elco EKEVO 6 G-E - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The Elco EKEVO 6/N6 to EKEVO 9/N9 series of gas burners are electronically modulating, fully automatic monoblock burners designed for burning natural gas (with EKEVO 6-7 models offering an option for propane gas). These burners are engineered to comply with EN676 standards, ensuring highly efficient and low-polluting combustion through their specialized burner head design. They are intended for use in systems that meet EN 676 requirements, with specific burner components needed for heat generators complying with the Pressure Equipment Directive 97/23/EC.

Function Description:

The EKEVO burners operate with an electronic compound control system that precisely adjusts fuel and air volumes to maintain an optimal fuel-air ratio across the entire control range. This system allows for infinitely variable control, increasing or decreasing output to match the current heat requirement. The air flap and gas flap are each controlled by a servomotor, with factory-configured air curves ensuring precise positioning relative to burner output. This precision is crucial for consistently low-emission combustion.

The burner's operational sequence includes a gas start-up mode where the burner control circuit initiates the program flow. An automatic test for gas valve leaktightness is performed before each start. The air flap, initially closed, opens to its full-load position for furnace ventilation. After a specified preventilation time, the air flap and gas control flap move to the partial load position, and the ignition transformer is activated. Following pre-ignition, main gas valves open, and the gas-air mixture is ignited by a high-voltage spark. A stable flame is monitored by a UV photocell during the safety time, after which the burner operates at minimum power. Once flame formation is established, the burner transitions to its operating mode, where the output controller automatically adjusts between partial-load and full-load positions based on heat demand.

Important Technical Specifications:

Gas Types: Natural gas (families 1, 2, 3 according to DVGW Worksheet G 260/1); EKEVO 6-7 models also support propane gas.
Emissions: Certified to emission class 2 for G-E models and class 3 for G-EU2/G-EU2N/G-EU3/G-EF3 models (natural gas mode only). Emission rates may vary depending on combustion chamber geometry, load, and firing system.
Electrical Connection: AC 220-240 V, 50 Hz.
Protection Level: IP 54.
Ambient Temperature: -10 °C to +60 °C.
Media Temperature: -15 °C to +60 °C (liquid gas 0 °C to +60 °C).
Gas Train Components: Siemens VGD double valves or Dungs MBC double gas valves for supply, shut-off, filtration, pressure regulation, and monitoring. Max inlet pressure for VGD is 500 mbar, for MBC300-1200 is 360 mbar, and for MBC1900-7000 is 500 mbar.
Servomotors: STE4.5 (for BT320/BT330 controllers), Lamtec 6/16 Nm servomotors.
Flame Sensors: FFS 08 (IR), FFS 08 UV-1 (UV), QRA-2 KPL (UV), KLC J8-508-3 (IR), and ionization electrodes for gas burners.
Burner Controller: BT 320 (intermittent operation) or BT 330 (continuous operation) from Lamtec.
Output Range: The specific output ranges for various models are detailed in the manufacturer's declaration, ranging from 2300 kW to 16000 kW depending on the model and fuel type.

Usage Features:

Electronic Compound Control: Provides precise fuel-air ratio adjustment for optimal efficiency and low emissions.
Speed Control (Optional): Allows reduction of blower speed during partial load operation to conserve electrical energy and reduce noise emissions.
O2/CO Control (Optional): Enhances system efficiency by measuring residual oxygen or CO content in exhaust gases, using a zirconium oxide sensor. This allows for compensation of ambient condition variations and reduction of air surplus.
Safety Functions: Includes automatic leaktightness tests for gas valves, monitoring of flame presence, air flow, and pressure. In case of faults, the burner enters a lockout state, indicated by a fault signal lamp.
Installation Flexibility: The air box can be rotated in 45° increments up to 180° anticlockwise to accommodate different air duct connections.

Maintenance Features:

Regular Inspections: Flame sensors, ignition electrodes, air flap, fan wheel, and electrical components should be regularly inspected and cleaned.
Filter Replacement: The multiblock filter screen should be checked at least once a year and replaced if clogged (pressure drop > 10 mbar).
Combustion Component Check: Turbulator, gas nozzles, ignition transformer, and electrode settings should be checked and cleaned/readjusted as necessary.
Fan Wheel Maintenance: The fan wheel can be stopped at any position on the motor shaft. It should be cleaned and degreased, and its axial position should be marked before removal to ensure correct reinstallation and prevent efficiency reduction.
Leakage Test: Gas trains and connections must be leak tested regularly using approved foaming agents.
Measurement Report: Annual maintenance should include recording fuel type, calorific value, gas flow, combustion efficiency, exhaust gas emissions (NOx, O2, CO, CO2, soot), temperatures, and atmospheric pressure.
Control Unit Maintenance: The Burnertronic control unit data (curves, parameters) should be backed up to facilitate quick restarts after replacement.
Safety Device Checks: After maintenance or changes to safety device settings, all safety equipment must be checked for proper functioning.

The burner is supplied in three packaging units: burner with integrated switch cabinet, flange seal, screws, operating instructions, circuit diagram, and spare parts list; burner head; and compact gas train with gas filter. Proper installation, commissioning, and maintenance by authorized specialists are crucial for safe, environmentally sound, and energy-efficient operation.