09/2005 - Art. Nr. 13 019 541A

Operating instructionsfor authorized experts

Gas burnersEK 4… G-ROA

Designs:ENTRD

2 09/2005 - Art. Nr. 13 019 541A

Survey

Table of contentsGeneral information

Table of contents Page

Survey Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Burner functions Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Compound control/Gas fittings group . . . . . . . . . . . . . . . . . . . . . 6Automatic burner control unit, controller . . . . . . . . . . . . . . . . . . . . 7

Installation Mounting the burner to the heat generator . . . . . . . . . . . . . . . . . . 8Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Start-up Burner head factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 10Gas pressure regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Adjustments Adjustment sequence, gas throughput . . . . . . . . . . . . . . . . . . . . . 12Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Servomotor, limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Air pressure monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Flame monitoring, UV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Flame monitoring, ionization . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Servicing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General InformationThe ELCO EK4...G-ROA series of gasburners is designed for the combustionof natural gas.Design and performance of the burnerscomply with the European Standard

EN 676Installation, start-up and maintenanceof the burner must be performed by aqualified expert in compliance withcurrently applicable guidelines andregulations.

DIN 4756Gas-firing installations in heatingsystems

TRG ITechnical regulations for gas fittings

DIN EN 298Gas burners, flame monitoringsystems

EN 60335-1Safety of electrical appliances fordomestic use

Heat generatorThe heat generator must meet therequirements for furnace loadsstipulated in EN 676.

Thermaloutput

Furnace loadkW/m3

kW min. max.12–24 1.2 1.724–70 0.95 1.6370–190 0.92 1.51190–480 0.97 1.53480–1200 1.07 1.681200–2450 0.95 1.35>2450 Standard does not apply.

Observe manufacturer’srecommandations

Compare the performance data with theburner data. In case of discrepancies,contact the manufacturer.

Site of installationThe burner must not be operated inrooms with aggressive fumes (e .g.hairspray, tetrachloroethylene, carbontetrachloride), dust-laden air or highatmospheric humidity (e .g. laundryrooms).For supply of combustion air, ensureadequate ventilation of the heatingroom.

ELCO rejects all warranty claims fordamage resulting from one of thefollowing reasons:– Improper use– Inexpert installation or maintenance

by the purchaser or third persons,including the installation of partsother than genuine parts suppliedby the manufacturer.

Start-upInitial start-up of the gas-firinginstallation must be performed by theinstaller, manufacturer, or by anotherexpert designated by them.

Delivery and operating instructionsAt the time of delivery at the latest, thecompany installing the gas burner mustsupply the user with a set of Operatingand Service Instructions.These should be kept in the roomwhere the heating unit is installed.The address and telephone number ofthe nearest service representative mustbe entered in the Instructions.

Note for the userThe system should be serviced by anexpert at least once a year. To ensuremaintenance at regular intervals, werecommend you to conclude a servicecontract.

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Burner type EK 4.90 G-ROA EK 4.135 G-ROA EK 4.175 G-ROA

Technical dataThermal output. . . . . . . . . . . . . min. 80 kW 95 kW 170 kWThermal output. . . . . . . . . . . . . max. 900 kW 1350 kW 1750 kWGas type . . . . . . . . . . . . . . . . Natural gas L+H* Natural gas L+H* Natural gas L+H*Gas supply pressure 20-100 mbar** 20-100 mbar** 20-100 mbar**Regulation . . . . . . . . . . . . . . . modulating modulating modulatingAir regulation. . . . . . . . . . . . . . suction side Air cut-off valve Air cut-off valve Air cut-off valveAir regulation. . . . . . . . . . . . . . pressure side in burner head OAS° in burner head OAS° in burner head OAS°Control ratio . . . . . . . . . . . . . . max. 20/100% 20/100% 20/100%Voltage . . . . . . . . . . . . . . . . 230/400 V, 50 Hz 230/400 V, 50 Hz 230/400 V, 50 HzPower consumption . . . . . . . . . . 2.5 kW 2.5 kW 3.5 kWWeight approx . . . . . . . . . . . . .

°OAS Optimized Air Speed

90 kg 111 kg 127 kg

Burner equipmentElectric motor . . . . . . . . . . . . . 2800 min.–1 2.2 kW 2.2 kW 3.0 kWAutomatic burner control unit . . . . . LFL 1 / LGK 16 LFL 1 / LGK 16 LFL 1 / LGK 16Flame monitor . . . . . . . . . . . . . UV QRA 2 / QRA 53 UV QRA 2 / QRA 53 UV QRA 2 / QRA 53Ignition transformer . . . . . . . . . . ZE 30/7 ZE 30/7 ZE 30/7El. servomotor for air damper . . . . . EA 2, electric EA 2, electric EA 2, electricAir pressure monitor . . . . . . . . . . DL 50 A DL 50 A DL 50 A

*Gas types CH I2H ** The minimum gas supply pressure required for burner operation must be calculatedDE I2ELL individually depending on the installation.AT I2HNL I2L

Survey

Technical data

Performance chartsThe performance charts reflect thevalues approved during officialhomologation.

Determining the required thermal output

QQ

KF

N�

�

QF = Thermal output (kW)QN = Rated boiler capacity (kW)�K = Boiler efficiency (%)

---- Gas pressure drop charac-teristics of burner head fornatural gasHun = 9.9 kWh/m3

Thermal output QF

Furnace pressureGas pressure drop (burner)

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1 Air pressure monitor2 Scale, gas nozzle and baffle plate

position3 Swivel hinge4 Switch box with ignition

transformer, switch andconnecting terminals

5 Gas connection6 Connecting flange7 Insulating p adding8 Burner tube9 Flame cup10 Electric motor11 Burner housing

12 Air suction box13 Inspection glass14 Compound control15 El. servomotor for compound

control16 Flame monitor

Burner type Thermaloutput kW

A B C dø Dø Eø Fø G Product ID -No.

EK 4.90 G-ROA 80–900 455 176 179 185 190 280 310 225 CE-0085AQ0597

EK 4.135 G-ROA 95–1350 455 176 179 185 220 280 310 225 CE-0085AQ0597

EK 4.175 G-ROA 170–1750 455 176 179 220 261 340 370 225 CE-0085AQ0597

Burner type H J K L M N O P Q R DN

EK 4.90 G-ROA M12 200 430 618 140-310 370 360 225 215 103 65

EK 4.135 G-ROA M12 230 430 628 140-310 370 360 225 215 103 65

EK 4.175 G-ROA M12 280 430 782 170-470 370 360 300 215 987 80

Survey

Dimensions

Boreholes in boiler connecting plate KeyEK = Manufacturer4 = Size90 = Performance ratingG = Natural gasR = Modulating, with mechanical

compound controlO = Optimized air speedA = Burner control unit mounted

on the burner

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Burner functions

Functional description

Starting FunctionAs soon as the firing system demandsheat, the burner is switched onautomatically via a controller. Theburner motor and the blower wheelstart. The automatic burner control unitcontrols and monitors the start-upsequence.

A gas valve leakage test is carriedout automatically every time theburner is started.

The air damper is closed when theburner is not operating.The electric servomotor moves theclosed air damper to the full-loadposition so that the burner prepurgesthe combustion chamber and the fluegas ducts with the prescribed quantityof air . Shortly after prepurging hasstarted, the air failure monitor mustswitch over to its working positionwithin a predetermined period of time,i.e. the set minimum air pressure mustbe reached and maintained until theburner is switched off. When the setprepurging time has elapsed, the airdamper is moved to low load or startload in combination with the linear gasnozzle.

The electric burner control makes itpossible to start the burner atincreased load and then return to lowload, which is advisable with sometypes of gas for safety reasons.Preignition is then initiated and gas isreleased by the gas valves. Within thesafety period of 3 seconds a regular,steady flame must be established. Oncompletion of the safety time, a flamesignal must be transmitted to the burnercontrol unit via the flame monitoringcircuit. This signal must be maintaineduntil controlled shut down.The start-up sequence of the burner iscompleted.

Operating FunctionAfter a regular flame has formed, theload control is activated, which meansthat the burner has reached itsoperating position. From now on thecontrol unit automatically regulates theburner between low load and full load.Depending on heat requirements, theelectric servomotor receives an OPENor CLOSE command from the controllerand then either increases or reducesthe air and gas quantities.

This compound control system adjuststhe linear gas nozzle and the linearizedair damper and regulates the gasquantity in combination with the air.Burner regulation is possible in twoways ; either 2-stage sliding or , if anappropriate controller is fitted,modulating. With modulating control,the burner can operate at any levelbetween low load and full load.The burner is always switched off in thelow load position. When the burner isidle, the air damper is always closed,thus preventing a cold air stream frompassing through the combustionchamber, the heat exchanger and theflue ducts. This reduces the coolingloss of the burner to a minimum.

Start loadBurner control units with a safety periodof 3 seconds:Safety time = 33% of full load

or 120 kWBurner control units with a safety periodof 2 seconds:Safety time = 50% of full load

or 120 kW

Safety functionsA fault shutdown is effected :� if a flame signal occurs during

preventilation (extraneous lightmonitoring)

� if no flame has formed upon expiry ofthe safety period of 3 seconds afterstarting the burner (fuel release)

� if a flame failure occurs duringoperation

� if the blower pressure drops belowthe set safety pressure duringoperation

A fault shut down is indicated by theflashing lamp in the reset button. Thesequence switch stops and indicatesthe type of malfunction (seeTroubleshooting in Maintenance).After rectifying the fault, press the resetbutton to release the shut down and tostart the burner.

A controlled shutdown is effected :� upon reaching the medium

temperature or medium pressure� if the gas pressure falls below the set

safety pressure� if the power supply fails

After restoring the operating conditions,the burner restarts automatically.

2-stage sliding

Full load

Operating positionLoad regulationReleaseLow load

Gas valves/ignition

modulating

Full load

Operating positionLoad regulationReleaseLow load

Gas valves/ignition

Compound control

On Off On Off

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Burner functions

Compound control fuel/airGas fitting groupFunctional diagram

Compound control fuel/airThe compound control system, whichalters the gas and air quantities evenlyand continuously, ensures thatcombustion values are maintained atalmost identical levels across the entirecontrol range.Two-stage sliding control permit soperation at either low or full load.These two load positions are reachedgradually according to heatrequirements, so that there is nosudden supply or cutoff of largeamounts of fuel.The modulating control systemoperates at any required level within thecontrol range, depending on heatrequirements.The only difference between burnerswith two-stage sliding and burners withmodulating control lies in the electricburner control, while mechanicalregulation remains the same. Thecontinuously variable and reversibleelectric servomotor moves thecompound control segment accordingto the heat required.

This segment also controls the airdamper and the air and fuel throughputin the burner head via the longitudinaladjustment lever.To achieve an optimum ratio of air andfuel across the entire control range, theair damper must be positioned correctlyvia an adjust able steel segment andball-bearing ratchet.

LinearizationAir regulation on the suction side iseffected by the linearized air damper forall burner types.This type of regulation allows thecombustion air to be dispensed in linewith the fuel quantity and thus ensuresa wide adjustment range and a highcombustion efficiency even at lowloads.

Gas Fittings GroupThe gas fittings group is determinedaccording to customer-specificconditions.

Important criteria are:� Burner capacity� Furnace backpressure� Gas pressure drop of the burner

head� Gas pressure drop of the gas fittingsThe total gas pressure drop mustalways be smaller than the availablegas flow pressure.

ImportantOnly gas fittings approved by officialburner testing may be used.

Functional Diagram1 Gas shut-off valve2 Gas filter3 Test burner4 Gas pressure monitor*5 Gas pressure regulator6 Gas valve7 Valve leakage detector8 Pressure gauge9 Compound control segment10 Gas regulator11 Air regulator

* If the burner design complies withTRD 604-72h, the pressuremonitors must either be tested forspecial design or two monitorsmust be installed.

A Gas connectionB Combustion air inlet

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Burner functions

Functional sequence of burner control units LFL 1.333 / LGK 16.333Controller RWF 40

Functional diagramLFL 1.333 / LGK 16.333A = Start commandA–B = Interval for flame formationB = Burner in operating positionB–C = Burner position

(heat generation)D = Controlled shutdownG Blower motorR Temperature or pressure

controllerZ Ignition transformerBV Fuel valve (s)FS Flame signalLK Air damperLR Load controllerRV Continuously variable fuel valve

(here gas control valve)

modulating

t1 Preventing timet2 Safety timet3 Preignition timet4 Release of fuel valve BVt5 Release of load controller LRt11 Opening time of air dampert12 Closing time of air damper

Burners with modulating control systems come equipped with the UniversalController RWF 40 and its appropriate modules.This controller has been designed specifically for use with burner installations, inparticular for controlling the temperature or pressure of burners with continuouslyadjust able fuel throughput. The actual values (i .e. the resistance values) fortemperature, pressure or furnace pressure are measured by means of a detectoran a range connector.

The burner control units LFL 1.333and LGK 16.333 are designed forcontrolling and monitoring burners withmulti-stage or modulating controlsystems.For a detailed functional description ofthe burner control unit s, includingtechnical data and planing information,refer toLFL 1…-7451 DLGK 16…7785 D

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Installation

Mounting the burner to the heat generatorElectrical connection

Mounting the burner to the heatgeneratorTo mount the burner to the heatgenerator, prep are the connectingplate according to the dimensions givenon page 4.The movable clamping flange forconnection is mounted at the front ofthe burner tube.� Loosely attach the burner to the heat

generator by means of the clampingflange

� Adjust the burner tube length in thefurnace by inserting the burner

Burner tube insertion depthIn boilers with reverse furnaces,provide sufficient insertion depth of theburner tube to ensure troublefreeoperation.

A = Front of boiler to turning edgeof second pass.

Electrical connectionElectric wiring of the burner and gasfittings must be carried out by anauthorized electrician according tothe enclosed wiring diagram.

For cable connection, ensure thefollowing:� Connect to terminal strip 11� Provide sufficient length of cable so

that the burner and the boiler doorcan be opened

� Do not install the sensor lead in themulticonductor cable.

Caution!The electric module can be removed forconnection, replacement or adjustmentof components.

� First tighten the flange clampingscrews, then the fixing screws.

If necessary, release the screw 1 todisplace the flame cup for correctadjustment of the burner head.

Boiler inspection glass coolingTo keep the boiler inspection glass cooland clean, a cooling line may beconnected to connection 2 R1/4”.The cooling line can either be a hose ora copper pipe. A hose union isenclosed with the burner.To connect a copper pipe, a suitableclamping ring connection is required.

Disassembling the electric module� Set the main switch to Off, remove

the fuse� Release the lock nuts 3� Carefully remove the electric module.

Caution!Never apply volt age to the electricmodule after disassembly.After making the connections, check allsystem components for correct wiring.Start the motor for a short time to checkthe sense of rotation.

2 Connection for inspection glasscooling

3 Lock nut4 Switch Manual-Automatic5 Pushbutton Higher/Lower6 Service pushbutton7 Burner control unit8 Auxiliary relay9 Motor contactor10 Overload relay11 Terminal strip

min. insertion depth

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Installation

Gas ConnectionFor installation and start-up of the gasconduits and fittings, observe theapplicable regulations of thesupervisory authorities and institutionsof your country.

Gas propertiesBefore installing the unit, ask your gassupply company for the followinginformation:

1. Gas type (gas group I, II, III)2. Calorific value Hun = kWh/m3 (kJ/m3)3. Maximum CO2 content of the flue gas4. Gas supply pressure and static

pressure

Checking the gas typeBefore connecting the burner to the gassupply line, check whether the gas typeand the burner type match (see typeplate on the burner). The burner typeand the gas type must coincide.

G = Natural gas

Gas supply pressureTo ensure optimum burnerperformance, a minimum gas supplypressure is required upstream of theburner gas fittings.

Minimum gas supply pressuresCH I2H G 20 = 20 mbarDE I2ELL G 20 = 20 mbarAT I2H G 20 = 20 mbarNL I2L G 25 = 25 mbarObserve the installation and mountinginstructions of the componentsmanufacturers (enclosed with thefittings).The dimensions of the gas conduitdepend on the throughput and theavailable pressure; the conduit must beinstalled so that the distance to theburner and the pressure drop are keptto a minimum.When determining the nominal widthDN of the gas fittings group, considerthe flue-gas side resistance of theheat exchanger as well as the gaspressure drop of the burner and thefittings group.

Gas fittings groupThe gas fittings group may beconnected directly to the gas supplyline. The order and the direction offlow (arrow on the housing) of thefittings must be observed. Removedirt and foreign objects from the fittingsand connection pieces prior toinstallation and start-up. To ensuregood start-up conditions, thedistance between the burner and thegas shut-off valve must be kept to aminimum.

Leakage testThe gas conduit upstream of the burnergas fittings group must be installed,tested for tightness, vented andcertified by the installing comp any inaccordance with applicable guide-lines.The tightness of the screw and flangeconnections must also be checked.The leakage test is to be carried outunder pressure with approved foamingagents which do not cause corrosion.The results of the leakage testsperformed on steam boilers also requirecertification.

VentingNote! Before starting the burner or afterrepair work, the complete gas supplyline and the gas fittings group must bevented to the out side (by means of ahose).

Never vent the gas conduit into theheating room or combustion chamber!

The test burner can be used fordetermining the presence of aninflammable mixture.

SupportThe gas fittings group must besupported from below by means of thetelescope support or a similar deviceafter or even during installation (e.g. atthe filter and/or valve).

Point of separationTo facilitate maintenance of the boiler(combustion chamber), a point ofseparation (flat sealing) should beprovided for swivelling the boiler door.

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Burner type Factory settings in mm

A B F H M

Baf

flepl

ate/

adju

stm

entl

ever

Gas

tube

/sw

irlpl

ate

Ele

ctro

de/

baffl

epl

ate

Baf

flepl

ate

flam

ecu

p

Gas

tube

gas

nozz

le

EK 4.90 G-ROA 42 21 3 -1 17

EK 4.135 G-ROA 49 24 3 -5 17

EK 4.175 G-ROA 56 26 3 -10 16

Start-up

Burner head factory settings

Factory settingsThe factory settings given below arestandard values and refer to about 80%of the maximum burner capacity.Readjustment may be necessarydepending on local circumstances, fluegas analysis and combustionbehaviour.

The values are set from the zeroposition.

Zero position signifies:� Scale value zero� Dimensions M and H according to

table

Important !Check the settings by means of thetable prior to start-up. To check,remove the nozzle assembly (seeServicing the Burner in Maintenance).

Burner head1 Burner tube2 Gas tube3 Linearized gas nozzle4 Electrode holder5 Flame cup6 Ignition electrode7 Nozzle adjustment lever8 Sleeve tube with swirl plate9 Segment baffle plate10 Perforated baffle plate

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Start-up

Gas pressure regulation

Start-upThe following checks must beperformed before the system is firstput into operation:� Observe the operating instructions of

the boiler manufacturer; the boilermust be installed ready for operation.

� Fill the heating system with sufficientwater.

� Check the entire system for correctelectric wiring of all component s andfittings.

� Check the sense of rotation of theblower motor.

� Check the settings of the temperatureor pressure controllers, limiters,safety devices and electric limitswitches.

� Ensure adequate gas supplypressure. The gas supply pressuremust be between 20 mbar and100 mbar. Higher connectionpressures require additional gasfittings.

� Carry out a leakage test on the gaselements.

� Ensure unobstructed flue gas pathsand adequate fresh air supply. Burnerin starting position; air damperclosed.

� Burner control unit reset and in start-up position.

Check the performance of the burnerprogram sequence before fuel is firstreleased. If gas is used, check thegas section as follows:� Make sure that the gas shut-off valve

of the valve group is closed.� Bridge the gas pressure monitor (see

wiring diagram).� Start the burner and check for correct

sequence of the start-up program:1. Blower2. Air damper in preventing position3. Air pressure check4. Air damper in low-load position5. Ignition sp ark6. Valves open7. Fault shut down after safety period

(see burner control unit)� Unlock (reset) the burner control unit,

remove the bridge from the gaspressure monitor.

Start-up with gas� Connect the measuring instruments

for gas chamber pressure 1 and airpressure (connect to inspection glasscooling).

� Connect the measuring instrumentsfor the flame monitoring current.

� Open the gas shut-off valve upstream of the valve group; check thegas pressure at the pressure gauge.

� Set the service switch to position 1.� Set the Manual/Automatic selector

switch to Manual.

Gas pressure regulationThe gas pressure is adjusted bychanging the spring pressure whichacts on the control diaphragm.

Thermal outputWhen calculating the thermal output,the calorific value of the individualgases must be taken into account.If low-grade gas is used, for example,the gas pressure for high-grade gasmust be multiplied by the factor 1.5 toachieve the required burner capacity .

If applicable, wait for the leakage test ofthe gas valves to complete.If the valves are leaky, the burner start-up sequence will stop.The burner starts according to theburner start-up sequence.

NoteThe gas output pressure (gas controlpressure) must always be lower thanthe gas entry pressure but higher thanthe total pressure drop of thesystem.

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Adjustments

Adjustment sequenceAdjusting the gas throughput

Adjustment sequence� Set the selector switch to Manual� Use the service switch to switch on

the burner� Adjust the gas throughput (low load)� Move the “Higher/Lower” switch to

full load� Adjust the gas throughput (full load)� Move the “Higher/Lower” switch to

low load� Gradually adjust the combustion air

(suction side) to the gas throughput

� Switch off the burner� Set the selector switch to Auto

Adjusting the gas throughputThe gas throughput is adjusted bymeans of the gas control nozzle in theburner head. The nozzle can beopened and closed continuously bymeans of the longitudinal adjustmentlever.

The gas throughput for low loadmust be 50%.

Gas throughput for low load� Burner in low-load position� Release the counternut 2� Use the turnbuckle sleeve 1 to move

the gas nozzle towards the open orclosed position

� Tighten the counternut 2 afteradjustment

� Mark the low-load position on thescale 3

Gas throughput for full load� Move the burner to full load� Use the control path adjustment to

move the gas nozzle towards theopen (+) or closed (-) position

� After adjustment, move the burner tolow load and reset the low-loadposition as marked on the scale(turnbuckle sleeve [1])

1 Turnbuckle sleeve2 Counternut3 Scale

I Control path adjustment

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Adjustments

Combustion air

Combustion air (pressure side)The distance H is given automaticallyby the control path H1 of the gasnozzle.Normally, the factory-set position of thebaffle plate requires no furtheradjustment. If necessary, minorcorrections can be made for optimumcombustion� by moving the baffle plate in the

baffle plate holder� and/or by moving the flame cup

Make sure that the control curve of thecam strip rises evenly. The segmentpath should be fully utilized at eachburner load level.After adjustment, move the burneragain to each load level from full load tolow load and repeat the measurements.

1 Gas control nozzle2 Baffle plate3 Flame cup

Combustion air (suction side)The combustion air on the suction sideis set by means of the air damper whichmoves on an adjustable cam strip.� Burner in full-load position (selector

switch to “Manual”)� Gradually move the “Higher/Lower”

switch to low load and performcombustion and air qualitymeasurements

� If necessary, readjust the cam strip 5.To do this, release the externalhexagon socket screws 4 by ¼ turnand adjust the cam strip using theinternal screws 4a (5 mm hexagonsocket screws)

Turn clockwise= less air

Turn anti-clockwise= more air

4 Adjusting screws5 Cam strip

Low load Full load

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Adjustments

Adjusting the limit switchesat the electric servomotor

Limit switchesThe limit switches are actuated by tripcams which are factory-set to standardvalues.

NoteLimit switch 1 indicates that the airdamper is CLOSED when the burner isidle; it is factory-set to scale position 0.Limit switch 5 for preventilation can beadjusted according to individual systemrequirements in compliance withapplicable regulations. The topswitching point of this limit switch mustalways be set below the switching pointfor full load.During preventilation, the air dampermust be fully open for at least 20seconds.

Normal construction

Limit switch 1Air damper closed

Limit switch 2Full load

Limit switch 3Low load

Limit switch 4Start load

Limit switch 5Preventilation

Adjusting the trip camsIf necessary, the trip cams can bereadjusted during burner adjustment.To facilitate access to the lockingscrew, the complete cam can beadjusted after releasing the set screwwith the Allen key incorporated in theservomotor.

Adjustment is made by means of ascrewdriver.

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Adjustments

Air pressure monitor

Air pressure monitorThe air pressure monitor is used tomonitor the pressure of blower burnersand of ventilation and air-conditioningequipment.The pressure monitor DL 50 A issuitable for making, breaking andswitching a cont act when the actualpressure deviates from the presetvalues. It can be used as an over-pressure, negative pressure ordifferential pressure monitor for air andnon-aggressive gases, but not for thegases described in the DVGWworksheet G 260/l.

Determining the prepurgingdifferential pressure and adjustingthe differential pressure monitor� Burner in preventing phase� Measure pressure at measuring

outlet 2� Measure vacuum at measuring point

3� Add up the measured pressures� Set the scale to 90% of the

calculated value

ApprovalsThe pressure monitor complies withDIN 3398, Part 2, and is DIN-DVGWapproved.Other approvals in major gasconsumption countries.

Control of switch functionThe switch function be tested viatesting key.By activating this key, the actualdifferential pressure is being modified(pressure monitor switches, burnergoes on fault position).key 4 testing of fan negative

pressure sidekey 1 testing of fan pressure relief

side*

* According to circumstances due to theinstallation itself or its capacity, suchtesting may not be successfull.As long as the testing of the negativepressure side results in a switch-off,the switch function is neverthelessguaranteed.

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Adjustments

Flame monitoring, UVSensor current measurement

Flame monitoring with UV detectorThis monitoring method uses the UVradiation of hot flame gases forobtaining the flame signal.The radiation detector is a UV-sensitivetube which is constantly under voltageand which consists of two electrodes;the tube fires when it is exposed to lightof the spectral range between 190...270 nm, thus transmitting a current tothe flame signal amplifier.The UV tube does not react toafterglowing chamotte in the furnace, tosunlight, daylight or heating roomillumination.The tube has a service life of about10,000 hours at ambient temperaturesof up to 50 C; higher ambienttemperatures will considerably reducethe tube life.The tube is tested automatically inconjunction with the burner control unitduring interruptions of operation andwith increased supply volt age.If the tube misfires, a lockout will beeffected immediately at the next start.Burners designed for continuousoperation or intermittent operation atstrong heat for more than 24 hours(e.g. multi-boiler cascade systems) orburners which are operated with steamboilers must be equipped with theburner control unit LGK 16... and thecorresponding self-checking flamemonitoring system (QRA 5...).For a det ailed technical description,specifications and planning information,see burner control unitsLFL 1... No. 7451 DLGK 16... No. 7785 D

Measuring the UV current with QRA5For precise measurement of UVcurrents, we recommend using the testunit KF 8832.If you use a standard measuringinstrument (microammeter) to measurethe UV current, we recommendproceeding as shown in the illustration.Integrate a capacitor C = 470 µF, 15 V(or higher electric strength) into themeasuring connections.

Measuring instrument: 100 µA/Ri = 3 k

Connect the measuring instrumentbetween the burner control unit and theUV flame detector QRA 5... (terminal22 (-), terminal 5 (+).

Ensure correct polarity!

Aligning the UV Detector QRA 5...The fixing flange can be moved alongthe feeler tube and allows precisealignment of the detector window withthe incident UV radiation.

NoteTerminal 22 must be earthed at alltimes!

Cleaning the detectorThe UV detector window must becleaned at regular intervals.Keep the window free from dust.If cleaning is unsuccessful, replace theUV tube.

Sensor currents* See also specifications of burner

control unit LFL 1.../LGK 16...** See data on device KF 8832

for sensor current measurement

Burner control unit LFL 1…UV monitoring with QRA 2...

Burner control unit LGK 16…UV monitoring with QRA 5…

Burnercontrol unit

Minimum Maximum

Monitoringtype*LFL 1…*LGK 16…

with UV70 µA**

with UV630 µA**

Recommended measuring range :

UV monitoring 0–1000 µA

1709/2005 - Art. Nr. 13 019 541A

Adjustments

Flame monitoring, ionizationSensor current measurement

Flame monitoring with ionizationArrangementThe flame is monitored by applying anAC voltage to the detector electrode,which is made of heat resistant materialand projects into the flame takingadvantage of the conductivity and therectifying effect of hot flame gases. Thecurrent that flows in the presence of aflame (ionization current) produces aflame signal, which is transmitted to theinput of the flame signal amplifier. Thelatter is designed in such a way that itresponds only to the DC component ofthe flame signal. This ensures that ashort circuit between the detectorelectrode and earth cannot simulate aflame signal(as in that case, AC would flow).A microammeter is used for measuring(use the correct measuring range).The microammeter is connectedbetween the burner control unit and theionization electrode. Ensure correctpolarity (see connection examples forburner control units LFL 1.../LGK 16...).For ionization monitoring, it is importantthat the signal is transmitted withvirtually no loss. The dectector leadmust not be installed in a multi-conductor cable.Dirt on the detector electrode holder ora defective ceramic part of theelectrode will favour the formation ofleak currents which reduce the intensityof the flame signal.

The burner (as the opposed electrode)must be properly earthed becauseotherwise the ionization current cannotflow . In many cases, earthing of theboiler alone will not be sufficient.When adjusting the burner for cleancombustion, i.e. when increasing powerfrom low load to full load, theionization current must bemonitored ; it must not fall below theminimum monitoring current.A marked drop in ionization currentindicates a lack of air or an excess ofair, which must be counteracted byappropriate measures. A constant highionization current indicates a steadyflame and clean combustion.

Sensor currents* See also specifications of burner

control unit LFL 1.../LGK 16...

Ionization monitoring

Burnercontrol unit

Minimum Maximum

Monitoringtype*LFL 1…*LGK 16…

6 µA12 µA

–100 µA

Recommended measuring range :

Ionization monitoring :0–150 µA

18 09/2005 - Art. Nr. 13 019 541A

Maintenance

Troubleshooting

If a malfunction occurs, check firstwhether all requirements for properoperation have been met.

Check whether:1. Fuel is available, gas is supplied, gaspressure is adequate, there is enoughoil in the tank, and the fuel selectorswitch is set correctly.2. The power supply works properly.3. All control and safety features, e .g.temperature controller, safety limiter,low-water cutout, electric limit switchesetc. work properly and are adjustedcorrectly.

If you find that the malfunction has notbeen caused by one of the abovementioned items, check the burnerfunctions carefully.

Situation:The burner is found out of action in thelockout mode. Reset the burner controlunit with the reset button and start theburner.

Do not press the reset key for longerthan 10 seconds.Closely watch the subsequent start-upprogram.The possible cause can be detectedquickly by means of the lockoutindicator on the burner control unit andby watching the sequence of the start-up and operating program.

Control program under faultconditions and lockout indication

LFL 1… / LGK 16…

a–b Start-up sequence

b–b’ For some time variants : Idlesteps of the sequence switchup to automatic shut downafter burner start-up(b’ = operating position of thesequence switch).

b(b’)–a Post-venting sequence aftercontrolled shut-down. In startposition a the sequence switchis deactivated automatically orinitiates another burner start-up immediately (e.g. after faultclearance)

� Duration of safety period forsingle-tube burners.

If a malfunction occurs, the fuelsupply is always interruptedimmediately.Simultaneously, the sequence switchand the lockout indicator stop. Thesymbol above the reading markindicates the type of malfunction:

� No start because the CLOSEDsignal has not been supplied toterminal 8 by the limit switch forair damper CLOSED; or becausea cont act has not been closedbetween terminals 12 and 4 or 4and 5 ; or because the cont act sof all control and safety unit s ofthe control loop are not closed(e.g. gas or air pressure monitor,temperature or pressure monitor,temperature or pressurecontroller).

� Start aborted because the OPENsignal from the limit switch for airdamper OPEN has not beensupplied to terminal 8. Check andadjust the corresponding limitswitch (see page 11).

� Fault shut down because the airpressure signal has not beenreceived at the start of the airpressure check. Any air pressurefailure after this point in time willalso produce a fault shut down!

� Fault shut down because of adefect in the flame monitoringcircuit.

� Start Aborted because theposition signal for the air damperin low-load position has not beensupplied by the limit switch toterminal 8. Check and adjust thecorresponding limit switch for lowload.

1 Fault shut down because noflame signal is present oncompletion of the 1st safety time.

Any flame signal failure occurringafter completion of the safety timewill also produce a fault shut down!

2 Fault shut down because noflame signal is present oncompletion of the 2nd safety time(for interrupted pilot burners, theflame signal of the main flame notapplicable for this burner type).

� Fault shut down because theflame signal has failed or becausean air pressure failure hasoccurred during burner operation.

� Fault shut down on completionof the control program sequencedue to inadmissible stray light(e.g. flame not extinguished,leaky fuel valves), or due to afaulty flame signal (e.g. defectiveflame monitoring circuit). Also seeflame monitoring.

If a fault shut down occurs at anyother point between start andpreignition which is not marked by asymbol, the cause is usually apremature, i .e. faulty , flame signal.

Resetting of the control unit after a faultshut down can be effected immediatelyeither externally or by pressing thereset key with the integrated lockoutindication lamp.After resetting (as well as aftereliminating a malfunction which causeda shutdown, or after a power failure),the sequence switch will always returnsto its starting position, supplyingvoltage to the terminals 7, 9, 10 and 11only, as determined by the controlprogram. Only then will the control unitinitiate another start-up sequence of theburner.

1909/2005 - Art. Nr. 13 019 541A

Removing the gas tubeFor replacement or adjustment of thebaffle and ignition arrangement, thecomplete gas tube must be removedfrom the burner pipe. Proceed asfollows:� Disconnect the power supply ; set

main switch to OFF.� Close all shut-off valves upstream

of the burner.� Remove the cover from the housing.

Maintenance

Servicing the burner

Burner installations should bechecked once a year. According toDIN 4755, 4756, to ensure thetroublefree operation, performance,safety and efficiency of theinstallation, the user should have theinstallation checked once a year by arepresentative of the manufactureror other qualified personnel.The entire installation is to be testedfor faultless performance, anddefects are to be repaired withoutdelay. It is expedient to carry out aninspection in addition.Inspection should include thefollowing items:

1. Disassemble the nozzle andcheck it. Clean the nozzle filter.

2. Check the ignition electrodes andthe ignition spark ; readjust, ifnecessary.

3. Check the gas valves fortightness and cleanness.

4. Check all electrical connections.5. Clean the UV flame detector.6. Check the pressure monitors for

proper adjustment andperformance.

7. Check the control units forperformance, adjustment andsafety times.

8. Check the burner head setting.Check the flat O-ring sealbetween the gas and burner tubefor tightness.

9. Inspect the boiler componentsand insulation and replace, ifnecessary. Check the boiler forcleanness.

10. Clean the burner inside and outside.

11. Check the combustion and makeflue gas measurements:� Adjust fuel throughput� Heating room temperature

(suction temperature)� Flue gas temperature� Furnace pressure/ pressure in

the flue gas tube� CO2/O2 content� CO measurement, soot test� Measure the UV current

12. Enter the measured values in thetest certificate.

� Release the locking screw 4.� Disconnect the UV cell 1.� Disconnect the ignition cables 6.� Pull out the hinge bolt 2.� Pull out the shaft locking pin 5 and

remove the retaining bolt 7.� Push the nozzle rod forwards in the

direction of the arrow and swivel theburner.

� Release the fixing screws 3 of thegas tube and pull off the gas tubebackwards.

Be careful with the baffle plate!Before reassembly, check the seal 8and replace it, if necessary.

20 09/2005 - Art. Nr. 13 019 541A

Adresse Service-Hotline

ELCO Austria GmbHAredstr.16-182544 Leobersdorf

0810-400010

ELCO Belgium n.v./s.a.Pontbeeklaan-531731 Zellik

02-4631902

ELCOTHERM AGSarganserstrasse 1007324 Vilters

0848 808 808

ELCO GmbHDreieichstr.1064546 Mörfelden-Walldorf

0180-3526180

ELCO France18 rue des Buchillons74106 Annemasse

0450877624

ELCO-Rendamax B.V.Amsterdamsestraatweg 271410 AB Naarden

035-6957350

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