elco VL 2.120 D, VL 2.160 D, VL 2.210 D Operating Instructions Manual
11/2010 - Art. Nr. 4200 1029 8600A
VL 2.120 D
VL 2.160 D
VL 2.210 D
Operating instructions
For specialist installation engineers
Fuel oil burners......................................2-25
en
de, fr..................................... 4200 1029 8400
it, nl ......................................4200 1029 8500
............................................. 4200 1029 8300
11/2010 - Art. Nr. 4200 1029 8600A2
Overview
Contents
Overview Contents.................................................................... 2
Important information ................................................ 2
Burner description..................................................... 3
Operation Operating mode, safety function............................... 4
Automatic combustion control unit.........................5-7
Terminal allocation chart, connection
socket.....................................................................8-9
Fuel oil burner pump ............................................... 10
Assembly Installing the burner, burner installation location.....11
Electrical connection, fuel oil connection ............... 12
Commissioning Checks before commissioning ................................ 13
Setting data, checking combustion
components ............................................................ 13
Air regulation, fuel oil pressure regulation............... 14
Adjusting burner output......................................15-20
Maintenance Servicing ............................................................ 21-22
Troubleshooting ...................................................... 23
Fault diagnosis menu.............................................. 24
Operating statistics menu .................................. 24-25
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.
Important information
The VL 2.120 D, VL 2.160 D and
VL 2.210 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 VL 2.120 D, VL 2.160 D and
VL 2.210 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 cm
2
per additional kW: : + 2.0 cm
2
CH: QF [kW] x 6= ...cm2; but at least
150 cm
2
.
Variations may arise as a result of local
regulations.
Declaration of conformity
for fuel oil burners
We, certified company No.AQF030,
F-74106 ANNEMASSE Cedex, declare
under our sole responsibility that the
products
VL 2.120 D
VL 2.160 D
VL 2.210 D
conform to the following standards
EN 50165
EN 55014
EN 60335-1
EN 60335-2-102
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
2006/ 42/EC Machinery directive
2004/108/EC EMC directive
2006/ 95/EC Low voltage directive
92/ 42/EEC EEC Working
efficiency directive
Annemasse, 26th March 2010
M. SPONZA
11/2010 - Art. Nr. 4200 1029 8600A 3
Overview
Burner description
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 tube
5 Housing
6 Plate hanging device
8 Burner tube
10 7-pin connector (hidden)
10.1 4-pin connector
18 Cover
19 Release knob
20 Hood securing screw
102 Fuel oil pump
Y1,Y5Solenoid valves
113 Air intake box
en
11/2010 - Art. Nr. 4200 1029 8600A4
Operation
Operation
Safety function
Principle diagram
1 two-stage pump.
2 Oil pressure regulator, full load
3 Solenoid valve, full load (NO)
4Pump
5 Oil pressure regulator, partial load
6 Solenoid valve (NC)
7 Nozzle line
8 Baffle plate
9 Flame tube
10 Burner motor
11 Air flap
12 Air flap electric servomotor
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.
11/2010 - Art. Nr. 4200 1029 8600A 5
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.
Operation
TCH 2xx safety 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).
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...
… causes …
... 1 second ... the control unit to
unlock.
... 2 seconds ... the control unit to
lock.
... 9 seconds ... the statistics to be
deleted
Screen Description Screen Description
Awaiting the heat request from
the boiler
Oil valve is opened, safety time
Air flap is forced open for pre-
ventilation.
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.
en
11/2010 - Art. Nr. 4200 1029 8600A6
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
VL 2 D burners)
Operation
TCH 2xx safety unit
• menu for setting the
servomotor,
• menu for storing the
servomotor setpoints in
the display
• fault diagnosis menu
• operating statistics
menu
• menu for setting/
adjusting the standard
configurations.
• menu for setting
industrial applications
• 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.
11/2010 - Art. Nr. 4200 1029 8600A 7
Operation
TCH 2xx safety 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: Flame stabilisation time, post-
ignition time
10: Awaiting regulator release
11: Opening the air flap, until the
opening position of the 2
nd
stage
valve is reached
12: Operation in 2
nd
stage
13: Closing the air flap, until the
closing of the 2
nd
stage valve
14: Operation in 1
st
stage
15: Regulator shutdown, closure of
the air flap to 0°
16: Awaiting a new heating request
en
11/2010 - Art. Nr. 4200 1029 8600A8
Earth
Pre-heater
Flame monitor
Fault
display
Air
pressure
switch
Igni tionBurner motor
2nd stage
solenoid valve
Connector
Terminal
Terminal
Connector
Remote
unlocking
L1 power
supply
1st stage
solenoid valve
3rd stage
solenoid valve
2nd stage
thermostat
Heating
request
Earth
Fuel pump
pump unit
Terminal Description Connector Terminal Description Connector
1 Burner motor live
4
21 Flame monitoring signal
11
2 Earth 22 Neutral
3 Neutral 23 Live
41
st
stage solenoid valve live
1
24 Not used
10
5 Earth 25 Not used
6 Neutral 26 Live
20
72nd stage solenoid valve live
2
27 Remote unlocking signal
8 Earth 28 Neutral
21
9 Neutral 29 Signal fault live
10 3
rd
stage solenoid valve live
3
30 Live
25
11 Earth 31 Preheater/release contact
12 Neutral 32 Earth
13 Igniter live
5
33 Neutral
14 Earth 34 Live L1
6
15 Neutral 35 Earth
16 2
nd
stage thermostat phase (T6)
T6/7/8
36 Neutral
17 Signal T7 37 Earth
18 Signal T8 38 Earth
19 1
st
stage thermostat live (T1)
19
39 Pump unit live
35
20 Heating request signal (option T2) 40 Earth
41 Neutral
Operation
Terminal allocation chart
230 Volt connection
11/2010 - Art. Nr. 4200 1029 8600A 9
Display-PC interface
Air flap servomotor
Connector
Terminal
Terminal
Connector
Terminal Description Connector Terminal Description Connector
1 Not used
17
18 Not used
31
2 Not used 19 Not used
3 Not used 20 Not used
30
4 Not used
27
28
29
21 Not used
5 Not used 22 Not used
6 Not used 23
Air flap servomotor
15
7 Not used 24
8 Not used 25
9 Not used 26
10
Display-PC interface
16
27
11 28
12
13
14
15
16
17
Operation
Terminal allocation chart
Low voltage connections
en
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