p. 1

vgl02.120 vgl02.210 operating instructions for specialist installation engineers dual-fuel burners 2-21 en de fr 4200 1017 6900 it nl 4200 1021 3400 4200 1017 7000 03/2011 art nr 4200 1033 6200b

[close]

p. 2

overview contents overview operation installation 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 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 vgl02.120 vgl02.210 comply with 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/ec gas devices directive 2004/108/ec emc directive 2006 95/ec low voltage directive 92 42/eec 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 commissioning servicing important information vgl02.120/210 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 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 vgl02.120/210 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 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 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 additional kw 2.0 cm2 ch up to 33 kw 200 cm² for every additional kw 6.0 cm2 variations may arise as a result of local regulations 2 03/2011 art nr 4200 1033 6200b

[close]

p. 3

overview burner description en a1 f6 m1 s10 t1 v1 y1 y16 2 5 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 6 plate hanging device 8 flame tube 10 7 pin plug 13 adjusting screw for dimension y 16 gas valve connecting flange 18 cover 19 release knob for control unit 20 cover retaining screw tx25 102 fuel oil pump 103b air flap manual control 113 air intake box 119 air pressure tap pl 03/2011 art nr 4200 1033 6200b 3

[close]

p. 4

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 is switched off at the end of the safety time which lasts no more than 3 seconds and the gas valve closes if the flame is lost during operation the gas supply is cut within a second a new start-up sequence is activated if the burner starts the operating cycle 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 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 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 gas train 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 4 03/2011 art nr 4200 1033 6200b

[close]

p. 5

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 periods 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 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 03/2011 art nr 4200 1033 6200b 5

[close]

p. 6

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 13-360mbar -15 to +60°c 230v/50hz 46w ip54 rp 3/4 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 adjusting screw 106 gas filter 119 inlet gas pressure measurement nipple 119pbr outlet gas pressure measurement nipple as47d bfp21 l3 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 6 03/2011 art nr 4200 1033 6200b

[close]

p. 7

operation tcg 1xx control unit pressing and holding the r for 1 second 5 seconds 9 seconds leads to 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 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 the control unit being unlocked the control unit being locked the statistics in the control unit to be erased en symbol 230 v description permanent power supply l1 boiler heat request electronic igniter orange indicator light lights up when the valve is opened green indicator light lights up during a heat request description valves open flame detection unauthorised flame detection operating hours counter symbol h burner motor 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 check 5 5 6 7 8 pre-ventilation pre-ignition activation of unauthorised flame monitoring flame formation safety time post-ignition time operation 9 10 burner shutdown regulator shutdown 03/2011 art nr 4200 1033 6200b 7

[close]

p. 8

operation control unit remote unlocking gas pressure switch air pressure switch earth flame detection 230v power supply connector no terminal igniter fan motor malfunction signal gas valve earth connector no terminal terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 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 24 description igniter phase neutral burner motor phase earth neutral neutral malfunction display phase safety valve phase neutral earth main gas valve phase earth connector no 5 4 21 1 8 03/2011 art nr 4200 1033 6200b

[close]

p. 9

assembly burner assembly burner assembly burner flange 3 is equipped with elongated slots and can be used with a drilling Ø of 150 180 mm these dimensions comply with 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 installation · 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 en 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 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 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 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 exhaust gas evacuation system to avoid unfavourable noise emissions right-angled connectors should not be used to connect the boiler to the flue 03/2011 art nr 4200 1033 6200b 9

[close]

p. 10

assembly setting/checking the combustion components setting and checking the combustion components · 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 03/2011 art nr 4200 1033 6200b

[close]

p. 11

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 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 fuel oil bleed filter recommended mesh size 70 m to guarantee a connection with no kinks or strain · 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 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 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 10 a 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 03/2011 art nr 4200 1033 6200b 11

[close]

p. 12

assembly choice of fuel checks before start-up choice of fuel the choice of fuel is made manually using switch s10 to be fitted on the burner side to do this · unscrew cap 1 · remove the gasket the tooth lockwasher and the knurled ring · pass the switch lever through the support window · 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 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 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 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 · · · · · · 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 03/2011 art nr 4200 1033 6200b 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.

[close]

p. 13

commissioning gas operation adjustment data air regulation he a d ga s pr e s s ur e 1 1 9 pbr da p a 40 55 107 71 103 149 pf c om bus tion c ha m be r pr e s s ur e da p a 4 7 10 10 15 20 bur ne r type bur ne r pow e r k w 35 75 120 100 130 160 dim e ns ion y m m 0 8 25 10 16 26 air fla p pos ition 1 0 3 b in ° 5 40 75 35 55 90 en vgl0 2 .1 2 0 vgl0 2 .2 1 0 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 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 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 03/2011 art nr 4200 1033 6200b 13

[close]

p. 14

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 gas train disconnect the burner from the power supply first · check that fuel selection switch s10 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 · · · · · · 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 unitmalfunction 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 unit start the burner · · · incremental advance setting flow setting pressure switch coil access to the filter connecting flanges 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 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 pbr pressure regulator setting pressure regulator setting the adjusting screw has a path of 60 turns for adjusting the output pressure three turns clockwise or anticlockwise increases or reduces pressure by 1 mbar respectively at commissioning · turn the screw through at least 10 turns clockwise · then fine tune the adjustment more or less pressure · check the gas pressure either at the multiblock pbr m4 or the gas collector measurement nipple Ø9 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 co2 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 s 50 from 4 to 50 mbar locking screw painted screw 14 03/2011 art nr 4200 1033 6200b

[close]

p. 15

commissioning setting the gas pressure switch/air pressure switch function check gas pressure switch setting · to set the switch-off pressure remove the cover from the gas pressure switch · install a gas pressure pa measuring instrument · start the burner · 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 · 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 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 en 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 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 control and safety unit locks starting attempt with brief opening of the air pressure switch during preventilation the control and safety unit restarts the pre-ventilation programme air pressure detected again within 60 seconds otherwise lockout occurs 03/2011 art nr 4200 1033 6200b 15

[close]