3
Operation Operation, safety operation....................................... 4
Automatic combustion control unit......................... 5-7
Terminal allocation chart, connection socket ......... 8-9
MB-ZRDLE gas train............................................... 10
Assembly Burner assembly, gas train assembly ............... 11-12
Checking the combustion components................... 13
Electrical/gas connection ........................................ 14
Testing before start up............................................ 14
Commissioning Adjustment data ..................................................... 15
Air regulation........................................................... 16
Setting the MB-ZRDLE gas train............................. 17
Pre-adjustment without flame ........................... 18-19
Setting the flame................................................20-22
Saving the adjustment values in the display .......... 23
Servicing Maintenance .....................................................24-25
Troubleshooting .................................................26-27
Fault diagnosis menu,
Operating statistics menu .................................. 28-29
Declaration of conformity
for gas burners
We, certified company No. AQF030,
F-74106 ANNEMASSE Cedex, declare
under our sole responsibility that the
products
VG4.460 D
conform to the following standards
EN 50165
EN 55014
EN 60335-1
EN 60335-2-102
EN 60555-2
EN 60555-3
EN 676
Belgian royal decree dated 08/01/2004
These products bear the CE mark in
accordance with the stipulations of the
following directives
2009/142/EC Gas appliances
directive
2004/108/EC EMC directive
2006/ 95/EC Low voltage directive
92/ 42/EEC EEC Working
efficiency directive
Annemasse, 1st December 2010
M. SPONZA
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.
Important information
VG4.460 D burners are designed for the
low-pollutant combustion of natural gas
and propane gas. The design and function
of the burners meet standard EN 676.
They are suitable for use with all heat
generators complying with standard EN
303 or for use by hot air generators
complying with standard DIN 4794 or DIN
30697 within their respective performance
range. Any other type of application
requires the approval of ELCO.
Installation, commissioning and
maintenance must only be carried out by
authorised specialists and all applicable
directives and regulations must be
complied with.
Burner description
VG4.460 D burners are two-stage fully
automatic monoblock devices. The special
design of the combustion head enables
combustion with low levels of nitrogen
oxide and increased output. Class 3 type-
approval in accordance with EN676
certifies that the lowest emission values
have been achieved and means that the
national environmental regulations have
been met
AT: KFA 1995, FAV 1997
CH: LRV 2005
DE: 1.BImSChV
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 housing with operating
instructions, circuit diagram and spare
parts list.
- Burner head with flange seal and
securing screws.
- Compact gas train with integrated 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
150 cm2.
Variations may arise as a result of local
regulations.

02/2011 - Art. Nr. 4200 1032 6400A 3
A1 Control and safety unit
A4 Display
F6 Air pressure switch
K1 Auxiliary motor supply relay
M1 Blower motor
T1 Igniter
Y10 Air flap servomotor
3 Adjusting screw for dimension Y
5 Housing
6 Plate hanging device
(Maintenance)
7 Combustion chamber pressure
take-off pipe
8 Burner tube
10 7-pin connector
10.1 4-pin connector
10.2 3-pin connector (auxiliary motor
supply relay)
18 Cover
19 Release knob
20 Hood securing screw
113 Air intake box
en
Overview
Burner description

02/2011 - Art. Nr. 4200 1032 6400A4
Compact train
Operation
Safety function
Description of the function
A pre-ventilation time of 24 seconds
begins when first powering up, after a
power cut or a lockout, after the gas
supply has been cut or after a shutdown
for 24 hours.
During the pre-ventilation time
- the air pressure is monitored
- the combustion chamber is monitored
to detect any flame signals.
At the end of the pre-ventilation time
- the ignition is switched on
- the main and safety solenoid valves
are opened.
- burner start-up
Monitoring
The flame is monitored by an ionisation
probe. The probe is fitted with insulation
to the gas head and is routed through
the turbulator into the flame zone. The
probe must not have any electrical
contact with earthed parts. The burner
switches to malfunction if a short circuit
occurs between the probe and the
burner earth. During burner operation,
an ionised zone is produced in the gas
flame through which a rectified current
flows from the probe to the burner tip.
The 2nd stage ionisation current must be
at least 7 µA.
Safety functions
- If no flame is produced when the
burner is started (gas release), the
burner is switched off at the end of the
safety time which lasts no more than
3 seconds and the gas valve closes.
- If the flame is lost during operation, the
gas supply is cut within a second. A
new start-up sequence is activated. If
the burner starts, the operating cycle
starts running. Otherwise a lockout
occurs.
- If there is an air failure during pre-
ventilation or operation, a lockout
occurs.
- If there is a gas failure, the burner
either stops or will not start. As soon
as the gas pressure recovers a
sufficient value, burner starts again.
During the regulator shutdown
- The control thermostat interrupts the
heat request.
- The gas valves close
- The flame goes out
- The burner is ready for operation
CH note
In accordance with SSIGE instructions,
it is compulsory to install a gas safety
valve (mark 1) in the pipe
DE Note
In compliance with the reference layout
applicable to boiler rooms, sites with gas
furnaces must be fitted with a thermal
gas shut-off valve (mark 1).
F4 Gas pressure switch
F6 Air pressure switch
Y12 Safety solenoid valve
Y13 Solenoid valve, 1st stage
Y14 Solenoid valve, 2nd stage
1 Thermal shut-off valve (to be
installed by the installer)
104 Gas pressure regulator
106 Screen
108 Gas cut-out valve (to be installed
by the installer)
119pBrGas pressure measuring point at
the valve outlet
119.1Gas pressure measuring point
upstream of the valves
119.2Air pressure measuring point

02/2011 - Art. Nr. 4200 1032 6400A 5
en
Operation
TCG 2xx control unit
The TCG 2xx control and safety unit
controls and monitors the forced draught
burner. The microprocessor-controlled
program sequence ensures maximum
stability of time periods, regardless of
fluctuations in the power supply voltage
or the ambient temperature. The
automatic combustion control unit is
designed to cope with brownouts.
Whenever the supply voltage drops
below its rated minimum level (< 185V),
the control unit shuts down - even in the
absence of a malfunction signal. The
control unit switches itself back on again
once the voltage has returned to normal
levels (> 195V).
Pressing the
unlocking button on
the unit for
… causes …
... 1 second ... the control unit to
unlock.
... 2 seconds ... the control unit to
lock.
... 9 seconds ... the statistics to
be deleted
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Reduces the marked value.
Modifies/Confirms the value
shown.
Unlocks the control unit.
Red LED (flashes if a fault is
present).
Locking and unlocking
The control unit can be locked (switched
to malfunction mode) by pressing the
unlocking button and unlocked (fault
deleted), provided the unit is connected
to the mains power supply.
Always switch off the power
supply before installing or
removing the control unit. Do not
attempt to open or carry out
repairs on the control unit.

Screen Description Screen Description
Awaiting the heat request from
the boiler
Opening the gas valve and
safety time
Air flap is forced open for pre-
ventilation.
Flame is present, awaiting
authorisation of regulation
Pre-ventilation
Burner in operation. The lower
cell shows the strength of the
signal and the operating time of
the burner.
Closing the air flap to the ignition
position, pre-ignition

02/2011 - Art. Nr. 4200 1032 6400A6
• menu for setting the
servomotor,
• menu for storing the
servomotor setpoints in
the display
• menu for consulting
faults
• menu for statistical data
Operation
TCG 2xx control unit
In parallel with its control and safety
functions, the TCH2xx control unit
allows the following to be set:
(see illustration)
- the position of the air flap during
ignition
- the position of the air flap during the
1st stage
- the opening position of the stage 2
valve (for switching from 1st to 2nd
stage)
- the position of the air flap during the
2nd stage
- the closing position of the stage 2 air
flap (for switching from 2nd to 1st
stage).
The parameters for the control unit are
set using the display and 5 keys.
Operating values are shown in real time
on the display.
Pressing the keys gives access to 7
menus:
(The menu on the bottom right is not
activated in VG4.460 D burners)
• menu for setting/
adjusting the standard
configurations*
• menu for setting
industrial applications*
• menu for manual control*
* In these menus, it is
possible to adjust the
control unit's standard
configurations. These
are pre-set in the
factory. No
modifications may be
carried out on-site
without prior
consultation with ELCO.
The access code and
the setting setpoints for
these menus are
available on request.

02/2011 - Art. Nr. 4200 1032 6400A 7
en
Operation
TCG 2xx control unit
Operating cycle phases:
1: No voltage
2: Powering up, no heat request
3: Checking the air flap is closed
4: Opening an air flap, arrival in pre-
ventilation position
5: Checking the rest status of the air
pressure switch
6: Pre-ventilation: energizing of the
motor, checking the air pressure
7: End of pre-ventilation
8: Air flap closes to the ignition position
9: Switching on the igniter, unauthorised
flame monitoring
10:Starting the burner: Opening of the
solenoid valve, flame formation,
safety time: max. 3 s.
11:Awaiting regulator release
12:Opening the air flap, until the opening
position of the 2nd stage valve is
reached
13:Operation in 2nd stage
14:Closing the air flap, until the 2nd
stage valve reaches the closed
position
15:Operation in 1st stage
16:Regulator shutdown, closure of the
air flap to 0°
17:Awaiting a new heating request

02/2011 - Art. Nr. 4200 1032 6400A8
Operation
Terminal allocation chart
230 Volt connection
Earth
Flame check Fault
display
Air
pressure
switch
Igniter
Burner motor
Connector
Terminal
Terminal
Connector
Remote
unlocking
L1 power
supply
Solenoid valve 2nd stage
thermostat Heating
request
Earth
Gas
pressure
switch
Terminal Description Connector Terminal Description Connector
1 Burner motor phase 420 1st stage thermostat live (T1) 19
2 Earth 21 Heating request signal (option T2)
3 Neutral 22 Flame monitoring signal 11
41
st stage solenoid valve live
2
23 Earth
5 Neutral 24 Live
6 Earth 25 Air pressure switch signal 10
7 Live 26 Live
82
nd stage solenoid valve live 27 Live 20
9 Live L1 628 Remote unlocking signal
10 Earth 29 Neutral 21
11 Neutral 30 Signal fault live
12 Earth 31 Live 8
13 Earth 32 Live
14 Igniter live 533 Not used 34
15 Earth 34 Not used
16 Neutral
17 Live for the 2nd stage thermostat T6/7/8
18 Signal T7
19 Signal T8

02/2011 - Art. Nr. 4200 1032 6400A 9
en
Operation
Terminal allocation chart
Low voltage connections
Display-PC interface
Air servomotor
Connector
Terminal
Terminal
Connector
Terminal Description Connector Terminal Description Connector
1 not used 30 18 not used
14
2 not used 19 not used
3 not used 20 not used
4 not used 27
28
29
21 not used
5 not used 22 not used
6 not used 23 not used
7 not used 24 not used 33
8 not used 25 not used
9 not used 26 not used 32
10
Display or PC interface
16
/
17
27 not used
11 28
Air servomotor 15
12 29
13 30
14 31
15 32
16 33
17

02/2011 - Art. Nr. 4200 1032 6400A10
Operation
MB-ZRDLE gas train
MBZRDLE... B01S.. (dual-stage)
Compact unit consisting of:
filter, adjustable pressure switch, non-
adjustable rapid opening and closing
safety valve, adjustable pressure
regulator, main valve (first and second
stage) with adjustable throughput and
hydraulic brake, plus rapid closing.
Default setting:
- Flow rate 1st stage and 2nd stage, set
to maximum.
- Ignition flow rate and pressure
regulator set to minimum.
Technical data
Input pressure 360 mbar max.
Ambient temperature -15 to +70 C°
Voltage 230 V/ 50 Hz
Absorbed output 60 VA
Protection level IP 54
Gas connection 3/4" Rp or 1" 1/4 Rp
Assembly position:
- Vertical with coil facing upwards
- Horizontal with coil hidden
Pressure regulator setting
The adjusting screw has a path of 60
turns for adjusting the output pressure.
Three turns clockwise or anticlockwise
increases or reduces pressure by
1 mbar respectively.
At commissioning:
• Turn the screw at least 10 turns
clockwise (+)
• Then fine tune the adjustment (more or
less pressure)
• Checking the gas pressure on the
pressure tap 119pBr.
Setting the ignition throughput
• Unscrew plastic cap B.
• Turn it over and use it as a tool for
turning the adjusting screw (three
turns to adjust from minimum to
maximum throughput)
• Reduce the ignition throughput by
turning the screw clockwise, reduce it
by turning it anti-clockwise.
Adjusting the nominal flow rate
• Unscrew the locking screw (the sealed
screw must not, however, be
unscrewed)
Setting the gas throughput for
the 2nd stage
• Reduce nominal gas throughput by
turning adjusting knob C, anti-
clockwise (located on the upper
section of the solenoid coil). Turning
clockwise increases throughput.
Setting the gas throughput for
the 1st stage
By hand (not tool).
• Reduce gas throughput by turning ring
Dclockwise (located on the lower
section of the solenoid coil). Turn anti-
clockwise to increase gas throughput.
Setting the hydraulic brake
Setting the 2nd stage
Setting the 1st stage
Gas pressure
switch
Solenoid valve
coil
Filter cap
Connecting
flange
Adjusting screw of
the gas pressure
regulator
pBr (4 - 20 mbar)
Locking
screw
Sealed
screw

02/2011 - Art. Nr. 4200 1032 6400A 11
Ø a Ø b c d
190-240 200-270 M10 45°
en
Assembly
Burner assembly
Preparing the boiler front
• Prepare the burner mounting plate/
boiler door in accordance with the
diagram.
• Establish the internal diameter aof
190-240 mm.
• To mount the burner head bracket, drill
four M10 holes (drill diameter 200 to
270 mm) as shown in the diagram
opposite.
Burner head assembly
• Screw the bolts into the burner fixing
plate/boiler door and position the
insulation material. For a drill hole of
< 270 mm, elongated slots should be
cut to the required dimensions.
• Remove the combustion components
from the head
• Attach the burner head with 4 nuts (ref.
4). At this point, check that the gas
connection flange is correctly
positioned (on the left or right).
Burner tube installation depth and
brickwork surround
Unless otherwise specified by the boiler
manufacturer, heat generators without a
cooled front wall require brickwork or
insulation 5as shown in the illustration
opposite. The brickwork must not
protrude beyond the leading edge of the
flame tube, and should have a maximum
conical angle of 60°. Space 6must be
filled with an elastic, non-flammable
insulation material.
Exhaust gas evacuation system
To avoid unpleasant noise emissions,
right-angled connectors should not be
used on the flue gas side of the boiler.
Fitting the burner body
• Remove the cover (2 screws W).
• Unscrew the two screws on the burner
body completely.
• Bring the burner body into contact after
having swivelled it at least 15° to the
left.
• Engage the two screws Zon the body
into the two lugs provided.
• Tighten the 2 screws.
For assembly in the position with
the volute facing upwards, unclip
the display, turn it over 180°, and
refit it.

On boilers with reverse firing, minimum
flame tube insertion depth Ashould be
observed as per the boiler
manufacturer's instructions.

02/2011 - Art. Nr. 4200 1032 6400A12
Assembly
Gas manifold
Gas train assembly
• Check the correct position of the O-
ring Bin the gas connecting flange C.
• 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.

02/2011 - Art. Nr. 4200 1032 6400A 13
en
Checking the burner head
• Check the adjustment settings of the
ionisation probe and of the ignition
electrode as per the diagrams.
Setting to liquid gas operation
• Remove the gas diffuser 5and the
turbulator 2.
• Remove adaptor 3.
• Fit the adaptor 6(supplied with the
housing) on the gas burner head.
• Turn the gas diffuser 5180° and refit it.
• Refit the turbulator 2and the 3 spacers
4, using the 3 new screws 1provided.
Assembly
Checking/adjusting the burner head
Check the radial position of the flame
tube
After untightening the three mounting
screws S, it is possible to change the
position of the flame tube using the lever
H. Nitrogen oxide emissions may be
affected by the radial position of the
flame tube
• To be set at the start to position 1.
Fitting the combustion components
• Check that the O-Ring J1 is in the
correct position in the gas elbow.
• Insert the combustion components
into the head, tighten the mounting
screw Xusing an Allen key, then
tighten the lock nut using an open-
ended spanner.
• Thread the ionisation cable IK and the
ignition cables ZK into the grommets
Rand S.
• Remove the cover.

02/2011 - Art. Nr. 4200 1032 6400A14
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.
Ionisation current measurement
To measure the ionisation current,
disconnect connector B10 and connect
a multimeter with a measuring range of
0-100 µA.
The 2nd stage ionisation current must be
at least 7 µA. It is also possible to read
the ionisation current on the display.
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: 6.3 A
The burner motor has its own
separate power supply (no. 3).
Fuse on the motor circuit: 6 A gM
Electrical connection
It must be possible to disconnect
the burner from the mains using an
omnipolar shutdown device
complying with the standards in
force. The burner and heat
generator (boiler) are connected
by a 7-pin connector 1and a 4-pin
connector 2(not supplied). The
diameter of the cables connected
to these connectors must be
between 8.3 and 11 mm.
Connecting the gas train
Connect the gas train to the plugs on the
burner (black to black, grey to grey).


02/2011 - Art. Nr. 4200 1032 6400A 15
The adjustment values above are guide
values and facilitate commissioning.
The factory settings are in bold set
against a grey background The final
settings are essential in ensuring that
the burner functions as well as possible
Setting the gas pressure switch
• Remove the transparent cover.
• Provisionally set to 15mbar.
Setting the air pressure switch
• Remove the transparent cover.
• Provisionally set to 1 mbar.
en
Commissioning
Adjustment data
MB-...420
1st stage 2nd stage Ignit. 1st stage 2nd stage G25 G20 G25 G31 G20 G25 G31
150 220 40 2,6 13 13 23 17 - - - - 3,2 / 6,3 4/ 7,9 2,3/ 5
180 350 40 3,5 17 17 44 20 - - - - 3,6 / 12,1 4,8 / 15,6 2,3 / 9,2
220 430 40 4 22 22 80 30 - - - - 5,2 / 17,2 7,1 / 21,8 3,4 / 12,5
105 250 40 2,6 5 5 27 17 - 0,7 / 5,2 0,7 / 5,7 0,5 / 4,8 -- -
180 350 40 3,5 17 17 44 20 - 2,2/ 8 2,2 / 9 1,8/ 7,6 -- -
220 430 40 4 22 22 80 30 - 2,7 / 10,5 3,1 / 11,5 2,3 / 9,8 -- -
125 220 40 2,6 9 9 23 17 1,3 / 4,7 ----- -
180 350 40 3,5 17 17 44 20 1,7 / 8,5 ----- -
220 430 40 4 20 20 80 30 2,1/10,9----- -
2dstage
valve
opening
VG4.460 D -
d1''1/4-Rp1''1/4
VG4.460 D -
d2''-Rp2''
MB-...412 MB-...407
Gasvalve setting
Gashead pressure pBr (mbar)
1. stage / 2. stage
Burner power Dimension
Y
(mm)
Furnace
pressure
pF
(mbar)
Air flap setting
VG4.460 D -
d3/4''-Rp3/4''

02/2011 - Art. Nr. 4200 1032 6400A16
Commissioning
Air regulation
Air regulation
Combustion air is regulated at two
points:
• on the pressure side, using the gap
between the baffle plate and the
burner tube.
• on the vacuum side, by the air flap
driven by servomotor Y10.
The regulation of air in the burner head
affects not only the air flow but also the
mixing zone and the air pressure in the
burner tube. Turning screw A
- right: more air
- left: less air
• Adjust dimension Yin accordance with
the settings table.
Air regulation by air flap
Air is regulated on the vacuum side by
an air flap. This is driven by servomotor
Y10.

02/2011 - Art. Nr. 4200 1032 6400A 17
en
Commissioning
Setting the MB-ZRDLE gas train
General adjustment procedure
The 2nd stage can only be adjusted via
the pressure regulator Set the 2nd stage
valve (button C) to fully open.
The incremental advance setting on
ignition and on switching stages is
performed using button B.
The 1st stage setting is performed using
ring D.
Adjusting the regulator:
The pressure in the regulator is
measured at pBr.
The set pressure supplies the required
flow rate.
Incremental advance setting on
ignition
This hydraulic function affects the gas
valve opening characteristics during
ignition and when switching stages.
• Unscrew plastic cap B.
• Turn it around and use it as a key.
• Turn in the direction of:
arrow to -: the incremental advance
increases
arrow to +: the incremental advance
decreases
Setting the 2nd stage using the
adjusting knob C.
This operation is only required when the
burner power is too high with a pressure
of 5 mbar between the valves, or when
the burner is tending to pulse.
Proceed as follows:
• Unscrew the locking screw without
touching the painted screw on the
other side. The cap Cis turned 4.5
times.
• Rotate clockwise arrow to -: the flow
is reduced, and vice-versa.
The pressure may need to be corrected.
Adjusting the flow of the 1st stage
By hand (not tool).
• Reduce gas throughput by turning ring
Dclockwise (located on the lower
section of the solenoid coil). Turn anti-
clockwise to increase gas throughput.
(there is a difference of 3 whole turns
between the minimum and the
maximum).
Note
Adjusting the gas throughput for the 2nd
stage may also alter the throughput for
the 1st stage. If this is the case, the 1st
stage must be readjusted.
• Afterwards, retighten the locking
screw.
Adjusting screw of the
gas pressure
regulator
Locking screw
Sealed screw

02/2011 - Art. Nr. 4200 1032 6400A18
Modifying a settings value for the servomotor position:
- To modify the value of a position, move the cursor to the
corresponding location with the button or .
- Select the value to be modified using the button , the
selected value will flash.
- Increase or decrease the value in increments of 0.1° by
repeatedly pressing or . For large modifications, press
and hold the button or , the value will scroll quickly up
or down.
- Confirm the new value using the button . The value stops
flashing.
N.B.:
It is possible to set different positions within a large range of
values. However, for safety reasons, the control unit enforces
a minimum interval of 2° between the different positions
(except between the ignition position and the 1st stage).
Commissioning
Pre-setting without flame
Setting is carried out in 2 phases:
- pre-adjustment without flame
- setting the flame, to fine tune the
settings based on the combustion
results
When the burner is switched on, the
control unit displays the screen below.
Important
At this point, no setting position for the
servomotor has been defined, therefore
the burner cannot be started under
these conditions.
• For the next step, press any
button.
The overall view of the menus
is displayed, and the air flap
positions settings menu is
selected.
• Open the settings menu by
pressing the button .
You must now enter the
access code (see the label on
the back of the display)
• Increase or decrease the
value in increments by
repeatedly pressing or
.
• When the first figure has
been set, move the cursor to
the right by pressing .
• Repeat the operation until
you reach the last figure.
• Confirm the access code by
pressing
The control unit then opens
the settings mode. The screen
displays the factory pre-
settings for the different
positions of the air flap (here
for example: for a VG4.460 D).
The following positions for the
air flap are presented:
- ignition position (when the
menu is opened, the curser
goes to this position)
- position of the air flap during
the 1st stage
- position of the air flap when
the 2nd stage fuel oil valve is
opened
- position of the air flap during
the 2nd stage

02/2011 - Art. Nr. 4200 1032 6400A 19
en
Commissioning
Pre-setting without flame
General advice before starting the burner
End of settings menu without flame
When all the positions of the servomotor have been determined according to the required
settings, it is then possible to move on to the next section for commissioning - "Setting the flame".
To do this, place the cursor in the lower part of the screen on the symbol and confirm by
pressing the button .
If it is necessary to quit the menu without saving the pre-settings, position the cursor on the
symbol and confirm with the button .
Optimising combustion values
Optimum combustion values can be
achieved by adjusting the position of the
baffle plate (dimension Y) if necessary.
Doing this can have an effect on starting
characteristics, pulsation and
combustion values. Any reduction in
dimension Yincreases the CO2value.
However, starting characteristics
become harsher.
Compensate for the change in airflow if
necessary by adjusting the air flap
position.
Precautions: To avoid condensation,
observe the minimum required flue
gas temperature specified by the
boiler manufacturer and comply with
the requirements for flue gas ducts.
Risk of deflagration
Continuously check CO, CO2
and soot emissions when
adjusting. Optimise
combustion values if CO is
present. The CO level must
not exceed 50 ppm.
Function check
Flame monitoring must be checked for
safety as part of initial commissioning
and also after servicing or if the system
has been out of operation for any
significant period of time.
- Starting attempt with gas valve closed:
once the safety time has elapsed, the
control and safety unit should indicate
a lack of gas or switch to malfunction
mode.
- Starting with the air pressure switch
closed:
after an 8-second test period, the
burner switches to malfunction mode.
- Starting attempt with air pressure
switch open:
after a 60-second waiting period, the
control and safety unit locks.
- Starting attempt with brief opening of
the air pressure switch during pre-
ventilation:
the control and safety unit restarts the
pre-ventilation programme (air
pressure detected again within 60
seconds) ; otherwise a lockout occurs.


02/2011 - Art. Nr. 4200 1032 6400A20
Commissioning
Setting the flame
- If the boiler heating
request is not present,
the boiler remains on
standby.
In this case, it is still possible
to return to the previous
setting menu "Pre-setting
without flame". To do this,
position the cursor on the
symbol and confirm with
the button .
- If a boiler heating
request is present (T1-
T2 contact closed), the
burner starts.
The air flap is opened to
move to the pre-ventilation
position.
Air pressure switch test
Pre-ventilation
The air flap switches to the
ignition/pre-ignition position.
The fuel valve opens.
Awaiting flame signal
If no flame is detected at
the end of the safety time,
the control unit switches to
malfunction mode.
Flame detected
Flame stabilisation
The control unit awaits the
regulation authorisation.