elco Firebird FB 4 R LN User manual

FB 4 R LN
LOW NOx
LIGHT OIL BURNER
Instructions to Assembly,
Commissioning and Maintenance
EN
Before installing and using the burner, read this manual carefully
and keep it close to the burner.

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Dear Client,
We would like to thank you for having chosen a FIREBIRD product.
The model chosen by you is a high-performance product with an advanced technological
conception, high reliability and excellent construction quality.
We advise you to entrust the running and maintenance of this appliance to know qualied
professionals, and also to use only original spare parts when needed.
This manual contains important guidelines and suggestions which should be complied with in
order to obtain a simple installation and the best possible use of the appliance.
RANGE
This manual refers to the following products:
BURNER MODEL FIREBIRD CODE ELCO CODE
FB 4 R 20 LN 414949 3146467
FB 4 R 26 LN 414950 3146468
FB 4 R 35 LN 414951 3146469
BURNER DESIGNATION
FB 4 R 20 LN
20 Boiler nominal power (max)
EMISSION
LN
Low NOx emissions (NOx < 120 mg/kWh according to European
Commission Regulation No 813/2013 and to pr EN267/2016 Class 4)
FB 4 Burner Series
R Light oil
BOILER TYPE

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CONTENTS
1 SAFETY 5
1.1 Overview ................................................................5
1.2 Intended use..............................................................5
1.3 Symbols used.............................................................6
1.3.1 Key to symbols used in the manual ......................................6
1.3.2 Other symbols.......................................................6
1.4 Requirements for personnel or operators........................................7
1.5 Primary hazards ..........................................................7
2 GENERAL 8
2.1 Burner description .........................................................8
2.2 Supply ..................................................................8
2.3 Identification ..............................................................9
2.4 Structure................................................................10
2.4.1 Structure of the burner ...............................................10
2.4.2 Structure of the combustion head .......................................12
2.5 Control box..............................................................13
2.6 Operating logic (Two-pipe system)............................................13
2.6.1 Operating function...................................................13
2.6.2 Controlled shutdown .................................................14
2.6.3 Safety function .....................................................14
3 TECHNICAL DATA 15
3.1 Dimensions and weights ...................................................15
3.2 Technical data ...........................................................16
3.3 Electrical diagram.........................................................17
4 INSTALLATION 18
4.1 Safety during assembly ....................................................18
4.2 Installation area ..........................................................19
4.2.1 Flue gas system ....................................................19
4.3 Assembly tools ...........................................................19
4.4 Preliminary checks before mounting the burner..................................20
4.5 Burner assembly .........................................................21
4.6 Oil systems..............................................................23
4.6.1 Hydraulic diagram ...................................................24
4.6.2 Oil pump ..........................................................24
4.6.3 Oil feed and suction line
with two-pipe system..............................26
4.7 Electrical connection ......................................................27
4.7.1 Electrical connection to the boiler .......................................27
4.8 Removing the burner ......................................................28

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5 COMMISSIONING 30
5.1 Safety during commissioning ................................................30
5.2 Checks before commissioning ...............................................30
5.3 Factory pre-setting ........................................................31
5.4 Combustion adjustment ....................................................31
5.4.1 Air flap position .......................................................32
5.5 Adjusting burner output ....................................................32
5.5.1 Burner start ........................................................33
5.5.2 Burner adjustment...................................................33
5.6 Oil pressure setting .......................................................33
5.6.1 Oil pressure setting ..................................................33
5.6.2 Checking negative pressure ...........................................33
5.6.3 Cleaning the pump filter ..............................................33
5.6.4 Check pump rotation.................................................34
5.7 Commissioning record .....................................................35
5.7.1 Setting and values recorded ...........................................36
6 MAINTENANCE 37
6.1 Safety during maintenance..................................................37
6.2 Important components for safety .............................................38
6.2.1 List of parts typically subject to wear ....................................38
6.3 Removing the burner ......................................................39
6.4 Burner maintenance.......................................................42
6.4.1 Cleaning and replacing combustion head components ......................42
6.4.2 Diffuser position check ...............................................43
6.4.3 Combustion head position check .......................................45
6.4.4 Electrode position check ..............................................45
6.4.5 Replacing the coil ...................................................46
6.4.6 Replacing the capacitor ..............................................47
6.4.7 Cleaning the internal rotor.............................................47
7 TROUBLESHOOTING 49
7.1 Combustion performances ..................................................49
7.2 Fault diagnosis and repair ..................................................49
7.3 Troubleshooting diagram ...................................................50
8 MANUFACTURER CERTIFICATE 52
8.1 Manufacturer Certificate / EU Design Conformity Declaration .......................52
9 APPENDIX 53
9.1 Use of bio fuel blends......................................................53
9.2 Important advice for the use of bio fuel blends...................................53
9.2.1 Introduction ........................................................53
9.2.2 General instructions and information ....................................53

SAFETY
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1 SAFETY
1.1 Overview
These instructions for the installation, commissioning and maintenance of the burner are for use
by technicians from professional heating companies that are qualied to carry out these activities.
The instructions contain indications and information on how to move, handle, activate, adjust,
maintain and remove the appliance and how to dispose of the components at the end of the their
useful life.
The instructions must be followed and all applicable legislation complied with in order to ensure
safe working conditions.
This manual should be stored near the product and made available to all operators involved in
its use.
1.2 Intended use
The burner is designed to act as a heat source for heating and DHW generation systems in which
water is the heating uid.
Any other or wider application is outside of the specied intended use.
To avoid risks, the burner should only be used:
–for its specically intended use
–under the appropriate safety conditions
–following the instructions for installation, commissioning and maintenance
–in compliance with the max. and min. operating values
–in compliance with the required maintenance activities
–immediately repairing any malfunctions that could compromise safety
–maintaining all notes and notices applied to the product so that they remain legible over time
the burner cannot be installed outdoors, unless installed in a boiler specically designed for that
use. If installed outdoors, climatic conditions could cause direct damage to the burner due to the
presence of water or frost or cause the components to overheat.

SAFETY
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1.3 Symbols used
1.3.1 Key to symbols used in the manual
DANGER
Maximum danger. Indicates operations that cause serious injury, death or long-term health
risks if performed incorrectly.
DANGER
Indicates a dangerous situation that could cause serious injury, death or long-term health risks,
caused by electricity, if handled without due care or incorrectly.
WARNING
Indicates operations that could cause serious injury, death or long-term health risks if performed
incorrectly.
PRECAUTION
Indicates potentially dangerous situations and operations that could cause damage to the device
or things and minor injury to persons, if handled without due care or performed incorrectly.
CAUTION
Indicates operations that could cause damage to the device or nearby things.
IMPORTANT INFORMATION
This symbol indicates important information that you must bear in mind.
1.3.2 Other symbols
DANGER FLAMMABLE MATERIAL
Indicates a dangerous situation that could cause serious injury, death or long-term health risks,
caused by the presence of ammable substances near the equipment, if handled without due
care or incorrectly.
CAUTION
Indicates potentially dangerous situations, caused by the presence of surfaces at high
temperatures that could cause minor injuries, or burns, if handled incorrectly.
PERSONAL PROTECTION
Several symbols are used to remind operators of the need to use all the personal protective
equipment required by applicable legislation during all installation, commissioning and
maintenance operations.
ENVIRONMENTAL PROTECTION
Reminds operators of the need to apply a suitable recycling procedure to replaced components.
ENVIRONMENTAL PROTECTION
Reminds operators of the need to deliver the product or its components to a suitable separated
waste collection centre at the end of its working life.
DANGERDANGER
WARNING
PRECAUTION
CAUTION

SAFETY
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1.4 Requirements for personnel or operators
CAUTION
It may be hazardous to assign activities to personnel that are not sufciently qualied. It may
harm the operators themselves if they perform manoeuvres or operations incorrectly, with a
serious impact on personal safety, things and property.
CAUTION
Installation, commissioning and maintenance activities must only be carried out by the personnel
of dedicated heating companies specically qualied to perform these tasks.
CAUTION
Operators should explain to the proprietor and person responsible for the domestic heating
system the burner is installed on, the importance of ensuring good inow of combustion air
and combustion product evacuation. They should also highlight that no modication should be
made to the heating system (comprised of air intake, burner, boiler and ue pipe) that could
alter the correct operation of the system.
1.5 Primary hazards
The following indications refer to “residual risks”, which must be highlighted for the full understanding
and responsibility of the proprietor, users and operators.
These risks derive from risk analyses carried out by Research and Development staff as required
by European Standard EN 267 and applicable directives (Machine directive, LVD, EMC).
DANGER
Danger of death!
-Contact with live electrical components may cause serious incidents.
-Only professionally-trained and qualied personal can operate on the electrical system.
-Before any operation, switch off the power supply to the system by operating the main switch.
Check there is no power and ensure restart is impossible.
-In the event of damage to the electrical insulation on the product, act immediately to restore
the correct level of insulation.
CAUTION
Hot surfaces - Risk of burns!
-Contact with components at high temperatures may cause more or less serious supercial
burns.
-Operators should wear suitable clothing and personal protective equipment.
-They should ensure that all components are at ambient temperature before carrying out any
maintenance operations.
FUEL LEAKS
-Fuel leaks may cause re to break out.
-They may be toxic via inhalation and cause skin irritation.
-Act swiftly to remove the cause of the leak. If it is connected to a maintenance operation, use
the dedicated personal protective equipment.
CAUTION
CAUTION
CAUTION
CAUTION

GENERAL
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2 GENERAL
2.1 Burner description
FB 4 R LN is a latest generation single-stage burner fuelled by light oil. The innovative combustion
head ensures low NOx and CO emissions within the emission limits set out by European
Regulations for energy related products (ErP).
The burner uses functional components that, in addition to ensuring a long working life, also allow
for easy installation, adjustment and maintenance. The high-performance electrical components
ensure low fuel consumption.
The ventilation system ensures a high level of efciency, and thanks to a powerful transformer,
cold starts don’t cause problems. The operation of FB 4 R LN burners is reliable even in the event
of persistent or intermittent wind, ignition takes place effectively and with smoke-developed index
control.
The contained dimensions, low noise and ease of installation make it possible to apply the burner
to boilers installed in domestic spaces.
2.2 Supply
The burner FB 4 R LN includes the following equipments:
–n°1 ange with xing bolt
–n°1 gasket
–n°2 exible oil pipes L=1000 mm
–n°2 nipple G 3/8 - 1/4 (for exible oil pipe)
–n°4 nuts for ange to be xed to boiler
–n°1 7-pin plug (mounted on the burner)
–n°1 hex key 4 mm
–gauge for checking the settings
–instruction manual

GENERAL
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2.3 Identication
Check the identication label of the burner (“Fig. 1”).
BRNxxxELN
414949
31-18
W210
Hz50~V1N-230
FB 4 R 20 LN
3146467
kW 20,6
WEIGHT
LIGHT OIL
0000000001
Made inItaly
7,1
Visc. @ 20 °C 1,6-6 mm²/s
FUEL
kg
IPxx
kg/h 1,72
414852|BRNxxxELN|3146166|SN0000
000001|SL005600012345|DH31/07/201
8 12.17.58
(B)
(E)
(H)
(D)
(I)
(C)
)A(
(G)
(F)
(J)
A Burner code
B Week and year of manufacture
C Burner model
D Factory power setting
E Burner power output
F Electrical supply
G Protection level
H Electrical consumption
I Types of fuel used
J Serial number
Fig. 1
CAUTION
It is strictly forbidden to remove the identication label.
Tampering, removal or absence of the data plate burner or anything that prevents the secure
identication of the burner will create difculties for any installation and maintenance work.
CAUTION

GENERAL
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2.4 Structure
2.4.1 Structure of the burner
10
9
5
4
3
7
8
6
21
1 Power indication LED
2 Connection PLUG-IN between control
box and ignition transformer
3 Snorkel
4 Air setting
5 Air intake
6 Air valve indicator
7 Housing for internal rotor
8 PEC
9 Reset button
10 Control box
Fig. 2

GENERAL
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22
21
20 19 18 17 15
1311 12
16
14
11 Combustion head
12 Burner fixing bolt
13 Burner flange (supplied)
14 7 pin plug
15 Electric motor for pump and fan
16 Capacitor
17 Extended pressure port
18 Burner base
19 Oil pressure regulator
20 Fuel-oil pump
21 Solenoid valve
22 Ignition transformer
Fig. 3

GENERAL
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2.4.2 Structure of the combustion head
1
5
6
4
3
2 76
1 Combustion head
2 Diffuser
3 Electrode group
4 Diffuser fixing screw
5 Electrode group fixing screw
6 Combustion head fixing screw
7 Nozzle
Fig. 4

GENERAL
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2.5 Control box
The EBR-M4 control box, controls and monitors the forced draught burner. The microprocessor-
controlled program sequence ensures maximum stability of time periods, regardless of uctuations
in the power supply or ambient temperature.
The design of the control box protects it from the effects of ame outs. Whenever the supply
voltage drops below its rated minimum level (170 ± 8 V), the control box shuts down - even in the
absence of a fault signal.
The control box switches itself back on again once the voltage has exceeded the 190 ± 8 V.
2.6 Operating logic (Two-pipe system)
M
M1
118
103
101
120
T1
104
102
106
105
Y1
M1 Burner motor
T1 Ignition transformer
Y1 Solenoid valve
101 Fan
102 Oil pump
103 Air ap
104 Oil pressure regulator
105 Flexible oil pipe
106 Filter
118 Nozzle
120 Pre Heater
Fig. 5
2.6.1 Operating function
–If heat is requested by the heating controls, the control box starts the program sequence.
–The motor starts, the ignition transformer is switched on and the preventilation period of 15 s
commences.
–The pre heater heats the oil in the oil line.
–During the preventilation period, the furnace is monitored for ame signals.
–At the end of the preventilation period, the fuel-oil solenoid valve opens and the burner starts.
–The ignition transformer remains switched off while the burner is in operation.

GENERAL
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2.6.2 Controlled shutdown
–Boiler temperature control interrupts heat request.
–The fuel-oil solenoid valve closes and the ame is extinguished.
–The post-ventilation starts: time factory-set at 15 s. After the burner motor switches off.
–Burner enters standby.
2.6.3 Safety function
A safety shutdown occurs:
–if a ame signal is present during preventilation (ame monitoring)
–if no ame is produced within 5 seconds (safety time) of start-up (fuel authorisation)
–if no ame is produced after an unsuccessful restart attempt in the event of 5 ame failures
during operation.
A safety shutdown is indicated by the malfunction lamp lighting up and it is then only possible to
reset the burner by pressing the reset button after the cause of the malfunction has been rectied.
For further information, see the automatic combustion control unit description.
Boiler
temperature
control
General
power
supply
Motor
Ignition
Transformer
Valve
Flame check
Flame
Pre heater
--
trto tp ts tpp
tpi
LINE
C
15s 5s
7s
<400s 15s
to Stand-by: the burner is
waiting for heat demand
tr Pre heater temps
tp Pre-Purge time
ts Ignition safety time
tpi Post-Ignition time
tpp Post-purge time
Fig. 6

TECHNICAL DATA
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3 TECHNICAL DATA
3.1 Dimensions and weights
306
150 Ø75
Ø 72
161
156
20698
Øi 100
= =
145
10
10
Ø 175
Ø 151,5
Ø 126,5
45°
45°
15 Max
Fig. 7
Model Weight (kg)
net with packaging
FB 4 R 20 LN 7,1 9,5
FB 4 R 26 LN 7,1 9,5
FB 4 R 35 LN 7,1 9,5
All measurements are given in millimetres.
270
300
390
Fig. 8

TECHNICAL DATA
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3.2 Technical data
FB 4 R 20 LN FB 4 R 26 LN FB 4 R 35 LN
Burner output factory setting (1)
20,6 kW 26,8 kW 36 kW
17.716 kcal/h 23.048 kcal/h 30.960 kcal/h
Oil throughput factory setting (1) 1,72 kg/h 2,23 kg/h 3,0 kg/h
Fuel oil (2) Light oil, visc 1,6-6 mm2/s at (Hi=11,97 kWh/kg)
NOx emissions
< 120 mg/kWh
(according to European Commission Regulation No 813/2013
and to pr EN267/2016 Class 4)
Control box EBR - M4 R 15-15
Flame sensor Photoelectric controller (PEC)
Ignition transformer Fida 2P 26 kV pp-35 mA rms
Fuel-oil pump Danfoss BFP special
Pump coil BFP T85
Electric motor
EBR 90 W, 2800 rpm
90 watt
Capacitor Inco 4 μF , TEKNO 45T (T = top series)
Electrical supply 1 / 230 / 50 Ph / V / Hz
Power consumption (operation) (+/- 10W) 210 W 210 W 200 W
Protection level IP20 (burner without cover)
IP40 (burner with cover)
Sound pressure level 65 dB(A)
Ambient temperature for storage -20°C ... +70°C
Temperature for use -10°C ... +60°C
(1) Reference conditions: Ambient temperature 20 °C – Barometric pressure 1013 mbar – Altitude 0 m. a.s.l.
WARNING
(2) The burner is suitable for light oil with bio content up to 10%. It is a minimum requirement
that the fuel blend (up to 10% Bio) is obtained with light oil in accordance with the relevant
standards and regional regulations.
In case of Bio oil content higher that 10% please contact the manufacturer.
WARNING

TECHNICAL DATA
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3.3 Electrical diagram
HLF HLB STS
STC
~50 Hz 230 V
PE
L
N
Q
MV YVg
B
R
CONTROL BOX EBR-M4 R 15-15 TV
B4 S3 T2 T1 L1N
B4 S3 T2 T1 L1N
TV Ignition transformer
B Photo-resistor
YVg Oil solenoid valve
MV Fan motor
HLB Security light
HLF Operating light
R Heater
STC Heater thermostat
STS Safety thermostat
Q General switch with fuse
Fig. 9

INSTALLATION
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4 INSTALLATION
4.1 Safety during assembly
DANGER
Danger of death!
-Contact with live electrical components may cause serious incidents.
-Only professionally-trained and qualied personal can operate on the electrical system.
-Before any operation, switch off the power supply to the system by operating the main switch.
Check there is no power and ensure restart is impossible.
-In the event of damage to the electrical insulation on the product, act immediately to restore
the correct level of insulation.
WARNING
Danger of death due to contact with fuel oil!
Risk of lung damage caused by inhalation or ingestion of fuel oil; take the following precautions:
-observe the instructions on the safety data sheets for the fuel oil and any additives (available
from the associated suppliers)
-in the event of the formation of an oil mist, use a protective mask with lter for organic
vapours and particulate lter
-do not eat, drink or smoke when working on the heating system.
WARNING
Danger of injury due to contact with fuel oil!
Repeated and prolonged skin exposure to fuel oil can damage and irritate the skin; take the
following precautions:
-as far as possible, avoid contact with the skin
-use personal protective equipment, such as a protective gloves and suitable clothing
-do not put rags soaked with oil in your pockets
-change clothes stained with oil as soon as possible.
CAUTION
It may be hazardous to assign activities to personnel that are not sufciently qualied. It may
harm the operators themselves if they perform manoeuvres or operations incorrectly, with a
serious impact on personal safety, things and property.
CAUTION
Installation, commissioning and maintenance activities must only be carried out by the personnel
of dedicated heating companies specically qualied to perform these tasks.
CAUTION
Operators should explain to the proprietor and person responsible for the domestic heating
system the burner is installed on, the importance of ensuring good inow of combustion air
and combustion product evacuation. They should also highlight that no modication should be
made to the heating system (comprised of air intake, burner, boiler and ue pipe) that could
alter the correct operation of the system.
WARNING
WARNING
CAUTION
CAUTION
CAUTION

INSTALLATION
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4.2 Installation area
Before installation, make sure that the installation area satises the following requirements:
–operating temperature between +5°C and +45°C
–dry, frost resistant, well-ventilated
–no accumulation of heavy powders
–no high levels of humidity
–no atmospheric pollutants created by halogenated hydrocarbons (contained in solvents,
adhesives, aerosols, etc.)
–no atmospheric pollutants created by sulphurous gases
–no vibration.
WARNING
Danger of death caused by re!
Highly ammable materials or liquids can catch re
-do not use or store explosive or highly ammable substances (such as petrol, paint, paper,
wood, etc.) in the installation area of the appliance
-do not dry clothing within the boiler installation area
-do not use the equipment in an explosive atmosphere.
CAUTION
Flammable materials or liquids should not be stored or used near the burner.
IMPORTANT INFORMATION
Failure to observe these instructions will invalidate the warranty with respect to any damages
caused by any of these causes.
4.2.1 Flue gas system
Before installation, check the design suitability of the combustion ue system with respect to the
type of boiler to be installed and with respect to the applicable standards and regulations.
CAUTION
Operators should explain to the proprietor and person responsible for the domestic heating
system the burner is installed on, the importance of ensuring good inow of combustion air
and combustion product evacuation. They should also highlight that no modication should be
made to the heating system (comprised of air intake, burner, boiler and ue pipe) that could
alter the correct operation of the system.
4.3 Assembly tools
The most common and frequent operations on the burner are carried out simply using only the
hex key supplied. This key can be used to:
–remove the burner cover (if it present)
–remove the diffuser
–adjust the electrodes group
–adjust the fuel pressure
–adjust the air setting
–operate on the pump.
WARNING
CAUTION
CAUTION

INSTALLATION
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4.4 Preliminary checks before mounting the burner
Before mounting the burner onto the boiler:
–check the distance between tips of electrodes (2 mm)
Fig. 10
–Check the position of the electrodes assuring that they are centered as shown in “Fig. 11”.
A-A 1 : 1
=
A
A
Fig. 11