EOGB X400 User manual

INSTRUCTION MANUAL FOR OIL BURNER MODELS
X400
X500
X600
E90-803-001-001-00 - 02/06

E90-803-001-001-00 - 02/06

CONTENTS
Technical Specifications
Technical Data ……………………………………………………………………. 2
Burner Dimensions …………………………………………………………………. 2
Working Fields ….……………………………………………………………….…. 3
Head / Electrode Settings …………………………………………………………. 3
Components ………………………………………………………………………. 4
BurnerInstallation
Mounting onto the appliance …………………………………………………….. 5
Air Intake Device ……………………………………………………………….…. 5
Electrical Connection ……………………………………………………………... 6
Fuel Supply ………………………………………………………………………… 6
Air Supply ………………………………………………………………………….. 6
Burner Operation
Before Start Up …………………………………………………………………….. 7
Start Up Procedure ……………………………………………………………….. 7
Normal Operating Mode ………………………………………………………….. 8
Burner Servicing ………………………………………………………………. 9
Fuel Pump Type BFP11L3 ……………………………………………………. 10
Fuel Pump Type BFP21L3 ……………………………………………………. 11
Fuel Pump Type BFP ….………………………………………………………. 12
Oil Line Tables …………………………………………………………………. 13
Nozzle Table …………………………………………………………………… 14
Fault Finding …………………………………………………………………… 15
Electrical Information
Wiring Diagram …………………………………………………………………... 20
Technical Data …………………………………………………………………… 20
IMPORTANT NOTE
The contents of the manual must be read and followed prior to the fitting and commissioning of the
burner.
Any work on this burner must be carried out by a suitably qualified, and experienced, engineer.
Any electrical or fuel supply must be isolated before any work is carried out.
The installation must be carried out in accordance with current Electrical Regulations and all relevant
Building Regulations.
Failure to meet with these requirements could lead to damage or injury, and could invalidate any
guarantee.
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1

TECHNICAL SPECIFICATIONS
Technical Data
Model X400 X500 X600
Burner output Min kW 14 30 58
Max kW 50 70 130
Fuel Flow rate Min Kg/h 1.2 2.5 4.8
Max Kg/h 4.2 5.8 10.8
Fuel Kerosene
Gas Oil
Max viscosity 5.5cst @ 20ºC
Electrical supply V 230V ±10% 50Hz 1 phase
Motor W 90 90 130
Transformer 40mA (rms) 15kV
Current Start A 1.60 1.60 2.20
Run A 0.53 0.53 0.87
Weight kg 9.2 9.2 9.5
Mode of operation On/off
Burner Dimensions (mm)
Model AØ
root
AØ
max B* C D E F G H J K L
X400-1N 89 89 73 231 50 161 194 138 268 90 125-150 10
X400-2N 89 89 73 231 50 161 194 138 268 90 125-150 10
X400-1 89 89 73 231 50 161 194 138 297 90 125-150 10
X400-2 89 89 73 231 50 161 194 138 297 90 125-150 10
X500-1 89 89 73 231 50 161 204 204 318 90 125-150 10
X500-2 89 89 80 231 50 161 204 204 318 90 125-150 10
X600-1 89 89 80 231 50 161 204 204 360 90 125-150 10
X600-2 89 109 120 231 50 161 204 204 360 90 125-150 10
*Standard lengths only - other lengths are available.
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2

TECHNICAL SPECIFICATIONS
Working Field
-0.5
0
0.5
1
1.5
2
2.5
3
3.5
4
0 204060801001201
BURNER OUT PUT k W
APPLIANCE RESISTANCE mbar
B
A
C
E
B
A
C
E
B
A
C
D
E
X600
X500
X400
40
Head / Electrode settings
X500-2
X600-1 mm
Model A B C D E
X400-1 2.5 0 9.0 43 4
X400-2 2.5 0 9.0 43 4
X500-1 2.5 0 9.0 43 4
X500-2 3.5 2.0 4.5 43 6
X600-1 3.5 2.0 4.5 — 6
X600-2 3.5 4.0 8.5 — 6
X400-1
X400-2
X500-1
X600-2
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3

TECHNICAL SPECIFICATIONS
Components
1
18 17 16
15
14
13
12 11
10
9
8
7
6
5
432
① Blast tube
② Mounting flange
③ Air intake
④ Fan housing
⑤ Air adjustment
⑥ Lockout reset button
⑦ Control box
⑧ Photocell
⑨ Ignition transformer
⑩ Fuel pump
⑪ Motor
⑫ Capacitor
⑬ Solenoid valve
⑭ HT leads
⑮ Ignition electrodes
⑯ Electrode holder
⑰ Nozzle
⑱ Nozzle assembly
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4

BURNER INSTALLATION
Mounting onto the appliance
The burner is mounted onto the appliance by means
of a removable 6-bolt flange.
The gasket needs to be put in place before the flange
is fixed onto the appliance. The burner tube is then
inserted through the centre hole.
With the burner rotated a few degrees clockwise the
flange bolts will pass through the locating holes. When
the burner is twisted into position the top bolt can then
be tightened to secure the burner. If necessary the
lower screw can be adjusted to give a more secure
fixing.
If required the burner can be mounted in any position.
It is important though to ensure that the solenoid valve
on the oil pump is not inclined below horizontal.
Air Intake Device
The burner is supplied with an air intake device
that can be rotated through 180º to allow the air
to be taken from a position suitable within the
appliance housing.
The intake has a 60mm diameter entry to allow a
snorkel tube, as used on some balanced flue
units, to be connected. There is a grill fitted to
the entry that can be removed if required.
Top
locating
hole
Bottom
locating
cut-out
Tube Adapter
An intake adapter is
available fo
r
applications
equipped with
70mm diameter ai
r
tubes.
For the part numbe
r
see pages 10 and 11
for details.
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5

BURNER INSTALLATION
Electrical Connection
The electrical connections to this burner must be
carried out by a suitably qualified engineer.
All Electrical connections to the burner must be
carried out in accordance with all current
applicable IEE Wiring Regulations.
All connections should be made according to the
wring diagram shown on the supplementary page -
page 20 within the manual.
If the burner is fitted with a 7-pin socket and
supplied with the matching plug then all
connections therefore are made within the 7-pin
plug.
To gain access to the electrical connection strip the
cover must be removed by means of undoing the
3mm Allen screw. Once undone the cover can be
removed exposing the connection strip.
Fuel Supply
The burner is usually supplied for one-pipe operation
but if required can be converted for a two-pipe system (see page 10 for
details). When used in conjunction with a gravity feed supply the inlet pressure
to the pump MUST NOT exceed 2 bar.
When using a two-pipe system the return line has to be fed back into the
tank. Alternatively, a de-aeration device could be incorporated for ease of
installation.
Oil lines must be completely air-tight and constructed in accordance with
current standards.
The final connection to the oil pump must be made with the flexible oil line
provided.
Air Supply
Combustion air and ventilation requirements are detailed in BS5410:Part1. It
requires that combustion air must be provided through purpose-made non-
closeable openings, having a total free area of 550mm2 per kW of the
appliance maximum output rating above 5kW.
Cover fixing
sc
r
ew
Electrical
Connection strip
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6

BURNER OPERATION
Before start-up
Check that the correct nozzle is fitted. Reference should be made to the
instructions of the appliance manufacturers.
If the burner is firing Kerosene the nozzle must be sized for a maximum pump
pressure of 10 bar (145 psi). If Gas Oil is being used then a smaller nozzle must
be selected to allow a pump pressure of approx 14 bar (200 psi). This is
necessary to give better fuel atomisation and therefore better combustion.
Fit a pressure gauge to the oil pump (as shown in the diagram below).
Start-up procedure
Close the main switch and the thermostats
to allow the burner to start up.
The burner motor and ignition transformer
are both powered during the pre-purge
period.
During pre-purge the oil pressure can be
set, as the pressure will register before the
solenoid valve is opened (see diagram).
If necessary the oil supply can be de-
aerated from the pump through the
pressure gauge manifold.
During this pre-purge period checks are
made for ‘stray-light’ onto the photocell
and the integrity of the solenoid coil of the
pump. If ‘stray-light’ is detected, or if the
coil is faulty, then the coil will not receive full
voltage and therefore will not release any
fuel.
If checks are ok then power is fed to the solenoid coil and the valve will open.
Fuel is then released to the nozzle.
The spark will ignite the fuel spray.
If a flame is formed this will be detected by the photocell and the control box
will turn off the ignition and assume normal run mode.
If a flame is not formed, or detected, then the control box will go to a lockout
condition and the indicator lamp on the control box will be illuminated. The
control box will need to be reset to enable the burner to re-attempt a start
up.
Pressure Gauge
Pressure
Regulator
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Normal operating mode
Check the oil pressure on the gauge and
adjust if necessary for the required burner
output.
From a suitable test point on the boiler, or in
the flue, a smoke reading should be taken
to ensure clean smoke-free combustion.
With the aid of a flue gas analyser, and by
making adjustments to the air damper
control, the combustion can be set for
maximum efficiency (see diagram).
The air control rotates around a central
fixing screw that passes through both the
control device and air inlet housing. This
spring loaded screw is pre-tensioned in the
factory but if the adjustment appears too
loose or tight then it can be pre-tensioned
to suit.
A CO2level of around 11.0% - 12.0% should be achievable.
If at any point during normal operating mode the photocell loses sight of the
flame the control box will attempt to re-establish the flame. The oil valve will
close and the ignition transformer will be powered. A pre-purge will be carried
out before the valve is re-opened and the fuel is released. If successful the
burner will continue in operating mode; if not the control box will go into
lockout mode.
After commissioning a safety check must
be carried out to ensure the correct
operation of the flame detection.
During normal operation the photocell is to
be removed and either covered with a
clean rag to prevent any light from being
sensed, or for the cell to be unplugged. As
soon as this happens the burner will
attempt to re-establish the flame
IMPORTANT: The photocell side opening
must be pointing at the flame for reliable
operation.
Turn air control 
CLOCKWISE for MORE AIR
o
r
ANTI-CLOCKWISE for LESS AIR

Photocell
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8

BURNER SERVICING
For ease of servicing and access to the burner
components the burner has, on the bottom
face, a keyhole cut-out. This allows the burner
to be hung from the mounting flange in a
more convenient position.
After loosening the fixing bolt the burner can
be extracted from the flange, turned around
and then the keyhole can be located onto the
bolt.
The burner service requires that all of the components are cleaned and
checked for correct operation, or signs of damage. A check must be carried
out on all safety devices i.e. photocell, solenoid valves, etc. The nozzle should
be replaced every 12 months, or sooner if worn or dirty. Filters and fuel lines
must be inspected and replaced if necessary.
Below are a series of diagrams showing the removal of the combustion head
components from the burner. This gives access for the nozzle to be replaced
and the electrodes to be inspected. As shown below the electrode assembly
is to be removed from the nozzle holder before the nozzle is replaced. This will
prevent any accidental damage.
Once the burner has been re-fitted a smoke check and combustion analysis
must be carried out. Once the burner has been commissioned on the
appliance and all settings are correct the figures should then be recorded.
The burner and all other related equipment must be left in a safe and reliable
working order.
9
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FUEL PUMP TYPE DANFOSS BFP11 L3
Technical Data
1 or 2 pipe operation
Oil Viscosity range: 1.3 – 12.0 cSt
Pressure range: 7 – 15 bar
Oil temperature: -10 - +70ºC
1 - Nozzle port 1/8”
2 - Vacuum gauge port 1/8”
3 - Suction line port 1/4”
4 - Return line port 1/4”
5 - Pressure adjustment (4mm allen key)
6 - Pressure gauge port 1/8”
The fuel filter and bypass
washer are located within the
pump housing. By removing the
4 fixing screws the housing can
be removed allowing access.
The bypass washer is located
under the bottom of the 3
internal screws.
In case of one-pipe operation
the horseshoe-shaped coppe
r
washer will be mounted unde
r
the screw head, and in case
of two-pipe operation, the
horseshoe-shaped coppe
r
washer will be removed.
1
2
3
6
5
4
2
1
⑥
⑤
①
④③
②
1 - Filter
2 – Bypass Washer
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10

FUEL PUMP TYPE DANFOSS BFP21 L3
Technical Data
1 or 2 pipe operation
Oil Viscosity range: 1.3 – 12.0 cSt
Pressure range: 7 – 15 bar
Oil temperature: -10 - +70ºC
1 - Nozzle port 1/8”
2 - Vacuum gauge port 1/8”
3 - Suction line port 1/4”
4 - Return line port 1/4”
5 - Pressure gauge port 1/8”
6 - Pressure adjustment (4mm allen key)
7 - Filte
r
1
2
3
6
7
4
5
2
1The fuel filter is located within
the pump housing in front o
f
the solenoid valve. B
y
unscrewing the filter it can then
be removed by lifting out.
The bypass plug is located
inside the vacuum gauge port.
In the case of one-pipe
operation the bypass plug
should be removed and in the
case of two-pipe operation,
the plug should be fitted.
1 - Filter
2 – Bypass plug
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11

FUEL PUMP TYPE DANFOSS BFP….
Function
As the oil pump turns it draws oil from the suction line connection S, through the
filter Hand into the suction side of the gear set C. Any suction generated before
the gear set can be measured with an appropriate vacuum gauge at
connection V.
The gear set then pumps the oil through and puts it under pressure. The pressure
is measured at connection P1. No oil will be released to the nozzle port Euntil the
normally closed solenoid valve NC is opened.
The pressure is controlled and kept constant by means of the diaphragm D
behind the pressure regulator P
1. The pressure regulator P1distributes the oil
quantity supplied by the gear set between the nozzle port Eand the return side of
the pump R.
The oil quantity supplied is determined by the setting of the pressure regulator P1
and the size of the oil nozzle in the nozzle line E.
When the opening pressure has been reached, the passage to the return side of
P1opens. The diaphragm and the spring keep the pump pressure constant at the
set value.
When used in a one-pipe installation connection Ris closed and Amust be
removed to allow internal recirculation of the fuel. If Ais not opened then
damage to the pump seals will occur.
If a two-pipe system is required then a return line must be fitted into
connection Rand A must be fitted to divert the recirculating oil out through
the return line.
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12

OIL SUPPLY LINE TABLES
One-pipe system Two-pipe system
Kerosene 2.15 mm2/s (cSt) Kerosene 2.15 mm2/s (cSt)
Gas Oil 6.00 mm2/s (cSt) Gas Oil 6.0 mm2/s (cSt)
These tables are shown merely as guidance for the suitability of the oil supply
line installation. The typical pipe system used for the calculations comprises – 1
x check valve, 1 x cut off valve, 1 x in-line filter and 4 x 90º elbows
H Ø4
Ø5 Ø6 Ø5 Ø6 Ø8
m mm
mm mm mm mm mm
4.0 66 100 100 33 80 100
3.5 57
100 100 29 70 100
3.0 49
100 100 25 60 100
2.5 41
100 100 20 50 100
2.0 33 80
100 16 40 83
1.5 25 60
100 12 30 62
1.0 16 40 83 8 20 41
0.5 8 20 41 4 10 20
Nozzle capacity 5.0 kg/h 10.0 kg/h
L
H
L
H
H Ø4
Ø5 Ø6 Ø5 Ø6 Ø8
m mm
mm mm mm mm mm
4.0 26 60 100 31 62 100
3.5 22
51 100 27 55 100
3.0 19
44 94 23 47 100
2.5 16
37 78 20 39 100
2.0 13 30
62 16 31 98
1.5 10 22
47 12 23 74
1.0 6 15 31 8 15 49
0.5 3 7 15 4 7 24
Nozzle capacity 5.0 kg/h 10.0 kg/h
H Ø6 Ø8 Ø10
m mm
mm mm
-0.0 17 53 100
-0.5 15
47 100
-1.0 13
41 99
-1.5 11
34 84
-2.0 9 28
68
-2.5 7 22
53
-3.0 5 15 37
-3.5 — 9 22
-4.0 — — 6
H Ø6 Ø8 Ø10
m mm
mm mm
-0.0 54 100 100
-0.5 48
100 100
-1.0 42
100 100
-1.5 36
100 100
-2.0 30 94
100
-2.5 24 75
100
-3.0 18 55 100
-3.5 11 36 88
-4.0 5 16 40
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Nozzle capacity – usg/h
Figures shown are for an oil of Viscosity 4.4mm2/s (cSt), Density 830 kg/cm3.
Pum
p
Pressure - ba
r
NOZZLE TABLE
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14

FAULT FINDING
Below is a list of some scenarios that may lead to a failure causing the burner
to go into lockout mode. There are also some relevant tests and solutions to
hopefully overcome any problem that may occur.
Push the reset button to re-start the burner. If the burner then functions
correctly the control has simply responded to a temporary fault. If the burner
still fails then a further investigation will be required to correct any fault.
Fault Probable cause Useful Test Solution
The burner will not start 1) Lack of voltage. 1) If there is 240V onto
terminal 9 of the control
box but it is not
responding then the box is
at fault.
2) If there is no voltage onto
terminal 9 then there is an
external fault.
1) Replace control box.
2) Check any thermostats,
switches, fuses, etc to
trace fault.
The burner starts but
no flame is present and
the burner goes to
lockout
1) No fuel to burner.
2) No fuel to the nozzle.
a) No voltage to
solenoid coil
b) Voltage to coil but
not energizing.
c) Coil energized but no
oil at pump outlet.
d) Oil at pump outlet
but none through the
nozzle.
3) No spark
1) Check if there is oil
present at the pump inlet
2)
a)
i) Cover photocell. If
burner fires up ok then
photocell must be
detecting a light source
during pre-purge.
ii) If there is still no flame
disconnect photocell. If
now ok then cell must
be faulty.
3) Check electrodes, HT
leads and voltage to igniter.
If all ok then igniter is faulty.
1) Check fuel tank, valves,
etc for problems.
2)
a)
i) Identify source, spark,
etc and remedy.
ii) Replace photocell
b) Replace coil.
c) Check valve opening.
Replace if necessary.
d) Replace nozzle, or
check line for blockage.
3) Replace igniter.
The burner starts, a
flame is established but
the burner goes to
lockout
1) Check burner wiring.
2) Flame recognition.
2) Expose photocell to
good ambient (or torch)
light.
a) If the problem
disappears then the
problem is with the flame
picture
b) If the problem does not
disappear then the
photocell must be at
fault
1) Remedy wiring
connections.
2)
a) Reset combustion.
b) Replace photocell.
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15

Flame is pulsating 1) Faulty or dirty nozzle
2) Excessive flue draught.
2) Measure draught.
1) Replace nozzle.
2) Reset combustion or
adjust draught stabilizer (if
fitted).
Smoking Flame 1) Faulty nozzle.
2) Combustion not set
correctly.
3) Insufficient air.
4) Fuel pressure too low
2) Check combustion.
3) Check combustion.
4) Check fuel pressure.
1) Replace nozzle.
2) Reset combustion
3) Increase air setting.
Check ventilation.
4) Increase fuel pressure.
Burner keeps bringing
ignition back on
1) Flame recognition.
2) Low sulphur fuel.
1) Expose photocell to
good ambient (or torch)
light.
a) If the problem
disappears then the
problem is with the flame
picture
b) If the problem does not
disappear then the
photocell must be at
fault
2) As above.
1)
a) Reset combustion.
b) Replace photocell.
2) Reset combustion to give
a higher CO2level.
Please note: The information given above is provided to assist the engineer
with any problems they may encounter. This is not a definitive list.
If further problems are encountered then please contact EOGB Energy
Products Ltd for advice.
Technical Helpline – Tel: [phone]
E90-803-001-001-00 - 02/06
16

ELECTRICAL INFORMATION
Fig B1 Wiring Diagram – (E03-002)
Technical Data
Burner Control TF830.3
Operating voltage 220/240 V (-15% - +10%) 50 Hz
Fuse rating 10 A fast, 6 A slow
Power consumption 5 VA
Pre-purge time 12 sec
Pre-ignition time 12 sec
Post ignition time 20 sec
Lockout safety time 10 sec
Reset time from lockout 90 sec
Flame detector MZ770S
Light sensitivity >6 Lux
Sensor operating current min. 30µA
Protection class IP44
Ambient temperature 0ºC …. +60ºC
Approval standard EN 230
A1
1
2
5
8
3
9
7
4
1 ~
X3 V1
M
T
PE
ENL
1 ph 230V ~ 50Hz
NN
F
H2H1 S1
L
N
S3
B4
BURNER COMPONENTS
A
1 - CONTROL BOX
PE - PHOTOCELL
T - IGNITION TRANSFORMER
M - MOTOR
V1 - OIL VALVE
EXTERNAL CONNECTIONS
S1 - ISOLATING SWITCH
F - FUSE
TC - CONTROL THERMOSTAT
H1 - REMOTE LOCKOUT LAMP
H2 - REMOTE BURNER RUN LAMP
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