Operating instructions

for authorized experts

Dual-fuel blower burners

EK 3... GL-RO
0211 / 13 010 616A / 121 973

0211 / 13 010 616A / 121 973

Survey

Table of contents
General information

Contents Page

Survey Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner functions Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compound control/gas fittings group . . . . . . . . . . . . . . . . . . . . . . 7
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Automatic burner control unit . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Mounting the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil connection, oil pressure regulation (supply oil) . . . . . . . . . . . . . . . 11
Start-up Burner head factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Nozzle selection A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustments Gas throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil throughput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electric servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil and air pressure monitors . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Flame monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Servicing the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

General information Heat generator ELCO rejects all warranty claims for
The ELCO EK3... GL-RO series of The heat generator must meet damage resulting from one of the
dual fuel blower burners is designed for the requirements stipulated in EN 676 following reasons:
the combustion of natural gas or extra- for furnace loads. – Improper use
light fuel oil. Design and performance of – Inexpert installation or
the burners comply with the standards Site of installation maintenance by the purchaser or
EN 267 and EN 676 The burner must not be operated in third persons, including the
Installation, start-up and maintenance rooms with aggressive fumes (e.g. installation of parts other than
of the burner must be performed by hairspray, tetrachloroethylene, carbon genuine parts supplied by the
a qualified expert in compliance with tetrachloride), dust-laden air or high manufacturer.
currently applicable guidelines and atmospheric humidity (e.g. laundry
regulations. rooms). Start-up
For supply of combustion air, ensure Initial start-up of the firing installation
DIN 4755 adequate ventilation of the heating must be performed by the installer,
Oil-firing installations in heating room. manufacturer, or by another expert
systems designated by them.
DIN 4756 Delivery and operating instructions
Gas-firing installations in heating At the time of delivery at the latest, the
systems company installing the burner must
supply the user with a set of Operating
TRG I and Service Instructions. These should
Technical regulations for gas fittings be kept in the room where the heating
unit is installed.
DIN EN 298 The address and telephone number of
Gas burners, flame monitoring systems the nearest service representative must
be entered in the Instructions.
EN 60335-1
Safety of electrical appliances for Note for the user
domestic use The system should be serviced by an
expert at least once a year. To ensure
maintenance at regular intervals, we
recommend you to conclude a service
contract.
2 0211 / 13 010 616A / 121 973
Survey

Technical data

Burner type EK 3.50 GL-RO EK 3.70 GL-RO

Technical data
Thermal output min. 113 kW 160 kW
Thermal output max. 465 kW 700 kW
Gas type Natural gas* Natural gas*
Gas supply pressure 20-100 mbar** 20-100 mbar**
Regulation Modulating Modulating
Air regulation suction side Air cut-off valve Air cut-off valve
Air regulation pressure side in burner head in burner head
Oil regulation return nozzle with flow controller with flow controller
Control ratio Fuel oil 1:2,5 Gas 1:4 Fuel oil 1:2,5 Gas 1:4
Voltage 230/400 V, 50 Hz 230/400 V, 50 Hz
Power consumption. 1.5 kW 1.5 kW
Weight approx 50 kg 56 kg

Burner equipment
Electric motor 2800 min.–1 0.9 kW 0.9 kW
Automatic burner control unit LFL 1 / LGK 16 LFL 1 / LGK 16
Flame monitor UV QRA 2 / QRA 5 UV QRA 2 / QRA 5
Ignition transformer ZM 20/14 ZM 20/14
El. servomotor for air damper SQM 53 SQM 53
Air pressure monitor DL 50 A DL 50 A
Solenoid valve for return and supply oil 2-way 2-way
Oil pressure pump AJ6-CE RSA 125
Electromagnetic clutch 12/54 12/54
Oil pressure monitor DSA 43 F001 DSA 43 F001

*Gas types CH 12H

Performance charts DE 12ELL
AT 12H
NL 12L
** The minimum gas supply pressure
required for burner operation must
be calculated individually depending
on the installation.
Gas-pressure drop (burner)

Determining the required thermal

output:
Fumace pressure

QN
QF
hK

QF = Thermal output (kW)

QN = Rated boiler capacity (kW)
hK = Boiler efficiency (%)

---- Gas-pressure drop

characteristics of burner head
for natural gas
Hun = 9.9 kWh/m3

Thermal output QF

0211 / 13 010 616A / 121 973 3

Survey

Dimensions

1 Solenoid valve (return oil) 9 Gas connection 17 Inspection glass

2 Oil pressure pump 10 Connecting flange 18 Burner housing
3 Return oil 11 Insulating padding 19 Air pressure monitor
4 Suction oil connection 12 Burner tube 20 Air suction box
5 Oil flow controller 13 Flame cup 21 El. servomotor for compound
6 Solenoid valves (supply oil) 14 Electric motor control
7 Oil pressure monitor, supply oil 15 Flame monitor 22 Compound control
8 Electrical connection 16 Ignition transformer 23 Electromagnetic clutch

Boreholes in boiler connecting plate Key

EK = Manufacturer
3 = Size
50 = Performance rating
GL = Natural gas/fuel oil light
R = Modulating, with mechanical
compound control
O = Optimized Air Speed

Burner type Thermal Oil throughput A B C dø Dø Eø Fø Product ID No.

output kW kg/h
EK 3.50 GL-RO 113–465 9.5–39 370 146 156 125 149 220 252 CE-0085AQ0598
EK 3.70 GL-RO 160–700 13.5–59 370 146 156 159 190 270 333 CE-0085AQ0598

Burner type G H J K L M N O P Q R DN
EK 3.50 GL-RO 192 M10 160 370 485 120–300 305 420 280 310 45 R 1½”
EK 3.70 GL-RO 192 M10 220 370 485 120–300 305 445 280 310 45 R 1½”

4 0211 / 13 010 616A / 121 973

Burner functions

Starting function oil

Operating function oil
General safety functions

Starting function oil

As soon as the firing system demands The solenoid valves open and release The compound control system adjusts
heat, the burner control circuit closes the pressurized oil to the nozzle and the return oil flow controller and the
and the program sequence begins. return line. The oil is atomized, mixed linearized air damper and regulates the
with combustion air and ignited. Within oil quantity in combination with the air.
The air damper is closed when the the safety period of 3 seconds a Burner regulation is possible in two
burner is not operating. regular, steady flame must be ways; either 2-stage sliding or, if an
established. appropriate controller is fitted,
The automatic burner control unit After completion of the safety time, modulating. With modulating control,
controls and monitors the starting a flame signal must be transmitted to the burner can operate at any level
sequence. the burner control unit via the UV flame between low load and full load.
The electric servomotor moves the air monitoring circuit. This signal must be The burner is always switched off in the
damper to the full-load position so that maintained until controlled shutdown. low load position. When the burner is
the burner prepurges the combustion The start-up sequence of the burner is idle, the air damper is always closed,
chamber and the flue gas ducts with completed. The burner is operating in thus preventing a cold air stream from
the prescribed quantity of air. Shortly the low-load position. passing through the combustion
after prepurging has started, the air chamber, the heat exchanger and the
failure monitor must switch over to its Operating function oil flue ducts. This reduces the cooling
working position within a predetermined After starting, the load control is loss of the burner to a minimum.
period of time, i.e. the set minimum air activated, which means that the burner
pressure must be reached and has reached its operating position.
maintained until the burner is switched From now on the control unit
off. When the set prepurging time has automatically regulates the burner
elapsed, the air damper is moved to between low load and full load.
low load. Preignition is then initiated Depending on heat requirements, the
and oil is released. electric servomotor receives an OPEN
or CLOSE command from the
controller.

Oil regulation

2-stage sliding Modulating

Full load Full load

Operating position Operating position

Load regulation Load regulation
Release Release
Low load Low load
Solenoid valves/pump/ignition Solenoid valves/pump/ignition

ON OFF ON OFF

0211 / 13 010 616A / 121 973 5

Burner functions

Starting function gas

Operating function gas

Starting function gas Operating function gas

As soon as the firing system demands The electrical burner control allows the After a regular flame has formed, the
heat, the burner control circuit closes burner to be started for safety reasons load control is activated, which means
and the program sequence begins. (depending on various types of gas) that the burner has reached its
A gas valve leakage test is carried with increased load, in order to be operating position. From now on the
out automatically every time the able to return to part-load operation. control unit automatically regulates the
burner is started. Pre-ignition takes place with burner between low load and full load.
The air damper is closed when the subsequent release of gas via the gas Depending on heat requirements, the
burner is not operating. valves. electric servomotor receives an OPEN
The electric servomotor moves the air Within the safety period of 3 seconds a or CLOSE command from the
damper to the full-load position so that regular, steady flame must be controller. The compound control
the burner prepurges the combustion established. After completion of the system adjusts the linear gas nozzle
chamber and the flue gas ducts with safety time, a flame signal must be and the linearized air damper and
the prescribed quantity of air. transmitted to the burner control unit via regulates the gas quantity in
Shortly after pre-ventilation begins, and the flame monitoring circuit. This signal combination with the air. Burner
within a certain time, the low air-level must be maintained until controlled regulation is possible in two ways;
detection system should switch over to shutdown. The start-up sequence of the either 2-stage sliding or, if an
operating mode, i.e. the preset min. air burner is completed. The burner is appropriate controller is fitted,
pressure must be achieved and operating in the low-load position modulating. With modulating control,
maintained until the burner is shut the burner can operate at any level
down. Once the pre-ventilation time has between low load and full load.
elapsed, the air flap is returned to its The burner is always switched off in the
initial-load setting in parallel with the low load position. When the burner is
gas linear nozzle. idle, the air damper is always closed,
thus preventing a cold air stream from
passing through the combustion
chamber, the heat exchanger and the
flue ducts. This reduces the cooling
loss of the burner to a minimum.

Gas regulation

2-stage sliding Modulating

Full load Full load

Operating position Operating position

Load regulation Load regulation
Release Release
Low load Low load
Gas valves/ignition Gas valves/ignition

ON OFF ON OFF

General safety functions

If no flame is established when the The failure is indicated by the lockout The unit restarts automatically when
burner is started (upon fuel release), indication lamp in the reset button. The the gas or power supply returns.
the burner switches off when the safety control unit can be reset immediately Basically, any malfunction will cut off
time of 3 seconds has elapsed (fault after any lockout condition by pressing the fuel supply at once and will also
shutdown). A fault shutdowns also the reset key. The sequence switch will stop the sequence switch with the
effected if the flame is extinguished then move to its starting position and malfunction indicator. The type of
during operation, if the air supply fails prepare the control unit for restarting malfunction is indicated by the
during prepurging. Any flame signal the burner. corresponding symbols (see on page
during prepurging will also produce a If the gas or power supply fails, a 21).
shutdown of the burner control unit. controlled shutdown is effected.

6 0211 / 13 010 616A / 121 973

Burner functions

Compound controller fuel/air

Gas fittings group
Functional diagram

Compound controller fuel/air Setting of the quantity of oil Gas fittings group
The compound control system, which During operation with oil, the oil which The gas fittings group is determined
alters the fuel and air quantities evenly is not used for combustion is returned according to customer-specific
and continuously, ensures that to the the tank from the nozzle by the conditions.
combustion values are maintained at return oil flow controller 11.
almost identical levels across the entire This flow controller continuously adjusts Important criteria are:
control range. the amount of return oil in relation to · Burner capacity
The infinitely adjustable electrical drive the air. · Furnace backpressure
system operates the combined To achieve an optimum ratio of air and · Gas pressure drop of the burner
regulator as per the amount of heat fuel across the entire control range, the head
required. air damper must be positioned correctly · Gas pressure drop of the gas fittings
This regulates the quantities of air and via an adjustable steel segment and
fuel by means of the air flap and gas ball-bearing ratchet. The total gas pressure drop must
linear nozzle. always be smaller than the available
The sliding two-stage regulating system Linearization gas flow pressure.
allows only the end-points of the Air regulation on the suction side is
adjustment range, and the part- and effected by the linearized air damper. Important
full-load points to be approached This ensures a wide adjustment range Only gas fittings approved by official
smoothly. This prevents abrupt startup and a high combustion efficiency even burner testing may be used.
and shutdown with larger amounts of at low loads.
fuel. Non-stepped regulation allows the
system to be adjusted to any part of the
setting range. The difference between,
two-stage sliding and non-stepped
burners lies in the electrical control of
the burner. The mechanical system
remains unchanged.

Functional Diagram
A Gas connection
B Supply oil connection
C Return oil connection
D Combustion air inlet

1 Gas shut-off valve

2 Gas filter
3 Test burner (option)
4 Gas pressure monitor*
5 Gas pressure regulator
6 Gas valve
7 Leakage detector (option)
8 Pressure gauge with shutoff valve
9 Compound control segment
10 Gas regulator
11 Oil flow controller
12 Air regulator
13 Return nozzle rod
14 Oil pressure pump
15 Dirt trap
16 Solenoid valve, supply oil
17 Safety solenoid valve
18 Solenoid valve, return oil
20 Oil pressure monitor*
21 Combustion air blower

* If the burner design complies with

TRD 604-72h, the pressure
monitors must either be tested for
“special design” or two monitors
must be installed.

0211 / 13 010 616A / 121 973 7

Burner functions

Functional sequence of burner control units LFL 1…/ LGK 16…

The burner control units LFL 1… LGK

16… are designed for controlling and
monitoring burners with multi-stage
or modulating control systems.
For a detailed functional description
of the burner control units, including
technical data and planing information,
refer to
LFL 1…-7451 E
LGK 16…-7785 E

Functional diagramm
Modulating LFL 1…/LGK 16…
A = Start command
B–B = Interval for flame formation
B = Burner in operating position
B–C = Burner operation
(heat generation)
D = Controlled shutdown
R Temperature or pressure
controller
G Blower motor
Z Ignition transformer
BV Fuel valve (s)
LR Load controller
LK Air damper
RV Continuously variable fuel valve
(here: gas control valve)
FS Flame signal

t1 Preventing time
t2 Safety time
t3 Preignition time
t4 Release of fuel valve BV
t5 Release of load controller LR
t11 Opening time of air damper
t12 Closing time of air damper

8 0211 / 13 010 616A / 121 973

Installation

Mounting the burner to the heat generator

Electrical connection

Mounting the burner to the heat

generator
To mount the burner to the heat If necessary, release the screw 1 to
generator, prepare the connecting plate displace the flame cup for correct
according to the dimensions given on adjustment of the burner head.
page 4.
The movable clamping flange for
connection is mounted at the front of
the burner tube.
· Loosely attach the burner to the heat
generator by means of the clamping
flange
· Adjust the burner tube length in the
furnace by inserting the burner
· First tighten the flange clamping
screws, then the fixing screws.

Burner tube insertion depth Boiler inspection glass cooling

– For three-pass boilers: To keep the boiler inspection glass cool
Combustion chamber front edge and clean, a cooling line may be
flush with brickwork connected to connection 2 R¼”.
– With reverse-type boiler: The cooling line can either be a hose or
as per drawing shown here a copper pipe. A hose union is
enclosed with the burner.
A = Front of boiler to turning edge of To connect a copper pipe, a suitable
second pass clamping ring connection is required.

min. insertion depth

Electrical connection Disassembling the electric module

Electric wiring of the burner and gas · Set the main switch to Off, remove
fittings must be carried out by an the fuse
authorized electrician according to · Release the lock nut 4.
the enclosed wiring diagram. · Carefully remove the electric module.
For cable connection, ensure the Caution!
following: Never apply voltage to the electric
· Provide sufficient length of cable so module after disassembly.
that the burner and the boiler door After making the connections, check all
can be opened system components for correct wiring.
· Do not install the sensor lead in the Start the motor for a short time to check
multiconductor cable. the sense of rotation.

The electric module can be removed for

connection, replacement or adjustment
of components.
2 Connection for inspection glass
cooling
3 Flame monitor
4 Lock nut
5 Pushbutton Higher/Lower
6 Service pushbutton
7 Terminal strip

0211 / 13 010 616A / 121 973 9

Installation

Gas connection

Gas Connection Gas supply pressure Leakage test

For installation and start-up of the gas To ensure optimum burner The gas conduit upstream of the burner
conduits and fittings, observe the performance, a minimum gas supply gas fittings group must be installed,
applicable regulations of the pressure is required upstream of the tested for tightness, vented and
supervisory authorities and institutions burner gas fittings. certified by the installing company in
of your country. accordance with applicable guidelines.
Minimum gas supply pressures The tightness of the screw and flange
Gas properties CH I2H G20 = 20 mbar connections must also be checked. The
Before installing the unit, ask your gas DE I2ELL G20 = 20 mbar leakage test is to be carried out under
supply company for the following AT I2H G20 = 20 mbar pressure with approved foaming agents
information: which do not cause corrosion.
Observe the installation and mounting The results of the leakage tests
1. Gas type (gas group I, II, III) instructions of the components performed on steam boilers also
2. Calorific value Hun = kWh/m3 manufacturers (enclosed with the require certification.
(kJ/m3) fittings).
3. Maximum CO2 content of the flue The dimensions of the gas conduit Venting
gas depend on the throughput and the Note. Before starting the burner or after
4. Gas supply pressure and static available pressure; the conduit must be repair work, the complete gas supply
pressure installed so that the distance to the line and the gas fittings group must be
burner and the pressure drop are kept vented to the outside (by means of a
Checking the gas type to a minimum. hose).
Before connecting the burner to the gas When determining the nominal width
supply line, check whether the gas type DN of the gas fittings group, consider Never vent the gas conduit into the
and the burner type match (see type the flue-gas side resistance of the heating room or combustion
plate on the burner). The burner type heat exchanger as well as the gas chamber!
and the gas type must coincide. pressure drop of the burner and the
fittings group. The test burner can be used for
G = Natural gas determining the presence of an
Gas fittings group inflammable mixture.
The gas fittings group may be
connected directly to the gas supply Support
line. The order and the direction of The gas fittings group must be
flow (arrow on the housing) of the supported from below by means of the
fittings must be observed. Remove telescope support or a similar device
dirt and foreign objects from the fittings after or even during installation (e.g. at
and connection pieces prior to the filter and/or valve).
installation and start-up. To ensure
good start-up conditions, the Point of separation
distance between the burner and the To facilitate maintenance of the boiler
gas valve must be kept to a (combustion chamber), a point of
minimum. separation (flat sealing) should be
provided for swivelling the boiler door.

10 0211 / 13 010 616A / 121 973

Installation

Oil connection
Oil pressure regulation (supply oil)

Oil connection Oil filters Mounting options

Hoses are used for connecting the To protect the oil pressure pump and · Two-pipe installation
oil pipes and the valve system. The the hydraulic system, a suitable filter · Dynamic pressure operation via vent
hoses must be properly installed must be installed upstream of the assembly
(suspended if possible) to avoid kinking pump.
and the risk of fracture. For the
dimensions of the supply and return
lines from the valve system to the tank,
please consult the relevant technical
data sheets.

Pump type for Connecting measuring instruments

EK3.50 GL-RO · Vacuum gauge for supply oil to
connection 15
· Oil pressure gauge to connection 13

Supply oil regulation

The supply oil pressure is regulated by
the pressure regulator incorporated in
the pump. The correct setting is approx.
20–28 bar, depending on burner
capacity and make of nozzle.
The pressure regulator is adjusted by
turning the screw 11.
Fill the pump with oil before starting it
for the first time.
To protect the pump, the oil pressure
regulator is delivered with the pressure
removed.
Pump type for When starting the burner for the first
EK3.70 GL-RO time, slowly increase the oil pressure to
the required rating (20–28 bar).

Vacuum test (suction line)

The maximum permissible vacuum
is 0.4 bar. A higher vacuum will cause
the heating oil to vaporize and may
cause malfunctions.
With dynamic pressure operation,
the oil pressure at the pump must not
exceed 0.5 bar.

R Return line connection

S Suction line connection

11 Supply oil pressure regulator

12 Screws, pump cover
13 Pressure gauge connection
(supply oil)
14 Pressure output
15 Vacuum gauge connection
(suction line)

0211 / 13 010 616A / 121 973 11

Start-up

Burner head factory settings

Factory settings Important

The factory settings given below are Check the settings by means of the
standard values and refer to about 80% table prior to start-up. To check,
of the maximum burner capacity. remove the nozzle assembly (see
Readjustment may be necessary servicing the burner in maintenance).
depending on local circumstances, flue
gas analysis and combustion
behaviour.

Burner head
1 Oil connection, min. low load
1a Oil connection, max. full load
2 Gas control nozzle
3 Flame cup
4 Nozzle rod
5 Swirl plate
6 Baffle plate holder
7 Return nozzle
8 Baffle plate
9 Ignition electrodes

Burner type Factory setting in mm

A B C D E H K L M
dinal adjustment
Electrode gap

max. longitu-

scale plate 0
Baffle plate/

Baffle plate/

gas nozzle
nozzle rod

nozzle rod
Electrode/

Electrode/
swirl plate
Gas tube/

flame cup

Gas tube/
Oil filler/
axis

EK 3.50 GL-RO 35 0 4 22 3 0 30 10 8

EK 3.70 GL-RO 35 0 4 22 3 0 30 7 8

12 0211 / 13 010 616A / 121 973

Start-up

Nozzle selection, type A 4 45°

Return nozzle
The Bergonzo nozzle A4 is a return
nozzle which is suitable for the
continuous oil regulation of oil
atomizing burners.
It is designed for a maximum control
ratio of 1:4. Throughput is regulated by
changing the return oil pressure while
the supply oil pressure is kept at a
constant level.
Prior to start-up, compare the nozzle
size with the required performance and
change the nozzle, if necessary.

Supply oil pressure 20 bar. Control ratio max 1:4 Nozzle size lg/h
Oil flow kg/h

Return oil pressure (bar)

0211 / 13 010 616A / 121 973 13

Start-up
Burner

Gas, oil

Burner Check the performance of the burner

The following checks must be · Ensure unobstructed flue gas paths program sequence before fuel is first
performed before the system is first and adequate fresh air supply. released: If gas is used, check the
put into operation: · Burner in starting position; air damper gas section as follows:
· Observe the operating instructions of closed. · Make sure that the gas shut-off valve
the boiler manufacturer; the boiler · Burner control unit reset and in start- of the valve group is closed.
must be installed ready for operation. up position. · Bridge the gas pressure monitor (see
· Fill the heating system with sufficient wiring diagram).
water. · Start the burner and check for correct
· Check the entire system for correct sequence of the start-up program:
electric wiring of all components and 1. Blower
fittings. 2. Air damper in preventing position
· Check the sense of rotation of the 3. Air pressure check
blower motor. 4. Air damper in start position
· Check the settings of the temperature 5. Ignition spark
or pressure controllers, limiters, 6. Valves open
safety devices and electric limit 7. Fault shutdown after safety
switches. period (see burner control unit)
· Ensure adequate gas supply · Remove the bridge from the gas
pressure. pressure monitor, unlock (reset) the
· Make sure that there is oil in the tank, burner control unit.
the lines and the oil pump and that
the right oil nozzle is fitted.
· Carry out a leakage test on the gas
elements.
· Vent the fuel lines so that there is no
air in the lines.

Start-up with gas Start-up with oil

Note Open all shut-off valves at the oil
Adjust the gas section before supply system.
adjusting the oil section. Set the fuel · Fill the pump with oil.
selector switch to Gas. · Set the fuel selector switch to “Oil”.
· Connect the measuring instruments · Connect the pressure gauges for
for gas chamber pressure 1 and air return and supply oil.
pressure (connect to inspection glass · Connect the pressure gauge for the
cooling). suction side of the pump.
· Connect the measuring instruments
for the flame monitoring current. Venting
· Open the gas shut-off valve upstream Switch on the burner for a short while
of the valve group; check the gas and check whether the sense of
pressure at the pressure gauge. rotation of the motor is correct. Loosen
· Set the service switch to position 1. the oil pipe union at the pressure output
· Set the Manual/Automatic selector of the pump, switch on the burner and
switch to Manual. run the burner until bubble-free oil
If applicable, wait for the leakage test of emerges. Then reconnect the oil pipe.
the gas valves to complete.
If the valves are leaky, the burner start- Important
up sequence will stop. The hydraulic system has been filled
The burner starts according to the with test oil at the factory. This may
burner start-up sequence. cause ignition problems when starting
the burner for the first time.
To protect the pump, the oil pressure
regulator is delivered with the pressure
removed.
When starting the burner for the first
time, slowly increase the oil pressure to
the required rating.

14 0211 / 13 010 616A / 121 973

Adjustments

Adjustment sequence, gas

Adjusting the gas throughput

Adjustment sequence Adjusting the gas throughput

· Set the fuel selector switch to “Gas” · Gradually adapt the combustion air The gas throughput is adjusted by
· Set the selector switch to “Manual” (suction side) to the gas throughput means of the gas linear injector in the
· Use the service switch to switch on · Switch off the burner burner head. The nozzle can be
the burner · Set the selector switch to Auto opened and closed continuously by
· Adjust the gas throughput (low load) · If in stock, adjust the electric means of the longitudinal adjustment
· Move the “Higher/Lower” switch to modulating control (see lever.
full load documentation RWF 40) At the same time, longitudinal
· Adjust the gas throughput (full load) adjustment optimizes the air speed on
the pressure side of the burner head by
· Move the “Higher/Lower” switch to
means of the baffle plate and the flame
low load
cup (OAS).

Gas pressure regulation Note

The gas pressure is adjusted by The gas output pressure (gas control
changing the spring pressure which pressure) is always lower than the gas
acts on the control diaphragm. entry pressure but higher than the
total pressure drop of the system.

Gas throughput for low load

· Burner in low-load position
· Release the counternut 2
· Use the turnbuckle sleeve 1 to move
the gas nozzle towards the open or
closed position
· Tighten the counternut 2 after
adjustment
· Mark the low-load position on the
scale 3

Gas throughput for full load

· Move the burner to full load
· Use the control path adjustment to
move the gas nozzle towards the
open (+) or closed (-) position
· After adjustment, move the burner to
low load and reset the low-load
position as marked on the scale
(turnbuckle sleeve [1]).

0211 / 13 010 616A / 121 973 15

Adjustments

Combustion air

Combustion air (pressure side)

The distance “H” is given automatically
by the control path “H1” of the gas
nozzle.
Normally, the factory-set position of the
baffle plate requires no further
adjustment. If necessary, minor
corrections can be made for optimum
combustion
· by moving the baffle plate in the
baffle plate holder
· and/or by moving the flame cup

1 Gas linear injector

Low load Full load 2 Baffle plate
3 Flame cup

Combustion air (suction side)

The combustion air on the suction side Make sure that the control curve of the
is set by means of the air damper which cam strip rises evenly. The segment
moves on an adjustable cam strip. path should be fully utilized at each
· Burner in full-load position burner load level.
(selector switch to “Manual”) After adjustment, move the burner
· Gradually move the “Higher/Lower” again to each load level from full load to
switch to low load and perform low load and repeat the measurements.
combustion gas measurements
· If necessary, readjust the cam strip
5. To do this, release the «external»
hexagon socket screws 4 by ¼ turn
and adjust the cam strip using the
internal screws 4a (5 mm hexagon
socket screws)

Turn clockwise = less air

Turn anti-clockwise = more air
4 Adjusting screws
5 Cam strip

16 0211 / 13 010 616A / 121 973

Adjustments

Oil flow (return oil regulation)

Oil flow
The oil flow is adapted to the air flow
set for operation with gas. Adjustment
is made by means of the regulating
steel segment 5.
To limit the adjustment range, set the
limit switches of the electric
servomotor. Separate limit switches are
available for operation with gas and oil.

Return oil regulation

· The flow controller 2 is used for
adjusting the regulation of the return
oil pressure.
· Connect the return oil pressure
gauge to the measuring point 1.

Minimum return oil pressure

Burner in low-load position
· Release the lock nut 3.
· Adjust for desired return oil pressure
using the set screw 3a.
· Retighten the lock nut 3.

Maximum return oil pressure

The return oil pressure is adjusted by
means of the regulating segment 5.
· Manually bring the burner to full load.
· Check return oil pressure, compare
with nozzle chart, measure nozzle
throughput, if possible.
· Readjust, if necessary. Release the
hexagon socket screws 4 a quarter
turn using a 6 mm Allen key. The
locking screws 4a are now accessible
for adjusting the steel segment with a
5 mm Allen key.
· Retighten the screws 4 after
adjustment.

0211 / 13 010 616A / 121 973 17

Adjustments

Electric servomotor
Adjusting the limit switches

Scope
The electric servomotors of the
SQM5... series are designed for
operation with gas and air dampers in
oil and gas burners of medium to high
capacity. They are intended primarily
for controlling the gas and combustion
air flow as a function of the load.
· in conjunction with controllers with
three-level or continuous
(e.g. 4...20 mA) control signals
or
· directly by the burner control unit

Technical documentation
SQM5...L&G 7815 D

Limit switches
The limit switches are actuated by trip
cams which are factory-set to standard
values.

1 Limit switch, full load oil

2 Limit switch, air damper closed
3 Limit switch, low load oil
4 Limit switch, low load gas
5 Limit switch, full load gas
6 Limit switch, start load gas
7 Limit switch, preventing
8 Limit switch, unassigned
9 Scale, red section for right-handed
rotation, black section for left-
handed rotation (the transmission
is set to right-handed rotation with
these burner types)
P Potentiometer module for
additional control functions

Disconnecting mechanism
The drive shaft and camshaft can be
disconnected separately.
A = drive shaft disconnecting
mechanism
N = camshaft disconnecting
mechanism

Caution
Do not disconnect the drive shaft and
the camshaft at the same time.

18 0211 / 13 010 616A / 121 973

Adjustments

Oil pressure monitor

Air pressure monitor

Oil pressure monitor Oil pressure compensation

With burners fitted with return nozzles, To compensate for oil pressure
the oil pressure monitor is used to variations, a throttle screw or capillary
monitor the supply and return oil tube can be installed in the connecting
pressure. sleeve 2.
Depending on the burner model,
pressure monitors may be mandatory Setting the switching pressure
only in the return line or both in the To adjust the switching pressure, pull
return and supply lines. The cut-off off the adjusting knob 1 and reattach it
pressure is factory-set and does not upside down.
normally require adjustment. After adjustment, attach the adjusting
knob in its original position for safety
reasons.

Factory settings

Type Cut-off pressure Application

DSA 43F 001 6 bar Return line according to DIN

DSA 70F 001 40 bar Supply line with separate oil pump

DSN 46F 001 6 bar Return line according to TRD / 72 h

DSB 58F 001 25 bar Supply line according to TRD / 72

Air pressure monitor Approvals

The air pressure monitor is used to The pressure monitor complies with
monitor the pressure of blower burners. DIN 3398, Part 2, and is DIN-DVGW
The pressure monitor DL 50 A is approved.
suitable for making, breaking and Other approvals in major gas
switching a contact when the actual consumption countries.
pressure deviates from the preset
values. It can be used as an
overpressure, negative pressure or
differential pressure monitor for air and
non-aggressive gases, but not for the
gases described in the DVGW
worksheet G 260/I.

Determining the prepurging Checking the performance of the

differential pressure and adjusting switches
the differential pressure monitor The switches can be checked for
· Burner in preventing phase proper performance by means of test
· Measure pressure at measuring keys.
outlet 2
· Measure vacuum at measuring Key 4 tests the vacuum side of the
point 3 blower
· Add up the measured pressures Key 1 tests the overpressure side of
· Set the scale to 90% of the the blower
calculated value

0211 / 13 010 616A / 121 973 19

Adjustments

Flame monitoring
Sensor current measurement

Burner control unit LFL 1... Flame monitoring with UV detector Measuring the UV current with
UV monitoring with QRA 2... This monitoring method uses the QRA 5
UV radiation of hot flame gases for For precise measurement of UV
obtaining the flame signal. currents, we recommend using the test
The radiation detector is a UV-sensitive unit KF 8832.
tube which is constantly under voltage If you use a standard measuring
and which consists of two electrodes; instrument (microammeter) to
the tube fires when it is exposed to light measure the UV current, we
of the spectral range between recommend proceeding as shown in
190...270 nm, thus transmitting a the illustration. Integrate a capacitor
current to the flame signal amplifier. C = 470 µF, 15 V (or higher electric
The UV tube does not react to strength) into the measuring
afterglowing chamotte in the furnace, to connections.
sunlight, daylight or heating room
illumination. Measuring instrument:
The tube has a service life of about 100 µA/Ri = 3 kW
10,000 hours at ambient temperatures
of up to 50°C; higher ambient Connect the measuring instrument
temperatures will considerably reduce between the burner control unit and the
Burner control unit LGK 16... the tube life.
UV monitoring with QRA 5... UV flame detector QRA 5...
The tube is tested automatically in (terminal 22 (-), terminal 5 (+).
conjunction with the burner control unit
during interruptions of operation and Ensure correct polarity!
with increased supply voltage.
If the tube misfires, a lockout will be Aligning the UV Detector QRA 5...
effected immediately at the next start. The fixing flange can be moved along
Burners designed for continuous the feeler tube and allows precise
operation or intermittent operation at alignment of the detector window with
strong heat for more than 24 hours the incident UV radiation.
(e.g. multi-boiler cascade systems) or
burners which are operated with steam Note
boilers must be equipped with the Terminal 22 must be earthed at all
burner control unit LGK 16... and the times!
corresponding self-checking flame
detector (QRA 5...). Cleaning the detector
For a detailed technical description, The UV detector window must be
specifications and planning information, cleaned at regular intervals.
see Burner Control Units Keep the window free from dust.
LFL 1... No. 7451 D If cleaning is unsuccessful, replace
LGK 16... No. 7785 D the UV tube.

Sensor currents
Burner Minimum Maximum
control unit * See also specifications of burner
control unit LFL 1.../LGK 16...
Monitoring with UV with UV ** See data on device KF 8832
type for sensor current measurement
*LFL 1… 70 µA 630 µA
*LGK 16… ** **

Recommended measuring range:

UV monitoring 0–1000 µA

20 0211 / 13 010 616A / 121 973

Maintenance

Troubleshooting

If a malfunction occurs, check first If you find that the malfunction has not Do not press the reset key for longer
whether all requirements for proper been caused by one of the above than 10 seconds.
operation have been met. mentioned items, check the burner Closely watch the subsequent start-up
functions carefully. program.
Check whether: The possible cause can be detected
1. Fuel is available, gas is supplied, gas Situation: quickly by means of the lockout
pressure is adequate, there is enough The burner is found out of action in the indicator on the burner control unit and
oil in the tank, and the fuel selector lockout mode. Reset the burner control by watching the sequence of the start-
switch is set correctly? unit with the reset button and start the up and operating program.
2. The power supply works properly? burner.
3. All control and safety features, e.g.
temperature controller, safety limiter,
low-water cutout, electric limit switches
etc. work properly and are adjusted
correctly?

Control program under fault

conditions and lockout indication w No start because the CLOSED 2 Fault shutdown because no
signal has not been supplied to flame signal is present on
terminal 8 by the limit switch for completion of the 2nd safety time
air damper CLOSED; or because (for interrupted pilot burners, the
a contact has not been closed flame signal of the main flame –
between terminals 12 and 4 or 4 not applicable for this burner
and 5; or because the contacts of type).
all control and safety units of the
control loop are not closed (e.g. I Fault shutdown because the
gas or air pressure monitor, flame signal has failed or
temperature or pressure monitor, because an air pressure failure
temperature or pressure has occurred during burner
controller). operation.

x Start aborted because the OPEN w Fault shutdown on completion of

signal from the limit switch for air the control program sequence
LFL 1… / LGK 16… damper OPEN has not been due to inadmissible stray light
a–b Start-up sequence supplied to terminal 8. Check and (e.g. flame not extinguished,
adjust the corresponding limit leaky fuel valves), or due to a
b–b’ For some time variants: switch (see page 11). faulty flame signal (e.g. defective
Idle steps of the sequence flame monitoring circuit). Also see
switch up to automatic P Fault shutdown because the air Flame monitoring.
shutdown after burner start-up pressure signal has not been
(b’= operating position of the received at the start of the air If a fault shutdown occurs at any
sequence switch). pressure check. Any air other point between start and
pressure failure after this point preignition which is not marked by a
b(b’)–a Post-venting sequence after in time will also produce a fault symbol, the cause is usually a
controlled shut-down. In start shutdown! premature, i.e. faulty, flame signal.
position “a” the sequence
switch is deactivated z Fault shutdown because of a Resetting of the control unit after a
automatically or initiates defect in the flame monitoring fault shutdown can be effected
another burner start-up circuit. immediately by pressing the reset key.
immediately (e.g. after fault After resetting (as well as after
clearance) v Start aborted because the eliminating a malfunction which caused
position signal for the air damper a shutdown, or after a power failure),
l Duration of safety period for in low-load position has not been the sequence switch will always returns
single-tube burners. supplied by the limit switch to to its starting position, supplying
terminal 8. Check and adjust the voltage to the terminals 7, 9, 10 and 11
ll Duration of safety period for corresponding limit switch for low only, as determined by the control
interrupted pilot burners load. program. Only then will the control unit
(not applicable for these burner initiate another start-up sequence of the
types). 1 Fault shutdown because no burner.
flame signal is present on
If a malfunction occurs, the fuel completion of the 1st safety time.
supply is always interrupted
immediately. Simultaneously, the Any flame signal failure occurring
sequence switch and the lockout after completion of the safety time
indicator stop. The symbol above the will also produce a fault shutdown!
reading mark indicates the type of
malfunction:

0211 / 13 010 616A / 121 973 21

Maintenance

Servicing the burner

Burner installations should be 1. Disassemble the nozzle and 12. Inspect the boiler components
checked once a year. According to check it. Clean the nozzle filter. and insulation and replace, if
DIN 4755, 4756, “to ensure the 2. Clean the filters and strainers. necessary. Check the boiler for
troublefree operation, performance, 3. Check the ignition electrodes and cleanness.
safety and efficiency of the the ignition spark; readjust, if 13. Clean the burner inside and
installation, the user should have the necessary. outside.
installation checked once a year by a 4. Perform pressure and vacuum 14. Check the combustion and make
representative of the manufacturer tests to check the oil pump. flue gas measurements:
or other qualified personnel. 5. Check the gas valves for · Adjust fuel throughput
The entire installation is to be tested tightness and cleanness. · Heating room temperature
for faultless performance, and 6. Check the hydraulic oil system for (suction temperature)
defects are to be repaired without tightness. · Flue gas temperature
delay. It is expedient to carry out an 7. Check all electrical connections. · Furnace pressure/pressure in
inspection in addition”. 8. Clean the UV flame detector. the flue gas tube
Inspection should include the 9. Check the pressure monitors for · CO2/O2 content
following items: proper adjustment and · CO measurement, soot test
performance.
· Measure the UV current
10. Check the control units for
15. Enter the measured values in the
performance, adjustment and
test certificate.
safety times.
11. Check the burner head setting.
Check the flat O-ring seal
between the gas and burner tube
for tightness.

Removing the Gas Tube

For replacement or adjustment of the · Release the fixing screw 2 of the gas
baffle and ignition arrangement, the tube and pull off the gas tube
complete gas tube must be removed backwards.
from the burner pipe. Proceed as Be careful with the baffle plate !
follows:
· Disconnect the power supply; set Before reassembly, check the seal and
main switch to OFF. replace it, if necessary.
· Close all shut-off valves upstream
of the burner.
· Remove the cover from the housing.
· Disconnect the oil return and supply
lines at the scale plate.
· Disconnect the UV cell.
· Disconnect the ignition cables 1.

22 0211 / 13 010 616A / 121 973

0211 / 13 010 616A / 121 973 23
 ELCO Klöckner
Heiztechnik GmbH
D - 72379 Hechingen

Fabriqué en EU. Made in EU. Hergestellt in EU.

Document non contractuel. Non contractual document. Angaben ohne Gewähr.

24 0211 / 13 010 616A / 121 973