elco VGL4.460 DP, VGL4.610 DP Operating Instructions Manual
en
Operating instructions
VGL4.460 DP
VGL4.610 DP
de, fr................................. 4200 1055 6201
it, nl.................................. 4200 1055 6301
en..................................... 4200 1055 6801
de, fr, it, nl, en................. 4200 1055 6101
......................................... 4201 1011 2500
For specialist installation engineers
Gas burners
......................................... 4200 1075 5001
09/2016 - Art. Nr. 4200 1055 6801A
Overview
Contents
Overview Contents ................................................................................................................................................ 2
Operation Gas operation
Assembly Burner assembly .................................................................................................................................... 18
Commissioning Adjustment data gas operation, Adjustment data fuel oil operation ....................................................... 23
Important information ............................................................................................................................... 3
Burner description ................................................................................................................................. 3-4
Operation, Safety function....................................................................................................... 5
TCG 5xx control unit.............................................................................................................6-8
Terminal allocation chart, 230 Volt connection........................................................................ 9
Fuel oil operation
MB-VEF gas train, Fuel oil pump ........................................................................................................... 17
Gas manifold, Pressure take-off pipes ................................................................................................... 19
Checking the burner head...................................................................................................................... 20
Electrical connection, Selection of fuel................................................................................................... 21
Gas connection, Checks before commissioning ....................................................................................22
Air regulation, Gas valve adjustment, Fuel oil pressure regulation ........................................................ 24
Gas operation
Fuel oil operation
Setting the gas pressure switch, Setting the air pressure switc
Saving the adjustment values in the display ..........................................................................................35
Terminal allocation chart, Low voltage connections.............................................................. 10
Operation, Safety function.....................................................................................................11
TCH 2xx control unit.........................................................................................................12-14
Terminal allocation chart, 230 Volt connection...................................................................... 15
Terminal allocation chart, Low voltage connections.............................................................. 16
Pre-setting without flame..................................................................................................25-26
General advice before starting the burner............................................................................. 26
Setting the flame ..............................................................................................................27-29
Operating mode..................................................................................................................... 29
Pre-setting without flame..................................................................................................30-31
General advice before starting the burner............................................................................. 31
Setting the flame ..............................................................................................................32-34
Operating mode..................................................................................................................... 34
h ........................................................... 35
Servicing Maintenance......................................................................................................................................36-37
Gas operation
Troubleshooting................................................................................................................ 38-39
Fuel oil operation
Troubleshooting..................................................................................................................... 40
Fault diagnosis menu ............................................................................................................................. 41
Operating statistics menu..................................................................................................................41-42
09/2016 - Art. Nr. 4200 1055 6801A2
en
Overview
Important information
Burner description
Important information
VGL4.460 DP and VGL4.610 DP
burners are designed for the lowpollutant combustion of natural gas and
extra light fuel oil. The design and
function of the burners meet standards
EN 676 and EN 267. They are suitable
for use with all heat generators
complying with standard EN 303 or for
use by hot air generators complying with
standard DIN 4794 or DIN 30697 within
their respective performance range. Any
other type of application requires the
approval of ELCO.
Installation, start-up and maintenance
must only be carried out by authorised
Burner description
VGL4.460 DP and VGL4.610 DP
burners are two-stage fully automatic
monoblock devices. The special design
of the combustion head enables
combustion with low levels of nitrogen
oxide and increased output. Class 3
type-approval in accordance with
EN676 (for gas) and with EN267 (for fuel
oil) certifies that the lowest emission
values have been achieved and means
that the national environmental
regulations have been met
AT: KFA 1995, FAV 1997
CH: LRV 2005
DE: 1.BImSChV
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 is supplied packaged in
three boxes on a pallet:
- Burner housing with operating
instructions, circuit diagram and spare
parts list.
- Burner head with flange seal and
securing screws.
- Compact gas train with integrated filter
specialists and all applicable guidelines
and regulations must be complied with.
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, -2-102
Specification for safety of household
and similar electrical appliances,
particular requirements for gas burning
appliances
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 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 cm
per additional kW: : + 2.0 cm
CH: QF [kW] x 6= ...cm2; but at least
150 cm2.
Variations may arise as a result of local
regulations.
2
2
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.
09/2016 - Art. Nr. 4200 1055 6801A 3
Overview
Burner description
A1 Control and safety unit
(Gas operation)
A1.1 Control and safety unit
(Fuel oil operation)
A4 Display
F6 Air pressure switch
K1 Auxiliary motor supply relay
M1 Blower motor
T1 Igniter
V1 Flame detection cell
Y1 Fuel oil solenoid valve, 1
Y2 Fuel oil solenoid valve, 2nd stage
Y10 Air flap servomotor
3 Adjusting screw for dimension Y
5 Housing
6 Plate hanging device
(Maintenance)
7 Combustion chamber pressure
take-off pipe
8 Burner tube
10 7-pin connector
10.1 4 pin connector
10.2 3-pin connector (auxiliary motor
supply relay)
18 Cover
19 Release knob
20 Hood securing screw
102 Fuel oil pump
113 Air intake box
st
stage
09/2016 - Art. Nr. 4200 1055 6801A4
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Compact train
Operation
Gas operation
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
- a check is made for the presence of
any abnormal flame signals.
At the end of the pre-ventilation time
- the ignition is switched on
- the main and safety solenoid valves
are opened.
- burner start-up
Monitoring
The flame is monitored by an IRD cell.
Safety functions
- 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
starts running. 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. As soon
as sufficient gas pressure is available
again, the burner restarts.
During the regulator shutdown
- The control thermostat interrupts the
heat request.
- The gas valves close
- The flame goes out
- The blower motor stops
- The burner is ready for operation
Principle diagram
F4 Gas pressure switch
F6 Air pressure switch
Y12 Safety solenoid valve
Y13 Main solenoid valve
1 Thermal shut-off valve (to be
installed by the installer)
104 Gas pressure regulator
106 Screen
108 Gas cut-out valve (to be installed
by the installer)
119pBrGas pressure measuring point at
the valve outlet
119.1Gas pressure measuring point
upstream of the valves
119.2Air pressure measuring point
pF Furnace pressure
pG Gas pressure at the head
pL Air pressure
CH note
In accordance with SSIGE instructions,
it is compulsory to install a gas safety
valve (mark 1) in the pipe
DE Note
In compliance with the reference layout
applicable to boiler rooms, sites with gas
furnaces must be fitted with a thermal
gas shut-off valve (1).
09/2016 - Art. Nr. 4200 1055 6801A 5
Operation
Gas operation
TCG 5xx control unit
The TCG 5xx control and safety 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).
Pressing the
unlocking button on
the unit for
... 1 second ... the control unit to
... 2 seconds ... the control unit to
... 9 seconds ... the statistics to
… causes …
unlock.
lock.
be deleted
Locking and unlocking
The control unit can be locked (switched
to malfunction mode) by pressing the
unlocking button and unlocked (fault
deleted), provided the unit 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.
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Reduces the marked value.
Modifies/Confirms the value
shown.
Unlocks the control unit.
Red LED (flashes if a fault is
present).
Screen Description Screen Description
Awaiting the heat request from
the boiler
Air flap is forced open for pre-
ventilation.
Pre-ventilation
Closing the air flap to the ignition
position, pre-ignition
Opening the gas valve and
safety time
Flame is present, awaiting
authorisation of regulation
Burner in operation. The lower
cell shows the strength of the
signal and the operating time of
the burner.
09/2016 - Art. Nr. 4200 1055 6801A6
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Operation
Gas operation
TCG 5xx control unit
In parallel with its control and safety
functions, the TCG5xx control unit
allows the following to be set:
(see illustration)
- the position of the air flap during
ignition
- the position of the air flap at minimum
pressure
- the position of the air flap at maximum
pressure
• menu for setting the
servomotor
• menu for storing the
servomotor setting
points in the display
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 9
menus:
• menu for setting
industrial applications*
• menu for manual control*
• fault diagnosis menu
• operating statistics
menu
• menu for setting/
adjusting the standard
configurations*
• Parameter mode menu*
• Menu for adjusting
screen contrast and
brightness settings
* 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
these menus are
available on request.
09/2016 - Art. Nr. 4200 1055 6801A 7
Operation
Gas operation
TCG 5xx control unit
Operating cycle phases:
1: No voltage
2: Powering up, no heat request
3: Heating request
4: Opening an air flap, arrival in pre-
ventilation position
5: Checking the rest status of the air
pressure switch
6: Pre-ventilation: energizing of the
motor, checking the air pressure
7: Pre-ventilation
8: Air flap closes to the ignition position
9: Switching on the igniter, unauthorised
flame monitoring
10:Opening of the solenoid valve, flame
formation, safety time: max. 3 s.
11:Awaiting regulator release
12:Opening the air flap, until the
maximum output is reached
13:Closing of the air flap until the
minimum regulation position is
reached
14:Operation at intermediate regulation
power
15:Operation at minimum regulation
power
16:Regulator shutdown, closure of the
air flap
17:Awaiting a new heating request
09/2016 - Art. Nr. 4200 1055 6801A8
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Operation
Earth
Flame check
Fault
display
Air pressure
switch
Igniter
Burner motor
Connector
Terminal
Terminal
Connector
Remote
unlocking
L1 power
supply
Solenoid valve
Control
thermostat
Heating
request
Earth
Gas pressure
switch
Terminal Description Connector Terminal Description Connector
1 Burner motor live 20 Minimum output thermostat li ve (T1)
2 Earth 21 Heating request signal (option T2)
3 Neutral 22 Flame monitoring signal
4 Solenoid valve live 23 Neutral
5 Neutral 24 Live
6 Earth 25 Air pressure switch signal
7 Solenoid valve live 26 Live
8 Live 27 Live
9 L i ve L1 28 Re mote unlocking si gnal
10 Earth 29 Neutral
11 Ne utral 30 S ignal fault live
12 Earth 31 Live
13 Earth 32 Gas pressure switch signal mini
14 Igniter live 33 Live
15 Earth 34
Gas pressure switch si gnal (if leakage test
present)
16 Neutral
17 Control thermostat live
18 Signal T7
19 Signal T8
8
5
34
T6/7/8
11
2
10
20
6
21
4
19
Gas operation
Terminal allocation chart
230 Volt connection
09/2016 - Art. Nr. 4200 1055 6801A 9
Operation
Display-PC interface
Air servomotor
Gas operation
Terminal allocation chart
Low voltage connections
Terminal Description Connector Terminal Description Connector
1 not used
2 not used 19 not used
3 not used 20 not used
4 not used
5 not used 22 not used
6 not used 23 not used
7 not used 24 not used
8 not used 25 not used
9 not used 26 not used
10
11 28
12 29
13 30
Display or PC interface
14 31
15 32
16 33
17
30
27
28
29
16
/
17
18 not used
21 not used
27 not used
Air servomotor
14
33
32
15
09/2016 - Art. Nr. 4200 1055 6801A10
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Operation
Fuel oil 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 two nozzles
and at one fuel oil pressure for partial
load and one for full load. Fuel oil
pressure is regulated by a pressure
regulator 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 position of the air flap can be
adjusted, the solenoid valve for the
second nozzles opens.
- 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 two-stage pump.
2 Fuel pressure regulator (partial
load and full load)
4Pump
5 Magnetic valve (partial load)
6 Magnetic valve (full load)
7 Nozzle line
8 Baffle plate
9Flame tube
10 Burner motor
11 Air flap
12 Air flap electric servomotor
09/2016 - Art. Nr. 4200 1055 6801A 11
Operation
Fuel oil operation
TCH 2xx control 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).
Pressing and
holding the
unlocking button
for...
... 1 second ... the control unit to
... 2 seconds ... the control unit to
... 9 seconds ... the statistics to be
… causes …
unlock.
lock.
deleted
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.
Moves the cursor upwards.
Moves the cursor downwards.
Increases the marked value.
Modifies/Confirms the value
shown.
Modifies/Confirms the value
shown.
Unlocks the control unit.
Red LED (flashes if a fault is
present).
Screen Description Screen Description
Awaiting the heat request from
the boiler
Air flap is forced open for pre-
ventilation.
Pre-ventilation and pre-ignition
Air flap closes to the ignition
position
Oil valve is opened, safety time
Flame is present, awaiting
authorisation of regulation
Burner in operation. The lower
cell shows the strength of the
signal and the operating time of
the burner.
09/2016 - Art. Nr. 4200 1055 6801A12
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Operation
Fuel oil operation
TCH 2xx control 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 during 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 during closing the
stage 2 valve (for switching from 2nd to 1st
stage).
• menu for setting the
servomotor
• menu for storing the
servomotor setting
points in the display
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 9 menus:
• menu for setting
industrial applications*
• menu for manual control*
• fault diagnosis menu
• operating statistics
menu
• menu for setting/
adjusting the standard
configurations*
• Parameter mode menu*
• Menu for adjusting
screen contrast and
brightness settings
* 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
these menus are
available on request.
09/2016 - Art. Nr. 4200 1055 6801A 13
Operation
Fuel oil operation
TCH 2xx control unit
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: Starting the burner: opening the
solenoid valve, flame formation,
safety time
9: Awaiting regulator release
10: Opening the air flap, until the
opening position of the 2
nd
stage
valve is reached
11: Operation in 2
12: Closing the air flap, until the
closing of the 2
13: Operation in 1st stage
14: Regulator shutdown, closure of
the air flap to 0°
15: Awaiting a new heating request
nd
stage
nd
stage valve
09/2016 - Art. Nr. 4200 1055 6801A14
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