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vl3.290 d vl3.360 d operating instructions for specialist installation engineers fuel oil burners 2-25 en de fr 4200 1021 1501 nl it 4200 1021 1601 4200 1021 1401 11/2010 art nr 4200 1026 6101a

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overview contents overview operation contents 2 important information 2 burner description 3 operating mode safety function 4 automatic combustion control unit 5-7 terminal allocation chart connection socket 8-9 fuel oil burner pump 10 installing the burner burner installation location 11 electrical connection fuel oil connection 12 checks before commissioning 13 setting data checking combustion components 13 air regulation fuel oil pressure regulation 14 adjusting burner output 15-20 maintenance 21-22 troubleshooting 23 fault diagnosis menu 24 operating statistics menu 25 declaration of conformity for fuel oil burners we certified company no.aqf030 f-74106 annemasse cedex declare under our sole responsibility that the products vl3.290 d vl3.360 d conform to the following standards en 50165 en 55014 en 60335-1 en 60335-102 en 60555-2 en 60555-3 en 267 belgian royal decree dated 08/01/2004 these products bear the ce mark in accordance with the stipulations of the following european directives important information the vl3.290 d and vl3.360 d burners are designed to burn extra light fuel oil in accordance with national standards at Önorm c1109 standard or low sulphur be nbn t52.716 standard or nbn en590 low sulphur ch sn 181160-2 extra-light fuel oil and low sulphur eco fuel oil de din 51603-1 standard and low sulphur the design and function of the burners meet standard en 267 installation commissioning and maintenance must only be carried out by authorised specialists and all applicable directives and regulations must be complied with burner description the vl3.290 d and vl3.360 d burners are two-stage fully automatic monoblock devices 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 packaging the burner is supplied packaged in two boxes on a pallet burner housing with operating instructions wiring diagram burner head with flange seal and securing screws the following standards should be observed in order to ensure safe environmentally sound and energyefficient operation en 226 connection of fuel oil and forceddraught gas burners to a heat generator en 60335-1 -102 safety of electrical equipment for domestic use 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 connection to an air exhaust system is provided for the air supply there must be a supply air inlet measuring de up to 50 kw 150 cm2 per additional kw 2.0 cm2 ch qf [kw x 6 cm2 but at least 150 cm 2 variations may arise as a result of local regulations 2006 42/ec 2004/108/ec 2006 95/ec 92 42/eec machinery directive emc directive low voltage directive eec working efficiency directive installation start-up servicing annemasse 6th october 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 2 11/2010 art nr 4200 1026 6101a

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overview burner description en y10 air flap servomotor a1 automatic combustion control unit a4 display b3 flame monitor m1 blower and pump motor t1 igniter 3 adjusting screw for dimension y 4 nozzle line hose 5 housing 6 plate hanging device 7 outlet for the hoses 8 burner tube 10 7-pin connector 10.1 4-pin connector 18 cover 19 release knob 20 hood securing screw 102 fuel oil pump y1,y5 solenoid valves 113 air intake box 11/2010 art nr 4200 1026 6101a 3

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operation operation safety function starting the burner after heat is requested by the boiler regulator the automatic combustion control unit starts the program sequence the blower motor starts up the ignition switches on pre-ventilation with air flap open air flap is only closed when the burner is switched off the solenoid valve 6 opens pressure set by the partial load regulator 5 flame formation ignition switches off burner operation regulation between partial load and full load the burner operates with one nozzle and at two different fuel oil pressures one for partial load and one for full load the oil pressures are controlled independently by two pressure regulators in the pump if an increase in load is requested by the boiler regulator the burner switches from partial load to full load after a delay of at least 13 seconds air flap 11 is moved to the full load position by the servomotor when the air flap position is adjustable the solenoid valve 3 closes the part-load pressure regulator 5 is deactivated and the full load pressure regulator 2 takes over regulation of the pressure the air flap continues to move to the full load position the full load is in operation safety function a safety shutdown is triggered if a flame signal is detected during preventilation unauthorised flame monitoring if no flame is produced within 5 seconds safety time of the burner being started fuel inlet authorisation if no flame is produced after an unsuccessful restart attempt in the event of flame failure during operation a safety shutdown is indicated by the malfunction lamp lighting up once the cause of the malfunction has been rectified it is possible to unlock the control unit by pressing the reset button principle diagram 1 2 3 4 5 6 7 8 9 10 11 12 two-stage pump oil pressure regulator full load solenoid valve full load no pump oil pressure regulator partial load solenoid valve nc nozzle line baffle plate flame tube burner motor air flap air flap electric servomotor 4 11/2010 art nr 4200 1026 6101a

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operation tch 2xx safety unit the tch 2xx fuel oil automatic combustion control unit controls and monitors the forced draught burner the microprocessor-controlled program sequence ensures maximum stability of time periods regardless of fluctuations in the power supply voltage or the ambient temperature the automatic combustion control unit is designed to cope with brownouts whenever the supply voltage drops below its rated minimum level 185v 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 195v locking and unlocking the control unit can be locked using the release knob or unlocked as long as the unit is powered on 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 en moves the cursor upwards moves the cursor downwards pressing and causes holding the unlocking button for 1 second the control unit to unlock the control unit to lock increases the marked value modifies/confirms the value shown modifies/confirms the value shown unlocks the control unit 2 seconds 9 seconds the statistics to be deleted red led flashes if a fault is present screen description screen description awaiting the heat request from the boiler oil valve is opened safety time air flap is forced open for preventilation flame stabilises post-ignition time pre-ventilation and pre-ignition flame is present awaiting authorisation of regulation air flap closes to the ignition position burner in operation the lower cell shows the strength of the signal and the operating time of the burner 11/2010 art nr 4200 1026 6101a 5

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operation tch 2xx safety unit in parallel with its control and safety functions the tch2xx control unit allows the following to be set the position of the air flap during ignition the position of the air flap during the 1st stage the position of the air flap by opening the stage 2 valve for switching from 1st to 2nd stage the position of the air flap during the 2nd stage the position of the air flap by closing the stage 2 valve for switching from 2nd to 1st stage the parameters for the control unit are set using the display and 5 keys operating values are shown in real time on the display pressing the keys gives access to 7 menus the last two menus are not activated for vl3.290 d and vl3.360 d burners · menu for setting the servomotor · menu for setting adjusting the standard configurations · menu for storing the servomotor setpoints in the display · menu for setting industrial applications · fault diagnosis menu · menu for manual control in these menus it is possible to adjust the control unit s standard configurations these are pre-set in the factory no modifications may be carried out on-site without prior consultation with elco the access code and the setting setpoints for this menu are available on request · operating statistics menu 6 11/2010 art nr 4200 1026 6101a

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operation tch 2xx safety unit en operating cycle phases 1 no voltage 2 powering up no heat request 3 heating request 4 air flap opens to the preventilation position 5 pre-ventilation switching on the motor and the igniter 6 closing the air flap switching to the ignition position 7 unauthorised flame monitoring 8 9 10 11 12 13 starting the burner opening the solenoid valve flame formation safety time flame stabilisation time postignition time awaiting regulator release opening the air flap until the opening position of the 2nd stage valve is reached operation in 2nd stage closing the air flap until the closing of the 2nd stage valve 14 15 16 operation in 1st stage regulator shutdown closure of the air flap to 0° awaiting a new heating request 11/2010 art nr 4200 1026 6101a 7

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operation terminal allocation chart 230 volt connection burner motor 1st stage solenoid valve 2nd stage solenoid valve 3rd stage solenoid valve ignition 2nd stage thermostat heating request connector terminal flame monitor connector air pressure switch remote unlocking fault display pre-heater l1 power supply earth earth fuel pump pump unit terminal terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 description burner motor live earth neutral 1st stage solenoid valve live earth neutral 2nd stage solenoid valve live earth neutral 3rd stage solenoid valve live earth neutral igniter live earth neutral 2nd stage thermostat phase t6 signal t7 signal t8 1st stage thermostat live t1 heating request signal option t2 connector 4 1 2 3 5 t6/7/8 19 terminal 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 description flame monitoring signal neutral live not used not used live remote unlocking signal neutral signal fault live live preheater/release contact earth neutral live l1 earth neutral earth earth pump unit live earth neutral connector 11 10 20 21 25 6 35 8 11/2010 art nr 4200 1026 6101a

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operation terminal allocation chart low voltage connections display-pc interface en terminal connector connector terminal air flap servomotor terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 description connector not used not used not used not used not used not used not used not used not used 17 27 28 29 terminal 18 19 20 21 22 23 24 25 26 27 28 description connector not used not used not used not used not used 31 30 15 air flap servomotor display-pc interface 16 11/2010 art nr 4200 1026 6101a 9

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operation pump the pump is a gear pump it must be connected as a two-line pump via a bleed filter for the connection of the fuel oil tank and the bleed filter it is better to use the single line option an intake filter and two oil pressure regulators are integrated in the pump pressure gauges for pressure measurements 4 and negative pressure measurements 5 must be connected before the equipment is commissioned 1 2 3 4 5 8 9 y1 y5 return connection g 1/4 vacuum connection g 1/4 nozzle supply line connection g1/8 pressure gauge connection vacuum gauge connection pressure setting 1st stage pressure setting 2nd stage solenoid valve 1st stage solenoid valve 2nd stage 10 11/2010 art nr 4200 1026 6101a

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assembly burner assembly preparing the boiler front · prepare the burner mounting plate boiler door in accordance with the diagram · establish the internal diameter a of 155-190 mm · to mount the burner head bracket drill four m10 holes drill diameter 175 to 220 mm as shown in the diagram opposite burner head assembly · screw the bolts into the burner fixing plate/boiler door and position the insulation material for a drill hole of 220 mm elongated slots should be cut to the required dimensions · remove the combustion components from the head · attach the burner head with 4 nuts 4 en Øa 155-190 Øb 175-220 c m10 d 45° fitting the burner body · unscrew the two screws z on the burner body completely · bring the burner body into contact after having swivelled it at least 15° to the left · engage the two screws z on the body into the two lugs provided · tighten the 2 screws for assembly in the position with the volute facing upwards unclip the display from its support turn it over 180° and refit it 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° space 6 must be filled with an elastic non-flammable insulation material exhaust gas evacuation system to avoid unpleasant noise emissions right-angled connectors should not be used on the flue gas side of the boiler on boilers with reverse firing minimum flame tube insertion depth a should be observed as per the boiler manufacturer s instructions 11/2010 art nr 4200 1026 6101a 11

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assembly electrical connection fuel oil connection · insert the burner head in the flame tube · thread the oil hose f and the ignition cables h into the grommets r and s · tighten the two screws w · connect the ignition cables to the igniter · fit the oil hose on the pump · fit cell b3 on the cover electrical installation and connection work must only be carried out by a suitably qualified electrician all applicable regulations and directives 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 it must be possible to disconnect the burner from the mains using an omnipolar shutdown device complying with the standards in force the burner and heat generator boiler are connected by a 7-pin connector 1 and a 4-pin connector 2 not supplied the diameter of the cables connected to these connectors must be between 8.3 and 11 mm fuel oil connection the fuel oil connection must be done via a bleed filter the filter must be positioned in such a way as to ensure the hoses are routed correctly the hoses must not be pinched the fuel oil pipes used must be in dn6 or dn8 copper pipe ch fuel oil pipe in din 16773 polyamide for the maximum values of the suction lengths and heights see the directive for carrying out and sizing installations with suction this directive forms an integral part of the elements elco planning is based fuel oil connection to ensure the operating safety of the system the fuel oil supply must be installed carefully in compliance with local regulations on the suction strainer must not be less than 5cm from the bottom of a square tank and not less than 10cm from the bottom of a cylindrical tank important · maximum pressure at the pump intake 1.5 bar · maximum vacuum pressure at the pump 0.4 bar · before commissioning fill the oil lines and check there are no leaks 12 11/2010 art nr 4200 1026 6101a

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commissioning checks before commissioning adjustment data checking the combustion components checks before commissioning the following must be checked before initial commissioning · that the burner is assembled in accordance with the instructions given here · that the burner is pre-set in accordance with the values in the adjustment table · setting the combustion components · the heat generator must be 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 burner power kw · · · · · system must be filled with 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 and 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 en burner air flap position nozzle pump pressure dimension in ° 60°b bar y gph mm stage ignition 1 stage danfoss 2 stage 1 stage 2 stage 1 stage 2 stage 1 stage 2 stage changeover fuel-oil flow kg/h vl3.290 d vl3.360 d 139 170 174 172 193 218 185 236 249 242 274 311 11,7 14,3 14,7 14,5 16,3 18,4 15,6 19,9 21,0 20,4 23,1 26,2 3,00 3,75 4,50 3,75 4,50 5,00 12 11 11 11 11 10 24 22 22 22 22 20 10 20 30 20 20 25 20 27 27 21 26 31 20 27 27 21 26 31 35 45 50 30 35 45 50 90 80 40 48 70 bold delivery setting 1kg f uel-oil at 10°c 11.86kwh the settings data below are basic settings the factory settings data is highlighted in bold and with a grey background with a normal case these settings enable the commissioning of the burner in all cases carefully check the settings values in most cases according to the installation corrections must be made checking the combustion components · remove cell b3 · remove the three screws w from the cover · remove the combustion components and suspend them in the maintenance position · check the nozzle calibre replace as per the above table if necessary · check the setting of the ignition electrode block and the baffle plate correct if necessary · check the distance between the nozzle and the baffle plate adjust if necessary vl3.290 vl3.360 b 4 9 c 6 6 d 4 5 e 3 3 11/2010 art nr 4200 1026 6101a 13

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commissioning air regulation fuel oil pressure regulation air regulation combustion air is regulated at two points · on the pressure side by the gap between the baffle plate and the burner tube · on the vacuum side by the air flap driven by servomotor y10 the regulation of air in the burner head affects not only the air flow but also the mixing zone and the air pressure in the burner tube rotation of setting screw a right more air 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 driven by servomotor y10 1 return connection 2 vacuum connection 3 nozzle supply line connection 4 pressure gauge connection 5 vacuum gauge connection 8 pressure setting 1st stage 9 pressure setting 2nd stage y1solenoid valve 1st stage y5solenoid valve 2nd stage g 1/4 g 1/4 g1/8 fuel oil pressure regulation the fuel oil pressure is adjusted using fuel oil pressure regulator 8 for the 1st stage and fuel oil pressure regulator 9 for the 2nd stage to check the pressure connect a r1/8 pressure gauge to connector 4 turn right to increase the pressure left to reduce the pressure checking the vacuum pressure the vacuum meter for checking negative pressure must be connected to point 5 r1/8 maximum authorised vacuum 0.4 bar at higher vacuum pressures the fuel oil gasifies which causes scraping noises in the pump and risks damaging it 14 11/2010 art nr 4200 1026 6101a

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commissioning pre-setting without flame setting is carried out in 2 phases pre-adjustment without flame setting the flame to fine tune the settings based on the combustion results when the burner is switched on the control unit displays the screen below important at this point no setting position for the servomotor has been defined therefore the burner cannot be started under these conditions en · press any button and the following screen will appear the control unit then opens the settings mode the screen displays the factory presettings for the different positions of the air flap here for example for a vl3.290 d the following positions for the air flap are presented the overall view of the menus is displayed and the air flap positions settings menu is selected · open the settings menu by pressing the button ignition position when the menu is opened the curser goes to this position position of the air flap during the 1st stage position of the air flap when the 2nd stage fuel oil valve is opened position of the air flap during the 2nd stage you must now enter the access code see the label on the back of the display · increase or decrease the value in increments by repeatedly pressing or · when the first figure has been set move the cursor to the right by pressing · repeat the operation until you reach the last figure · confirm the access code by pressing modifying a settings value for the servomotor position to modify the value of a position move the cursor to the corresponding location with the button or select the value to be modified using the button the selected value will flash increase or decrease the value in increments of 0.1° by repeatedly pressing or for large modifications press and hold the or button the value will scroll quickly up or down confirm the new value using the button the value stops flashing n.b it is possible to set different positions within a large range of values however for safety reasons the control unit enforces a minimum interval of 2° between the different positions except between the ignition position and the 1st stage 11/2010 art nr 4200 1026 6101a 15

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