Operating instructions For specialist installation engineers

VGL2.120
VGL2.210
Operating instructions
For specialist installation engineers
Dual fuel burners ................................... 2-21
de, fr..................................... 4200 1017 6901
it, nl ...................................... 4200 1021 3401
............................................. 4200 1017 7001
07/2011 - Art. Nr. 4200 1033 6201A
en
Overview
Contents
Overview
Operation
Installation
Commissioning
Servicing
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gas or fuel oil operation, safety function . . . . . . . . . . . . . . 4-5
MBDLE gas train, fuel oil pump. . . . . . . . . . . . . . . . . . . . . . 6
TCG 1xx control and safety unit . . . . . . . . . . . . . . . . . . . . 7-8
Installing the burner
Inspection glass/flue cooling . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting/checking the combustion components . . . . . . . . . 10
Fuel oil and gas connections, electrical connection . . . . . 11
Choice of fuel
Checks before commissioning . . . . . . . . . . . . . . . . . . . . . 12
Gas operation
Adjustment data, Air regulation
Program sequence test . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Setting the gas pressure switch/air pressure switch,
Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel oil operation
Adjustment data, air regulation
Program sequence test . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Important information
VGL2.120/210 burners are designed for
the combustion of natural gas and extra
light domestic fuel oil in accordance with
the following national standards:
AT: ÖNORM C1109: Standard and lowsulphur
BE: NBN T52.716: Standard and NBN
EN590: low-sulphur
CH: SN 181160-2 : EL heating oil and
Eco-heating oil low-sulphur
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
VGL2.120/210 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 ELCO. 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 contains the
following:
1
Gas connecting flange
1
Compact gas train with gas filter
1
Burner flange with insulating gasket
1
Bag containing mounting parts
1
Bag containing technical
documentation
2
The following standards should be
observed in order to ensure safe,
environmentally sound and energyefficient operation:
EN 267
Fuel oil burners
EN 676
Forced draught gas burners
Declaration of conformity
for dual fuel burners
We, certified company No.AQF030,
18 rue des Bûchillons
Ville-la-Grand F-74106 ANNEMASSE
Cedex declare under our sole
responsibility that the products
VGL2.120
VGL2.210 conform to the following
standards
EN 50165
EN 60335-1
EN 60335-2, -102
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
2009/142/CE Gas AppliancesDirective
2004/108/CE EMC Directive
2006/ 95/CE Low Voltage Directive
92/ 42/CEE Efficiency Directive
these products bear the CE marking.
Annemasse, 1st March 2011
M. SPONZA
EN 60335-1, -2-102
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 cm2
for every further kW: + 2.0 cm2
CH: up to 33 kW: 200 cm² for every
further kW: + 6.0 cm2.
Variations may arise as a result of local
regulations.
07/2011 - Art. Nr. 4200 1033 6201A
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
en
A1
A4
F6
M1
S4
T1
V1
Y1
Y16
2
5
Control unit
Display (concealed)
Air pressure switch
Blower motor
Fuel change switch
Igniter
Flame detection cell
Fuel oil solenoid valve
Fuel oil safety solenoid valve
Burner retaining flange
Housing (volute casing
downwards)
6
Plate hanging device
8
Flame tube
10 7 pin plug
13 Adjusting screw for dimension Y
16 Gas train connecting flange
18 Cover
19 Release knob for control unit
20 Cover mounting screw (Tx25)
102 Fuel oil pump
103B Air flap manual control
113 Air intake box
119 Air pressure tap pL
07/2011 - Art. Nr. 4200 1033 6201A
3
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 µA.
Safety function
- If no flame is produced when the
burner is started (gas release), the
burner will be switched off at the end
of the safety time lasting no more than
3 seconds and the gas valve closes.
- If the flame is lost during operation, the
gas supply is cut within a second. A
new start-up sequence is activated. If
the burner starts, the operating cycle
runs. Otherwise a lockout occurs.
- If there is an air failure during preventilation or operation, a lockout
occurs.
- If there is a gas failure, the burner
either stops or will not start. 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 period: 3 x 2 min., then 1 hour.
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
Gas train
Note
In Germany, the draft combustion
ordinance requires that gas-fired
installations be equipped with a
thermally triggered shut-off valve.
4
07/2011 - Art. Nr. 4200 1033 6201A
Operation
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 µA.
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 preventilation 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 period: 3 x 2 min., then 1 hour.
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
en
Basic circuit diagram
1
2
3
4
5
6
7
8
9
10
11
07/2011 - Art. Nr. 4200 1033 6201A
Fuel oil burner pump, complete
Fuel oil pressure regulator
Fuel oil burner pump
Solenoid valve (NO)
Nozzle line
Flame tube
Baffle plate
Safety solenoid valve
Air flap
Blower
Burner motor
5
Operation
MB-DLE 407 gas train
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.
Technical data
Inlet pressure
Ambient temperature
Voltage
Power consumption
Protection level
Gas connection
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 (MBDLE407)
may be adjusted using the screw. The
inlet and outlet pressure can be
measured at the pressure taps.
AS47D
6
13-360mbar
-15 to +60°C
230V/50Hz
46W
IP54
Rp 3/4"
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
adjusting screw
106
Gas filter
119
Inlet gas pressure
measurement nipple
119pBr Outlet gas pressure
measurement nipple
BFP21 L3
07/2011 - Art. Nr. 4200 1033 6201A
The fuel oil pump used is a self-priming gear
pump, which must be connected as a two-line
pump via a bleed filter. There is an intake filter
and a fuel oil pressure regulator integrated in
the pump. Before commissioning, install
pressure gauges for the pressure (4) and
vacuum (5) measurements.
1
Suction intake connection
2
Return connection
3
Pressure connection
4
Pressure gauge connector (fuel oil
atomisation pressure)
5
Vacuum meter connector (suction
intake)
6
Fuel oil pressure regulation
10
Solenoid valve electrical connection
Y1
Fuel oil solenoid valve
Operation
TCG 1xx control and safety unit
Pressing and
holding the R
button for...
... 1 second ...
... 2 seconds ...
... 9 seconds ...
… causes …
the control unit to
unlock.
the control unit to
lock.
the statistics in the
control unit to be
erased.
A4 Display and operating unit
BP1 Button 1
Query: fault code
BP2 Button 2
Query: value
Symbol
Description
Awaiting boiler heat request
Awaiting air pressure switch upon start-up
The SG 113 automatic gas combustion
control unit
TCG 1xx controls and monitors the forced
draught burner. The microprocessorcontrolled program sequence ensures
maximum stability of time 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) and unlocked
(malfunction cleared) by pressing the R reset
button, provided the system is connected to
the mains power supply.
Always switch off the power supply
before installing or removing the
control unit. Do not attempt to open or
carry out repairs on the control unit.

Motor supply
Igniter on
Flame present
1:
2:
3:
4:
No voltage
No heat request when the power is
on
Heat request, checking rest status
of the air pressure switch
Motor powered, air pressure
5:
5:
6:
7:
check
Pre-ventilation
Pre-ignition, activation of
unauthorised flame monitoring
Flame formation, safety time
Post-ignition time
07/2011 - Art. Nr. 4200 1033 6201A
8:
9:
10:
Operation
Burner shutdown
Regulator stop
7
en
Operation
Control unit
Flame detection
Remote
unlocking
Gas pressure
Air pressure
230V power supply
Earth
Connector
no.
Terminal
Igniter
Malfunction signal
Blower motor
Gas valve
Earth
Connector
no.
Terminal
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
13
8
Description
Flame monitoring signal
Neutral
Live
Remote unlocking signal
Live
Live
Gas pressure switch signal
Air pressure switch signal
Live
Live
Earth
Neutral
Earth
Connector no. Terminal
14
15
16
17
18
19
20
21
22
23
24
25
11
20
8
10
6
Description
Igniter phase
Neutral
Burner motor phase
Earth
Neutral
Neutral
Malfunction display phase
Safety valve phase
Neutral
Earth
Main gas valve phase
Earth
07/2011 - Art. Nr. 4200 1033 6201A
Connector no.
5
4
21
2
Assembly
Burner assembly
Burner assembly
Burner flange 3 has oblong holes and
may be used for a drilling Ø of 150 to 184
mm. These dimensions comply with
standard EN 226.
The insertion depth of the combustion
components 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.
Assembly:
• Secure connecting flange 3 to the
boiler using screws 4.
• Fit pipe bracket 2 to the burner pipe
and secure using screw 1. Tighten
screw 1 to a 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
brickwork surround
Unless otherwise specified by the boiler
manufacturer, heat generators without a
cooled front wall require brickwork 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, nonflammable insulation material. On boilers with
reverse firing, minimum flame tube insertion
depth A should be observed as per the boiler
manufacturer's instructions.
Gas train assembly
• Check that O-ring gasket J1 is present
and correctly fitted to the flange.
• Fit the gas train.
• Route the connection cable for the gas
train through clamp 7 and connect it to
the gas train.
To fit the burner in the reverse
reverse the display.
 position,
To do this, when the burner is
powered on, hold down buttons
BP1 and BP2 at the same time,
until the change is complete.
This operation is only possible
when the burner is switched off!
Exhaust gas evacuation system
To avoid unpleasant noise emissions,
right-angled connectors should not be
used on the flue gas side of the boiler.
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.
• For the connecting nipple and
connection hose, use accessories
article No. 12 056 459.
07/2011 - Art. Nr. 4200 1033 6201A
Flue gas evacuation system
To avoid unfavourable noise emissions,
right-angled connectors should not be
used to connect the boiler to the flue.
9
en
Assembly
Setting/checking the combustion components
Checking and setting combustion
head
• Disconnect the ignition cables on the
igniter.
• Disconnect the cables from safety
valve Y16, and from cell V1.
• Disconnect flexible hose pL.
• 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.
• Check the position of the ignition
electrodes using the diagram.
• During assembly, check that O-ring J2
is fitted and correctly positioned.
• Unscrew spherical-head screw E
(clockwise) to secure the head.
• Fit the grommets onto the cover.
• Fasten the cover (3 screws W).
• Refit hose/solenoid valve assembly
Y16 to the nozzle line.
• Tighten the ignition cables and
connect them to the igniter.
• Connect the cables from the cell, the
safety valve and flexible hose pL to
the cover.
• Check it is airtight.
10
07/2011 - Art. Nr. 4200 1033 6201A
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 < 2 bar.
• Maximum intake vacuum at the pump
< 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
ELCO brochure Art. no. 12002182 must
be observed when configuring and
dimensioning systems with a suction
intake device for extra-light fuel oil.
• Connect the supplied fuel oil hoses to
the fuel oil pump and pass them
through the opening in the housing.
• Position the oil filter with venting option
(recommended mesh filter: 70 µm) in
such a way that the fuel oil hose
connections are not placed under
strain or kinked.
• Make sure that the supply and return
lines are correctly connected.
Before commissioning, draw fuel oil

in using a hand pump and check the fuel
oil lines for leaks.
en
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
• Check to ensure that the power supply
is as specified (230V, 50 Hz single
phase with neutral and earth)
Boiler fuse: 10A
07/2011 - Art. Nr. 4200 1033 6201A
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
connector must be between 8.3 and 11
mm.
Connecting the gas train
Connect the gas train to the plugs on the
burner (black to black, grey to grey).
11
Assembly
Choice of fuel
Checks before commissioning
Choice of fuel
The choice of fuel is made manually
using switch S4 to be fitted on the
burner side.
Choice of fuel
When both fuels are available, or failing
that, apply the following principle:
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.
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
assembled correctly, checked for
leaks and bled.
• A standard-compliant measuring point
must be available, the exhaust gas
duct up to the measuring point must
be free of leaks to prevent anomalies
in the measurement results caused by
outside air.
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
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.
Checks before commissioning
The following must be checked before
initial commissioning:
• Correct assembly of the burner in
accordance with the present
instructions.
• 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
•
•
•
•
•
•
07/2011 - Art. Nr. 4200 1033 6201A
Commissioning
Gas operation
Adjustment data
Air regulation
Burne r
type
VGL2 .1 2 0
VGL2 .2 1 0
Burne r
pow e r
(k W )
Dim e ns ion
Y
(m m )
35
75
120
100
130
160
0
8
25
10
16
26
He a d ga s
Air fla p
pre s s ure 1 1 9
pos ition 1 0 3 B
pBr
in °
(da Pa )
5
40
75
35
55
90
40
55
107
71
103
149
pF c om bus tion
c ha m be r
pre s s ure
(da Pa )
en
4
7
10
10
15
20
The adjustment data above are Basic adjustment values. The factory adjustment data is shown in bold. These adjustment
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.
- Rotation of screw A:
to the right: more air
to the left: 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.
07/2011 - Art. Nr. 4200 1033 6201A
13
Commissioning
Gas operation
Program sequence test
Setting the burner
Testing the burner program
sequence before initial gas release
• Close the manual valve located
upstream of the gas train.
• Bridge the gas pressure switch
(terminals 2 and 3) if necessary if there
is insufficient gas pressure upstream
of the compact gas train. Disconnect
the burner from the power supply first.
• Check that fuel selection switch S4 is
in the GAS position.
• Start the burner by switching on the
heat generator and test the program
sequence.
• The blower starts after a delay,
depending on the control and safety
unit setting.
Adjusting screw of the gas
pressure regulator
Locking
screw
Sealed
screw
•
•
•
•
•
•
•
•
•
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).
Cut the power to the burner by
disconnecting the electrical
connection and remove the wire
jumper for the gas pressure switch if
necessary.
Reconnect the electrical connection.
Unlock the control and safety unit.
Start the burner.
Pressure regulator setting
The adjusting screw for the pressure
regulator has a path of 60 turns. 3 turns
clockwise or anticlockwise increases or
reduces pressure by 1 mbar
respectively.
At commissioning:
• turn the screw at least 20 turns
clockwise (+ direction)
• the gas pressure upstream of the
regulator pBr should rise to: 1215 mbar.
Initial load flow adjustment - rapid
stroke adjustment
• Twist off 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 middle
position (approximately 3 half turns).
The initial gas flow is now set to
around half open.
• To achieve smooth starting
characteristics, the initial gas flow
should be adapted to the pressure
characteristics of the heat generator.
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.
• Retighten the locking screw after the
adjustment has been made.
• Measure the gas pressure on connector
119pBr (factory settings see page 13).
Doing this can have an effect on starting
characteristics, pulsation and combustion
values.
Any reduction in dimension Y increases
the CO2 value
and starting characteristics (ignition)
become harsher.
Compensate for the change in airflow if
necessary by adjusting the air flap
position.
Optimising combustion values
Optimum combustion values can be
achieved by adjusting the position of the
baffle plate (dimension Y) if necessary.
Checking the adjustment capacity
• Run the burner at full capacity.
• Measure the gas pressure at 119 and
119pBr.
• Slowly close the manual shut-off valve
upstream of the gas train until the gas
inlet pressure at 119 drops by
20daPa.
During this operation, the gas outlet
pressure at 119pBr must not drop by
more than 10%.
14
07/2011 - Art. Nr. 4200 1033 6201A
N.B. Observe the minimum required
flue gas temperature specified by the
boiler manufacturer and the
requirements demanded of flue gas
ducts for avoiding condensation.
If it does, check and correct the
setting.
If the installation's adjustment
capacity is insufficient, the
installation must not be started up.
• Reopen the manual shut-off valve.
Commissioning
Setting the gas pressure switch/air pressure switch
Function check
Setting the gas pressure switch
• To set the switch-off pressure: remove
the gas pressure switch cover.
• Install a gas pressure pBr measuring
instrument.
• Start the burner.
• Reduce the pressure upstream of the
gas train by gradually closing the
manual shut-off valve, until
- the gas pressure pBr downstream of
the train drops to 70% of its initial
value
- the flame becomes visibly less
stable
- the CO level increases
- or the flame signal deteriorates
considerably
• Turn the dial clockwise until the gas
pressure switch shuts down the
burner.
• Continue turning the dial clockwise to
set the gas pressure switch to 10%
above the shutdown value determined
above.
The gas pressure switch adjustment
value must be higher than the air
pressure, but lower than the gas
pressure downstream of the gas valve.
If the switch-off value determined
in this way is greater than
150 mbar, adjust the pressure
switch to 150 mbar.

Checking the switch-off pressure
• Open the manual shut-off valve
• Start the burner
• Close the manual shut-off valve
The gas failure procedure should start
without the burner control unit locking.
Setting the air pressure switch
To adjust the switch-off pressure:
• Commission the burner.
• Increase the shut-off point by turning
the adjustment scale clockwise until
the burner switches off.
• Set the shut-off point to approximately
15% below the triggering pressure
that is now set.
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.
- Start-up test with the gas valve closed:
the automatic combustion control unit
must switch to malfunction mode at
the end of the safety time.
- Start-up with the air pressure switch
closed: after an 8-second test period,
the burner switches to malfunction
mode.
- Start-up test with the air pressure
switch contact open: after a 60second waiting period, the control and
safety unit locks.
- Start-up test with the air pressure
switch briefly open during preventilation: the control and safety unit
restarts the pre-ventilation
programme (air pressure detected
again within 60 seconds) ; otherwise a
lockout occurs.
07/2011 - Art. Nr. 4200 1033 6201A
15
en
Commissioning
Fuel oil operation
Adjustment data
Air regulation
Nozzle
type
Pump
pressure
(bar)
0,75
Danfoss 45° B
11
pF
combustion
chamber
pressure
(daPa)
4
40
75
35
1,65
2,50
2,25
Danfoss 45°S
Danfos s 45°S
Danfos s 45°S
11
12
10,5
7
10
10
55
90
2,75
3,75
Danfoss 45°B
Danfos s 45°B
11
10
15
20
Burner
power
(kW)
Fuel
flow
(kg/h)
35
3,0
0
5
VGL2.120
75
120
100
6,3
10,1
8,4
8
25
10
VGL2.210
130
160
11,0
13,5
16
26
Burner
type
Dimension
Air flap
Y
position 103 B
(mm)
(in °)
Nozzle
(Gph)
At delivery the pump is set at 11bar ± 0.5bar.
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 the air flap that can
be adjusted manually using a knob.
AS47D
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.
- Rotation of screw A:
to the right: more air
to the left: 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.
BFP21 L3
1
2
3
4
5
6
10
Y1
Suction intake connection
Return connection
Pressure connection
Fuel oil pressure gauge
connection
Vacuum pressure gauge
connection
Fuel oil pressure regulation
Solenoid valve electrical
connection
Fuel oil solenoid valve
Setting the fuel oil pressure
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
- to the left to reduce the pressure
For the checks, a pressure gauge with
an 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
permissible negative pressure is 0.4 bar.
16
07/2011 - Art. Nr. 4200 1033 6201A
At higher 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 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
Fuel 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.
• Check that fuel selection switch S4 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.
 Risk of deflagration
Continuously check CO, CO2 and
soot emissions when adjusting the
output of the burner. Improve
combustion values in the event of CO
emissions. The CO level must not
exceed 50 ppm.
en
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, CO2,
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 CO2 value. However, starting
characteristics become harsher.
Compensate for the change in airflow if
necessary by adjusting the air flap
position.
N.B. Observe 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-up with the flame detector lit: the
control and safety unit must switch to
malfunction after 10 seconds of preventilation.
- Normal start-up; if the burner is
operational, the flame detector should
be unlit: after restarting and at the end
of the safety time, the control and
safety unit must switch to malfunction.
07/2011 - Art. Nr. 4200 1033 6201A
17
Maintenance
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.

• Switch off the power supply before all
maintenance and cleaning work.
• Use original spare parts.
18
Work recommended as part of annual
burner maintenance:
- Burner test run, input measurement in
the boiler room
- Clean the combustion components
and replace defective parts if
necessary
- Clean the blower fan wheel and check
the pump coupling
- Check the oil nozzle, replace if
necessary
- Check the fuel oil filter, replace if
necessary
- Visual inspection of oil hoses, replace
if necessary
- Clean the gas filter, replace if
necessary
- Visual inspection of burner electrics,
repair 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
vacuum pressure on the burner pump
- Draw up a measurement report
Checking and setting combustion
head
• Disconnect the ignition cables on the
igniter.
• Disconnect the cables from safety
valve Y16, and from cell V1.
• Disconnect flexible hose pL.
• 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.
• Check the position of the ignition
electrodes using the diagram.
• During assembly, check that O-ring J2
is fitted and correctly positioned.
• Unscrew spherical-head screw E
(clockwise) to secure the head.
• Fit the grommets onto the cover.
• Fasten the cover (3 screws W).
• Refit hose/solenoid valve assembly
Y16 to the nozzle line.
• Tighten the ignition cables and
connect them to the igniter.
• Connect the cables from the cell, the
safety valve and flexible hose pL to
the cover.
• Check it is airtight.
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.
• Screw the cover back into place.
• Reopen the manual shut-off valve.
• Check it is airtight.
07/2011 - Art. Nr. 4200 1033 6201A
General checks
- Emergency stop button function check
- Visual inspection of fuel oil lines in the
boiler room
Maintenance
Maintenance
Replacing the flame tube
It is necessary to remove the burner for
this work.
• Loosen the clamping screw on the
connecting flange.
• Turn the burner out of the bayonet
socket, lift it slightly and pull it out of
the connecting flange.
• Place the burner on the floor.
• Loosen the 4 screws X.
• Pull the flame tube out towards the
front.
• Fit and secure the flame tube.
The flame tube may be hot

Cleaning the pump filter
The filter is located in the pump housing.
It must be cleaned with every
maintenance service. To do this:
• Close the fuel oil shut-off valve.
• Place a container under the pump to
catch the fuel oil.
• Remove the screws and cover.
• Remove, clean or replace the filter.
• Refit the filter, close the cover again
and use a new gasket.
• Tighten securely.
• Reopen the fuel oil shut-off valve.
• Check pressure and tightness.
Cleaning 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.
• Remove the air box, clean it and refit it
in reverse order.
• Check that the air flap and the
servomotor are correctly positioned.
Cleaning the cover
• Do not use abrasive products or
products containing chlorine.
• Clean the cover with water and a
suitable cleaning product.
• Refit the cover.
Important

Combustion values must be checked
under normal operating conditions
(boiler room door closed, hood fitted,
etc.) after any work is carried out
inside the unit. Record the results in
the relevant documents.
Checking the exhaust gas
temperature
• 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
commissioning.
• Use an exhaust gas temperature
gauge to make the check easier.
07/2011 - Art. Nr. 4200 1033 6201A
19
en
Troubleshooting
Gas operation
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?
2.
Is there gas pressure?
3.
Is the gas shut-off valve open?
4.
Are all control and safety devices,
such as the boiler thermostat, low
water detector, limit switches, etc.
correctly set?
Symbol
If the malfunction is still present, refer to
the table below.
It is not permitted to repair any
components relevant to safety. These
components must be replaced with parts
having the same part number.
Observation
 Only use original spare parts.
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.
Cause
Burner does not start after thermostatic Drop in supply voltage or power failure.
closure.
No malfunction indicated on the control Control unit malfunction.
and safety unit.
No heat requested.
Thermostats defective or incorrectly
adjusted
The burner starts briefly when switched Control unit was deliberately shut down.
on, then switches off and the red
indicator light comes on.
Burner does not start.
Corrective action
Check the cause of the drop in voltage or
the power failure.
Replace the control unit.
Adjust the thermostats, replace if
necessary.
Unlock the unit.
Air pressure switch: not in rest position.
Incorrect adjustment
Burner blower starts up.
Burner does not start.
Gas pressure switch wrongly set or
defective
Air pressure switch: contact does not
close.
Readjust the pressure switch.
Replace the pressure switch.
Check the gas lines.
Clean the filter.
Check the gas pressure switch or
replace the compact gas unit.
Check the pressure transmitter (foreign
bodies) and wiring.
Burner blower starts up.
Burner does not start.
Flaring during pre-ventilation or preignition.
Check the valve. Check flame
monitoring.
Burner does not start.
Gas pressure normal
Contact welded
Insufficient gas pressure.
The burner starts, the ignition switches No flame at the end of the safety time.
on, then failure
Gas throughput set incorrectly.
Adjust the gas flow stage Check the
Malfunction in flame monitoring system condition and position of the ionisation
probe in relation to earth.
Check the condition and connections of
the ionisation circuit (cables and
measurement bridge).
No ignition sparks.
Adjust, clean or replace electrode(s).
Electrode(s) short-circuited.
Ignition cable(s) damaged or defective. Connect or replace the cable(s).
The burner switches off during
operation.
20
Igniter defective.
Control and safety unit
Replace the igniter.
Replace the control unit.
Check the cabling between the control
unit and external components.
Solenoid valves do not open.
Replace the compact gas unit.
Valves jamming.
Air pressure switch: contact opens
during start-up or during operation.
Replace the valves.
Adjust or replace the pressure switch.
Flame failure during operation.
Check the ionisation probe circuit
Check or replace the control and safety
unit.
07/2011 - Art. Nr. 4200 1033 6201A
Troubleshooting
Fuel oil operation
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?
2.
Is there fuel oil in the tank?
3.
Are all shut-off valves open?
4.
Are all control and safety devices,
such as the boiler thermostat, lowwater detector, limit switch, etc.
adjusted correctly?
If the cause of the malfunction cannot be
ruled out by the checks described
above, check the operation of the
various burner components.
It is not permitted to repair any
components relevant to safety. These
components must be replaced with parts
having the same part number.
Only use original spare parts.
Switch off the power supply
before carrying out
maintenance or cleaning.
Combustion values must be checked
under normal operating conditions
(boiler room door closed, hood fitted,
etc.) after any work is carried out
inside the unit. Record the results in
the relevant documents.
en

A4 Display and operating unit
BP1 Button 1
Query: fault code
BP2 Button 2
Query: value
Symbol
Observation
Cause
Corrective action
No heat requested.
Thermostats defective or
incorrectly adjusted
Adjust the thermostats, replace if necessary.
Burner does not start after
thermostatic closure.
Drop in supply voltage or
power failure.
Check the cause of the drop in voltage or the power
failure.
No malfunction indicated on
the control and safety unit.
Control unit malfunction.
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 detected
during the pre-ventilation/preignition period
Check for the ignition spark/adjust the electrode/
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.
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.
Flame failure during
operation.
The flame goes out during the
operating phase.
Check the ignition circuit, the electrodes and their
settings. Clean the electrodes.
Clean flame detector, or replace.
Replace the following parts as required:
ignition electrodes/ignition cables/igniter/nozzle/
pump/solenoid valve/control unit.
07/2011 - Art. Nr. 4200 1033 6201A
21
22
07/2011 - Art. Nr. 4200 1033 6201A
07/2011 - Art. Nr. 4200 1033 6201A
23
www.elco.net
Hotline
ELCO Austria GmbH
Aredstr.16-18
2544 Leobersdorf
ELCO Belgium nv/sa
Z.1 Researchpark 60
1731 Zellik
ELCOTHERM AG
Sarganserstrasse 100
7324 Vilters
ELCO GmbH
Dreieichstr.10
64546 Mörfelden-Walldorf
ELCO Italia S.p.A.
Via Roma 64
31023 Resana (TV)
ELCO Burners B.V.
Amsterdamsestraatweg 27
1411 AW Naarden
OOO «Ariston Thermo RUS LLC»
Bolshaya Novodmitrovskaya
St.bld.14/1 office 626
127015 Moscow -Russia
Made in EU. Non contractual document.
24
07/2011 - Art. Nr. 4200 1033 6201A
0810-400010
02-4631902
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0180-3526180
800-087887
035-6957350
+7 495 783 0440
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