комбинированные горелки NC12-21 BX. Инструкция по монтажу
Contents
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5. 07 2009 Art 13 022 1
6. 1 F6 M1 10 T1 V1 Y1 Y16 20 102
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10. 2 2 2 1 108 106119 F4 Y12 104 Y13 119 lt a H 24 07 2009 Art Nr 13 022 182A
11. VDE 230 50 10 07 2009 Art Nr 13 022 182A A
12. 10 CO CO 50
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14. 10 FUEL e 0 4
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16. 7 Y 25 103B 113 119 07 2009 Art 13 022 182A pL 23
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18. 10 Y1 6 R1 8 4 O oa 36 07 2009 Art Nr 13 022 182A
19. 8 3 31 amp E t dami 10 1
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21. 07 2009 Art 13 022 182A 41 42 07 2009 Art Nr 13 022 182A 07 2009 Art Nr 13 022 182A 43 CUENOD 18 rue des Buchillons F 74100 Annemasse Made EU EC Non contractual document 44 07 2009 Art Nr 13 022 182A
22. Y 103 33
23. Y 103 5 R1 8 0 4
24. 40 07 2009 Art 13 022 182A A 1 2
25. MB DLE407 F4 Y12 Y13 2 8 9 104 106 119 119 MB DLE 407
26. 5 180 60 1
27. 2 3 4
28. 1 22 267 676 60335 2 G1 SSIGE EKAS 1942 2
29. 24 24 8
30. 12002182 70
31. 07 2009 Art 13 022 182A 37 2 i
32. NC12 NC21 117 303 DIN 4794 DIN 30697 CUENOD
33. 119 pF pBr gana 103
34. 14 F4 F6 13 12 1 104 106 108 119 119 1
35. 3 W 16 07 2009 Art Nr 13 022 182A pL
36. J1 7 R1 8 6 1 8 12 056 459 07 2009 Art 13 022 182A 3 4
37. 0085 AP3156 13 360 15 60 230 50 46 1 54 3 4 4 5 07 2009 Art 13 022 182A 5
38. DIN 4755 lt 2 lt 0 4 K
39. V 07 2009 Art Nr 13 022 182A e e
40. 4 5 e Y Y
41. CO COs Y
42. DVGW TVR TRGI 50 150 2 0 33 200 2 KBT 6 0 07 2009 Art 13 022 182A AQF030 18 rue des B chillons Ville la Grand F 74106 ANNEMASSE Cedex co
43. 2 3 10 GAZ 50 4 50 34 54 3 3
44. NC12 B117 NC21 B117 50165 60335 60555 2 60555 3 55014 267 676 08 01 2004 89 396 92 42 89 336 CEE 2006 95 1 2009 SPONZA
45. 24 24 8 3
46. 36 37 38 39 40 41 1 12 21 117 1 1 1 ONORM C1109 BE NBN 752 716 NBN 590 SN 181160 2 EL DE DIN 51603 1 676 267
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48. 7 3 5 8 9 1 4 07 2009 Art 13 022 182A 0 27 230 28 07 2009 Art 13 022 182A 21 1 1 1 14 5 2 15 3 16 4 4
49. 6 10 Y1 RON 1 1 5 9 2 230 L1 1 68 ways
50. W 2 3 W 16 07 2009 Art Nr 13 022 182A
51. 70 15 60
52. 60 35 103 B pF Gph Y MM Tun 30 0 5 078 Danfoss 45 7s 63 e 165 Danfoss 4555 Danfoss 45 S B117 0 55 215 DanfossasB m 15 Danfoss 45 S B117 16 135 26 90 375 Danfoss 45 8 11 0 5 1 10 11 86
53. TCG 1
54. 3 X 2 1 07 2009 Art 13 022 182A cpl 25 MB DLE 407 AS47D Y12 Y13
55. 1 32
56. 2 Ha 1 1 6 5 5 5 60 6
57. 16 17 Servicing Maintenance 18 19 Troubleshooting 00 cee eee eee 20 21 Important information NC12 NC21 B117 burners are designed for the combustion of natural gas and extra light domestic fuel oil in accordance with the following national standards AT ONORM C1109 standard and low sulphur BE NBN T52 716 standard and NBN EN590 low sulphur CH SN 181160 2 low sulphur green fuel oil and EL fuel oil DE DIN 51603 1 standard and low sulphur The design and function of the burners meet standards EN 676 and EN267 Installation start up and maintenance must only be carried out by authorised specialists and all applicable guidelines and regulations must be complied with Burner description NC12 NC21 B117 burners are single stage fully automatic monoblock type burners They are suitable for use with all heat generators complying with standard EN 303 or for use by hot air generators complying with DIN 4794 or DIN 30697 within their respective performance range Any other type of application requires the approval of CUENOD 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 packaging co
58. ee 23 24 25 MBDLE 26 TCG 1 27 28 29 30 31 le eee Rede 32 33 34 35
59. e B
60. 1 10 pBr 4 9 07 2009 Art Nr 13 022 182A e 6 6
61. 20 17 5 18 6 8 19 21 7 20 8 1 0 21 1 9 22 10 2 4 23 11 24 12 25 13 3 150 180 226 2 2
62. 3 4 e B
63. 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 the control and safety unit must lock at the end of the safety time 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 Gas pressure switch setting set the switch off pressure remove the cover from the gas pressure switch Install a gas pressure pa measuring instrument Start the burner e Lower the pressure upstream of the gas train by gradually closing the manual valve until gas pressure pa downstream of the train drops to 70 of its initial value the stability of the flame reduces visibly the CO level rises or the flame signal weakens significantly e Turn the dial clockwise until the gas pressure switch shuts down the burner e Continue turning the dial clockwise to set the gas pressure switch to 10 above the shutdown value determined above Setting the air pressure switch To adjust the switch off pressure e Commission the burner e Increase the shut off point by turning the adjustment scale clockwise until the burner switches off e Set the shut off point to approximately 15
64. plugs on the burner black to black grey to grey 11 Assembly Choice of fuel Checks before start up 509 789 0 ee y a Choice of fuel The choice of fuel is made manually using switch S10 to be fitted on the burner side To do this Unscrew 1 e Remove the gasket the tooth lockwasher and the knurled ring e Pass the switch lever through the support window e Refit only cap 1 to secure the switch Moving the switch during operation causes lockout of the control unit During operation the two fuel circuits must be left open when the burner is operating Checks before commissioning The following must be checked before initial commissioning Correct assembly of the burner accordance with the present instructions e Correct pre adjustment of the burner in accordance with the values in the adjustment table Setting combustion components The heat generator must be fitted and 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 12 with gas However when powering up or during operation if no fuel oil is available it is essential to remove the pump coupling which must be stored in a visible place so it can be repositioned when liquid fuel is to be used Choice of fuel When both fuels are available or failing that app
65. to clean the filter it is necessary to loosen the screws and remove the cover first Check the pump cover gasket and replace it if necessary Commissioning AFuel oil operation Setting the burner Function check Starting the burner Before starting the burner draw fuel oil in using a hand pump until the filter is completely filled e Check that fuel selection switch 10 is in the FUEL OIL position Then start the burner by switching on the boiler regulator Open the bleed screw on the fuel oil filter to allow the fuel oil line to bleed fully during the pre ventilation phase The vacuum pressure must not fall below 0 4 bar Close the bleed screw when the filter is completely filled with fuel oil and fuel oil is flowing out without bubbles Burner output adjustment Use the pressure regulator to adjust the fuel oil pressure in accordance with the burner output desired Monitor the combustion values continuously as you do so CO COs soot test Adjust the airflow gradually if necessary Optimising combustion values Optimise the combustion values by setting the position of the turbulator dimension Y Doing this can have an effect on starting characteristics pulsation and combustion values Any reduction in dimension Y increases the value However starting characteristics become harsher Compensate for the change in airflow if necessary by adjusting the air flap position Precautions O
66. 022 182A 10 13 16 18 19 20 102 Control unit Air pressure switch Fan motor Fuel change switch Igniter Flame detection cell Fuel oil solenoid valve Fuel oil safety solenoid valve Burner retaining flange Housing volute casing downwards Plate hanging device Flame tube 7 pin plug Adjusting screw for dimension Y Gas valve connecting flange Cover Release knob for control unit Cover retaining screw Tx25 Fuel oil pump 103B Air flap manual control 113 119 Air intake box Air pressure tap pL Operation Gas 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 solenoid valve and the safety solenoid valve open burner start up Monitoring The flame is monitored by a cell The flame current must be above 8 pA Safety function 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
67. 82A 1 90 2
68. 9 Art Nr 13 022 182A During the regulator shutdown The control thermostat interrupts the heat request The fuel oil solenoid valves close The flame goes out The blower motor stops The burner is ready for operation Basic circuit diagram Fuel oil burner pump complete Fuel oil pressure regulator Fuel oil burner pump Solenoid valve NO Nozzle line Flame tube Turbulator Safety solenoid valve Air flap Blower Burner motor OONOORWN Operation MB DLE 407 gas train AS47D fuel oil pump The MB DLE 407 compact gas train with integrated gas pressure regulator is suitable for use with single stage forced draught gas burners The compact gas train bears the CE 0085 AP3156 approval marking Operation When the magnetic coils are switched on valves Y12 and Y13 open The valve seats are protected against impurities by a fine screen fitted upstream The integrated pressure regulator regulates the desired outlet pressure The adjustment values required for the gas pressure switch the gas pressure regulator the starting gas pressure MB DLE407 may be adjusted using the screw The inlet and outlet pressure can be measured at the pressure taps F4 Pressure switch adjusting screw under the cover Y12 Safety valve Y13 Main valve 2 Valve electrical connections 8 Inlet flange 9 Pressure switch electrical connection 104 C Gas pressure regulator ad
69. F 74106 ANNEMASSE Cedex declare under our sole responsibility that the products NC12 B117 NC21 B117 comply with the following standards EN 50165 EN 60335 EN 60555 2 EN 60555 3 EN 55014 EN 267 EN 676 Belgian royal decree dated 08 01 2004 In accordance with the provisions of the following directives 89 396 CEE Gas devices directive 89 336 CEE EMC directive 2006 95 Low voltage directive 92 42 CEE Efficiency directive these products bear the CE marking Annemasse 1 March 2009 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 Overview Burner description 07 2009 Art Nr 13
70. Fuel oil 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 fuel oil solenoid valves open burner start up Monitoring The flame is monitored by a cell The flame current must be above 8 pA Safety function 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 fuel oil valves close If the flame is lost during operation the fuel oil supply is cut within a second A new start up sequence is activated If the burner starts the operating cycle runs Otherwise a lockout occurs If there is an air failure during pre ventilation or operation a lockout occurs If there is a fuel oil failure the burner either will not start or will stop A waiting period of 2 minutes will follow A new start up sequence will be activated If there is still no fuel oil a new waiting period of 2 minutes will follow The waiting period can only be stopped by switching the burner off Waiting periods 3 x 2 min then 1 hour 07 200
71. NC12 B117 NC21 B117 rad Operating instructions For specialist installation engineers Dual fuel burners 2 13 022 181 13 022 204 07 2009 Art Nr 13 022 182A Overview Contents Overview Contents 0 cece eee eee 2 Important information 2 Burner 3 Operation Gas or fuel oil operation safety function 4 5 MBDLE gas train fuel oil 6 TCG 1 control and safety 7 8 Installation Installing the burner Inspection glass flue 9 Setting checking the combustion components 10 Fuel oil and gas connections electrical connection 11 Choice of fuel Checks before commissioning 12 Commissioning Gas operation Adjustment data Air regulation Program sequence 13 14 Setting the gas pressure switch air pressure switch Function check eee e eee eee eee 15 Fuel oil operation Adjustment data air regulation Program sequence
72. The thermostat no longer starts the burner No heat requested by thermostats Defective control unit Check replace the thermostat Replace the control unit The burner starts up briefly when the power supply is switched on and then stops Control unit has been locked intentionally Unlock the unit The burner starts then stops after pre ventilation Unauthorised flame is detected during the pre ventilation pre ignition period Check for the ignition spark adjust the electrodes replace Check replace the fuel oil solenoid valve The burner starts and stops after the solenoid valves have opened No flame at the end of the safety time Flame failure during operation The flame goes out during operation Check fuel oil level in tank Top tank up as required Open the valves Check the fuel oil pressure and the operation of the pump coupling filter and solenoid valve Check the ignition circuit the electrodes and their settings Clean the electrodes Clean replace the flame detection cell Replace the following items as required ignition electrodes ignition cables igniter nozzle pump solenoid valve control unit 07 2009 Art Nr 13 022 182A 21 22 ele bayer Shaw el pb aa ae 22
73. ad e Fit the grommets onto the cover e Fasten the cover 3 screws W e Refit hose solenoid valve assembly Y16 to the nozzle line e Tighten the ignition cables and connect them to the igniter e Connect the cables from the cell the safety valve and flexible hose pL to the cover e Check it is airtight 07 2009 Art Nr 13 022 182A vacuum pressure on the burner pump Draw up a measurement report General checks Emergency stop button function check Visual inspection of fuel oil lines in the boiler room Gas filter replacement The filter element of the multiblock must be checked at least once a year and replaced if clogged Loosen the screws of the filter cap on the multiblock Remove the filter element and clean its housing Do not use any pressurised cleaning products Replace the filter element with a new element e Screw the cover back into place Reopen the manual shut off valve e Check it is airtight Servicing Maintenance Replacing the flame tube It is necessary to remove the burner for this work Loosen the clamping screw the connecting flange Turn the burner out of the bayonet socket lift it slightly and pull it out of the connecting flange e Place the burner on the floor Loosen the 4 screws X e Pull the flame tube out towards the front Fit and secure the flame tube A A flame tube may be hot Cleanin
74. below the triggering pressure that is now set 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 lockout occurs 07 2009 Art Nr 13 022 182A The gas pressure switch adjustment value must be higher than the air pressure but lower than the gas pressure downstream of the gas valve Checking the switch off pressure Open the manual shut off valve Start the burner e Close the manual shut off valve The gas failure procedure should start without the burner control unit locking 15 Commissioning AFuel oil operation Adjustment data Air regulation Burner type NC12 B117 Dimension Air flap pF Nozzle Nozzle Pump combustion Y position 103 B type pressure chamber mm in Gph bar pressure daPa 5 05 Danfoss 45 40 nes _ Danfossass _11_ 7 Danfoss 45 S 0 16 ss 215 Danfossa5B 11 15 es Danfoss 45 S B117 16 135 375 Danfoss 45 B At delivery the pump is set at 11bar 0 5 Highlighted equipment on delivery 1kg fuel oil at 10 C 11 86kWh Air regulation Combustion air is regulated at two points on the pressure side by the gap between the turbulator and the burner tube on the vacuum side by th
75. bserve the minimum required exhaust gas temperature specified by the boiler manufacturer and the requirements demanded of exhaust gas ducts for avoiding condensation 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 flame detector unlit the control and safety unit must switch to malfunction at the end of the safety time Start with flame detector lit the control and safety unit must switch to malfunction after 10 seconds of pre ventilation A Risk of air blast Continuously check CO CO and soot emissions when adjusting Optimise combustion values if CO is present The CO level must not exceed 50 ppm Normal start flame detector goes out when burner in operation the control and safety unit must switch to malfunction after the restart and end of the safety time 07 2009 Art Nr 13 022 182A 17 Servicing Maintenance Burner and boiler servicing must only be carried out by a professionally qualified heating engineer The system operator is advised to take out a maintenance contract to guarantee regular servicing e Switch off the power supply before all maintenance and cleaning work Use original spare parts Work recommended as part of annual burner maintenance Burner test run input measurement in th
76. creases or reduces pressure by 1 mbar respectively At commissioning Turn the screw through at least 10 turns clockwise e Then fine tune the adjustment more less pressure e Check the gas pressure either at the multiblock pBr M4 or the gas collector measurement nipple 9 07 2009 Art Nr 13 022 182A Full load flow adjustment Loosen the locking screw until rotary knob 6 becomes adjustable Do not loosen the sealed screw on the opposite side Reduce the main flow by turning knob 6 clockwise or increase it by turning it anticlockwise The total path to adjust from minimum to maximum flow is approximately 4 5 turns e Retighten the locking screw after the adjustment has been made Optimising combustion values Optimum combustion values can be achieved by adjusting the position of the turbulator dimension Y if necessary Doing this can have an effect on starting characteristics pulsation and combustion values Any reduction in scale value Y increases the CO value However starting characteristics become harsher Compensate for the change in airflow if necessary by adjusting the air flap position Precautions To avoid condensation forming observe the minimum required exhaust gas temperature specified by the boiler manufacturer and comply with the exhaust gas duct requirements Commissioning Setting the gas pressure switch air pressure switch Function check
77. e air flap that can be adjusted manually using a knob 1 Suction intake connection 2 Return connection 3 Pressure connection 4 Fuel oil pressure gauge connection 5 Vacuum pressure gauge connection 6 Fuel oil pressure regulation 10 Solenoid valve electrical connection Y1 Fuel oil solenoid valve 16 Fuel oil pressure regulation The fuel oil pressure and therefore burner output is adjusted using fuel oil pressure regulator 6 in the pump Turn to the right to increase the pressure left to reduce the pressure For the checks a pressure gauge witha R1 8 thread must be connected to pressure gauge connector 4 Checking the vacuum pressure The vacuum meter for checking the vacuum pressure must be connected to connector 5 R1 8 Maximum authorised vacuum 0 4 bar At higher 07 2009 Art Nr 13 022 182A The regulation of air in the combustion head influences not only the airflow but also the mixing zone and the air pressure in the burner tube Turning screw A clockwise more air anticlockwise less air Adjust dimension Y in accordance with the settings table Air regulation by air flap Air is regulated on the vacuum side by an air flap This is controlled by knob 103B vacuum pressures the fuel oil gasifies which causes scraping noises in the pump and ultimately leads to pump damage Cleaning the pump filter The filter is located under the pump cover To be able
78. e boiler room Clean the combustion components and replace defective parts if necessary Clean the blower fan wheel and check the pump coupling Check the fuel oil nozzle replace if necessary Check the fuel oil filter replace if necessary Visual inspection of the fuel oil hoses replace if necessary Clean the gas filter replace it if necessary Visual inspection of the burner s electrical components eliminate malfunctions if necessary Check burner start characteristics Leakage test Burner safety devices function check air pressure gas pressure switches Flame detector and control unit function check Start burner with gas operation Check the gas flow Correct the adjustment values if necessary Start burner with fuel oil operation Check the fuel oil pressure and Checking and setting combustion head Disconnect the ignition cables on the igniter e Disconnect the cables from safety valve Y16 and from cell V1 Disconnect flexible hose pL e Remove hose solenoid valve assembly Y16 from the nozzle line connection M Remove the 3 screws W Remove the cover Loosen lock nut C on the gas bend Tighten spherical head screw E anticlockwise to remove the head e Check the position of the ignition electrodes using the diagram e During assembly check that O ring J2 is fitted and correctly positioned Unscrew spherical head screw clockwise to secure the he
79. est when the power is Heat request checking rest status of the air pressure switch Motor powered air pressure check Oro Pre ventilation Pre ignition activation of unau thorised flame monitoring Flame formation safety time Post ignition time Operation 07 2009 Art Nr 13 022 182A 9 Burner shutdown 10 Regulator shutdown Operation Control unit Flame detection Gas pressure switch Air pressure switch 230V power supply aad 11 20 10 24 Terminal Igniter Fan motor Malfunction signal Gas valve Connector J 4 21 Terminal Terminal Description Connector Terminal Description Connector no 1 Flame monitoring signal 1 1 14 Igniter phase 5 2 Neutral 15 Neutral 3 Live 16 Burner motor phase 4 4 Remote unlocking signal 20 17 Earth 5 Live 18 Neutral 6 Live 8 19 Neutral 21 7 Gas pressure switch signal 20 Malfunction display phase 8 Air pressure switch signal 1 0 21 Safety valve phase 1 9 Live 22 Neutral 10 Live 2 4 23 Earth 11 Earth 24 Main gas valve phase 12 Neutral 25 Earth 13 Earth 07 2009 Art Nr 13 022 182A Assembly Burner assembly Burner assembly Burner flange 3 is equipped with elongated slots and can be used with a drilling of 150 180 mm These dimensions comply with EN 226 The insertion depth of the combustion comp
80. g the fan wheel Remove the plate and attach it in the maintenance position see illustration Remove and clean the fan wheel If necessary replace and refit it Cleaning the air box Remove fastening screws V from the air box e Remove the air box clean it and refit it in reverse order e Check that the air flap and the servomotor are correctly positioned Cleaning the cover Do not use abrasive products or products containing chlorine e Clean the cover with water and a suitable cleaning product e Refit the cover 07 2009 Art Nr 13 022 182A Cleaning the pump filter The filter is located in the pump housing It must be cleaned with every maintenance service To do this e Close the fuel oil shut off valve e Place a container under the pump to catch the fuel oil e Remove the screws and cover Remove clean or replace the filter Refit the filter close the cover again and use a new gasket e Tighten securely Reopen the fuel oil shut off valve e Check pressure and tightness A Important After any operation check the combustion performance under real operating conditions doors shut cover fitted etc Record the results in the relevant documents Checking the exhaust gas temperature e Check the exhaust gas temperature at regular intervals Clean the boiler if the exhaust gas temperature is more than 30 C above the value measured at the time of commis
81. generator and test the program sequence The blower starts after a delay depending on the control and safety unit setting Incremental advance setting Flow setting 0 switch Coil Access to the filter Connecting flanges Pressure regulator setting S 50 from 4 to 50 mbar Painted Locking Screw screw 14 Pre ventilation time 54 s Pre ignition time 3 s Magnetic valves open Safety time 3 s Safety shutdown at the end of the safety time with locking of the control and safety unit malfunction lamp lit e Cut the power to the burner by disconnecting the electrical connection and remove the wire jumper for the gas pressure switch if necessary e Reconnect the electrical connection e Unlock the control unit e Start the burner Ignition throughput setting incremental advance setting Unscrew protective cap 5 and turn it through 180 to use it as an adjustment tool Turn the adjustment spindle to the minimum position then turn it back towards the plus symbol to the centre position approximately 3 half turns The initial gas flow is now set to around half open To achieve smooth starting the initial gas flow should be adapted to the boiler pressure conditions Pressure regulator setting The adjusting screw has a path of 60 turns for adjusting the output pressure Three turns clockwise or anticlockwise in
82. justing screw 106 Gas filter 119 Inlet gas pressure measurement nipple 119pBr Outlet gas pressure measurement nipple Technical data Inlet pressure 13 360mbar Ambient temperature 15 to 60 C Voltage 230V 50Hz Power consumption 46W Protection level IP54 Gas connection Rp 3 4 The fuel oil pump used is a self priming 1 Suction intake connection gear pump which must be connectedas 2 Return connection a two line pump via a bleed filter There 3 Pressure connection is an intake filter and fuel oil pressure 4 Pressure gauge connector fuel oil regulator integrated in the pump Before atomisation pressure commissioning install pressure gauges 5 Vacuum meter connector suction for the pressure 4 and vacuum 5 intake measurements 6 Fuel oil pressure regulation 10 Solenoid valve electrical connection Y1 Fuel oil solenoid valve 07 2009 Art Nr 13 022 182A Operation TCG 1xx control unit Pressing and leads to holding the R for 1 second the control unit being unlocked 5 seconds the control unit being locked 9 seconds statistics in the control unit to be erased orange indicator light lights up when the valve is opened 2 green indicator light lights up during a heat request Symbol Description Symbol Description 230 V Permanent power supply L1 Valves open pply n gt p Boiler heat req
83. ly the following principle system must be filled with sufficient 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 correctly and be 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 Fuel storage tanks must be full The fuel supply lines must be 07 2009 Art Nr 13 022 182A Adjust in the following order 1 Domestic liquid fuel oil to 90 new boiler rated output or failing that adjust the percentage according to the circumstances 2 Gaseous fuel The nominal gas throughput is subject to the nominal air flow defined in the fuel oil setting This procedure corresponds to optimum use of the boiler burner unit assembled correctly checked for leaks and bled Astandard 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 caused by outside air Commissioning AGas operation Adjustment data Air regulation Head gas pF combustion B pressure 119 chamber pBr pressure daPa daPa Burner Dimension Air flap power Y position 103 kW mm i Burner type The adj
84. mesh size 70 um to guarantee a connection with no kinks or strain Make sure that the supply and return lines are correctly connected A Before commissioning draw fuel oil in using a hand pump and check the fuel oil lines for leaks 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 awarded by the supplier and should carry out the corresponding sealing tests and purge the system of air All electrical installation and connection work must only be carried out by a suitably qualified electrician All VDE regulations and power supply company regulations and requirements must be observed Electrical connection e Check to ensure that the power supply is as specified 230V 50 Hz single phase with neutral and earth Boiler fuse 10 A 07 2009 Art Nr 13 022 182A Electrical connection The burner and heat generator boiler are connected by a 7 pin connector It must be possible to disconnect the burner from the mains using an omnipolar shutdown device complying with the standards in force The diameter of the cables connected to this must between 8 3 and mm Connecting the gas train Connect the gas train to the
85. ntains the following 1 Gas connection flange 1 Compact gas train with gas filter 1 Burner flange with insulating gasket 1 Bag containing mounting parts 1 Bag containing technical documentation The following standards should be observed in order to ensure safe environmentally sound and energy efficient operation EN 267 Fuel oil burners EN 676 Forced draught gas burners EN 60335 2 Safety of electrical appliances for domestic use 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 flexible hose connection is provided for the air supply there must be a supply air inlet measuring DE up to 50 kW 150 cm for every additional kW 2 0 CH up to 33 kW 200 cm for every additional kW 6 0 cm Variations may arise as a result of local regulations 07 2009 Art Nr 13 022 182A Declaration of conformity for dual fuel burners We certified company no AQF030 18 rue des B chillons Ville la Grand
86. onents can be adjusted to the geometry of the combustion chamber by sliding pipe bracket 2 on the burner s flame tube The installed depth remains the same during fitting and removal Pipe bracket 2 secures the burner to the connecting flange and therefore to the boiler This completely seals off the combustion chamber Gas train assembly e Check that O ring gasket J1 is present and correctly fitted to the flange Fit the gas train e Route the connection cable for the gas train through clamp 7 and connect it to the gas train Inspection glass cooling The burner housing can be equipped with an R1 8 connection to support a line for cooling the inspection glass of the boiler To do this drill through boss 6 and cut an 1 8 thread Use accessories article no 12 056 459 for the threaded union and connection hose 07 2009 Art Nr 13 022 182A Installation Secure connecting flange to the boiler using screws 4 e Fit pipe bracket 2 to the burner pipe and secure using screw 1 Tighten screw 1 to maximum torque of 6 Nm Turn the burner slightly guide it into the flange and secure using screw 5 Removal Unscrew screw 5 Turn the burner out of the bayonet socket and pull it out of the flange Burner tube installation depth and en brickwork surround Unless otherwise specified by the boiler manufacturer heat generators without a cooled front wall require brickwork
87. onnect the cables from the cell the safety valve and flexible hose pL to the cover e Check it is airtight 10 07 2009 Art Nr 13 022 182A Assembly Fuel oil and gas connections Electrical connection Fuel oil connection To ensure the operating safety of the system the fuel oil supply must be installed carefully in accordance with DIN 4755 and in compliance with local regulations The burner is fitted with a self priming gear pump which must be connected as a two line pump via a fuel oil filter Important Max supply pressure at pump lt 2 bar e Maximum intake vacuum at the pump lt 0 4 bar 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 input pressure does not drop below the specified level A gas ball valve must be fitted upstream of the gas train customer side In Germany a thermally triggered shut off valve customer side must be fitted as specified by the draft CUENOD brochure Art no 12002182 must be observed when configuring and dimensioning systems with a suction intake device for extra light fuel oil e Connect the supplied fuel oil hoses to the fuel oil pump and pass them through the opening in the housing e Position the fuel oil bleed filter recommended
88. or insulation 5 as 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 Gap 6 must be filled with an elastic non flammable insulation material On boilers with reverse firing minimum flame tube insertion depth A should be observed as per the boiler manufacturer s instructions Exhaust gas evacuation system To avoid unfavourable noise emissions right angled connectors should not be used to connect the boiler to the flue Assembly Setting checking the combustion components Setting and checking the combustion components e Disconnect the ignition cables on the igniter Disconnect the cables from safety valve Y16 and from cell V1 Disconnect flexible hose pL e Remove hose solenoid valve assembly Y16 from the nozzle line connection M Remove the 3 screws W Remove the cover Loosen lock nut C on the gas bend Tighten spherical head screw E anticlockwise to remove the head e Check the position of the ignition electrodes using the diagram e During assembly check that O ring J2 is fitted and correctly positioned Unscrew spherical head screw clockwise to secure the head e Fit the grommets onto the cover e Fasten the cover 3 screws W e Refit hose solenoid valve assembly Y16 to the nozzle line Tighten the ignition cables and connect them to the igniter C
89. riefly when switched on then switches off and the red indicator light comes on Burner does not start Control unit has been locked intentionally Air pressure switch not in rest position Incorrect adjustment Contact welded Unlock the unit Readjust the pressure switch Replace the pressure switch Burner does not start Gas pressure normal Insufficient gas pressure Gas pressure switch wrongly set or defective Check gas lines Clean filter Check the gas pressure switch or replace the gas train Burner blower starts up Burner does not start Air pressure switch Contact does not close Check the pressure transmitter foreign bodies and wiring Burner blower starts up Burner does not start Flaring during pre ventilation or pre ignition Check the valve Check flame monitoring The burner starts the ignition switches on then failure No flame at the end of the safety time Gas throughput set incorrectly Malfunction in flame monitoring system No ignition sparks Electrode s short circuited Ignition cable s damaged or defective Igniter defective Control and safety unit Solenoid valves do not open Valves jamming Adjust the gas flow stage Check the condition of the cell Check the condition of the flame detection circuit connections cable Adjust clean or replace the electrodes Connect or replace the cable s Replace the igniter Replace
90. sequence is activated If the burner starts the operating cycle runs 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 will not start or will stop A waiting period of 2 minutes will follow A new start up sequence will be activated If there is still no gas pressure a new waiting period of 2 minutes will follow The waiting period can only be stopped by switching the burner off Waiting periods 3 x 2 min then 1 hour 1 108 106119 F4 Y12 104 Y13 119 ER Gas train 119 1 F6 07 2009 Art Nr 13 022 182A During the regulator shutdown The control thermostat interrupts the heat request The gas valves close The flame goes out The blower motor continues to run for 14 seconds as standard The blower motor stops The burner is ready for operation Basic circuit diagram F4 Gas failure protection F6 Air failure protection Y13 Main solenoid valve Y12 Safety solenoid valve 1 Thermally triggered safety shut off valve customer side 104 Gas pressure regulator 106 Filter 108 90 manual shut off valve customer side 119 Gas outlet pressure measuring point 119 1Air pressure measuring point Note In Germany the draft combustion ordinance requires that gas fired installations be equipped with a thermally triggered shut off valve Operation
91. sioning Use an exhaust gas temperature gauge to make the check easier 19 Troubleshooting Gas operation A Malfunction diagnosis and repair In the event of a malfunction first check that the prerequisites for correct operation are fulfilled Is there any current Is there gas pressure Is the gas shut off valve open Are all control and safety devices such as the boiler thermostat low water detector limit switches etc correctly set PON Ss Observation If the malfunction is still present refer to the table below Important safety components must not be repaired these components must be replaced by parts with the same part number Cause Only use original spare parts Switch off the power supply before carrying out maintenance or cleaning A Note After any work on the system Under normal operating conditions doors closed cover fitted etc check combustion and check the individual lines for leaks Record the results in the relevant documents Corrective action Burner does not start after thermostatic closure No malfunction indicated on the control and safety unit Drop in supply voltage or power failure Control unit malfunction Check the cause of the drop in voltage or the power failure Replace the control unit No heat requested Thermostats defective or incorrectly adjusted Adjust the thermostats replace if necessary The burner starts b
92. the control unit Check the cabling between the control unit and external components Replace the gas train Replace the valves burner switches off during operation Air pressure switch contact opens during start up or during operation Flame failure during operation Adjust or replace the pressure switch Check the flame detection cell circuit Check or replace the control and safety unit 20 07 2009 Art Nr 13 022 182A Troubleshooting Fuel oil operation A Malfunction diagnosis and repair In the event of a malfunction first check that the prerequisites for correct operation are fulfilled 1 Is there any current Is there fuel oil in the tank Are all shut off valves open Are all control and safety devices such as the boiler thermostat low water detector limit switches etc PON If the malfunction is still present refer to the table below Important safety components must not be repaired these components must be replaced by parts with the same part number Only use original spare parts Switch off the power supply before carrying out maintenance or cleaning A Note After any work on the system Under normal operating conditions doors closed cover fitted etc check combustion and check the correctly set individual lines for leaks e Record the results in the relevant documents Observation Cause Corrective action
93. uest amp 5 Flame detection on Electronic igniter 5 Unauthorised flame detection Burner motor Operating hours counter The TCG 1xx control and safety unit controls and monitors the forced draught burner The microprocessor controlled program sequence ensures highly stable periods regardless of fluctuations in the power supply voltage or the ambient temperature The control and safety unit is designed to cope with brownouts This system protects the installation even during major voltage drops Whenever the supply voltage drops below its rated minimum level 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 Locking and unlocking The control unit can be locked switched to malfunction mode by pressing the R unlocking button provided the unit is connected to the mains power supply If the button is pressed during normal operation or start up the unit enters malfunction mode If the button is pressed in malfunction mode following a safety shutdown the control unit is unlocked A 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 230V Li 5s lt 1 lt 1805 on Or No voltage No heat requ
94. ustment data above are Basic adjustment values The factory adjustment data is shown in bold These adjustment en values are normally suitable for commissioning the burner Always check the adjustment values on a case by case basis Individual system conditions may require certain corrections The regulation of air in the combustion head influences not only the airflow but also the mixing zone and the air pressure in the burner tube Turning screw A clockwise more air anticlockwise less air Adjust dimension Y in accordance with the settings table Air regulation Combustion air is regulated at two points on the pressure side by the gap between the turbulator and the burner tube on the vacuum side by the air flap that can be adjusted manually using a knob Air regulation by air flap Air is regulated on the vacuum side by an air flap This is controlled by knob 103B 07 2009 Art Nr 13 022 182A 13 Commissioning AGas operation Program sequence test Setting the burner Testing the burner program sequence before initial gas release e Close the manual valve located upstream of the gas train e Bridge the gas pressure switch terminals 2 and 3 if necessary if there is insufficient gas pressure upstream of the gas train Disconnect the burner from the power supply first Check that fuel selection switch 10 is in the GAS position Start the burner by switching on the heat
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