FBR FGP 50/2 EVO-2 Quick start guide

FGP 50/2 EVO-2
Installation, use and maintenance instructions
070002_3_B
LIGHT-OIL BURNERS AT TWO STAGES

INDEX 070002_3_B
FGP 50/2 EVO-2 1
TECHNICAL CHARACTERISTICS
TECHNICAL DATA FGP 50/2 EVO-2 ______________________________________________________ 2
OPERATING RANGE DIAGRAM FGP 50/2 EVO-2 _____________________________________________ 2
DIMENSIONS [MM] _________________________________________________________________ 3
BURNER INSTALLATION _____________________________________________________________ 4
BURNER SIGNAL DESCRIPTION ________________________________________________________ 5
INSTALLATION
SAFETY ________________________________________________________________________ 6
PRELIMINARY CHECKS ______________________________________________________________ 6
CHECK SUPPLY, TRANSPORT, PACKAGING, STORAGE ___________________________________ 6
BURNER CHARACTERISTICS CHECK ________________________________________________ 6
CORRECT BURNER POSITION _________________________________________________________ 7
BOILER PLATE ____________________________________________________________________ 7
FLAME TUBE LENGTH _______________________________________________________________ 7
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM LAYOUT _________________________________________________________ 9
ELECTRICAL SYSTEM
ELECTRICAL PANEL LAYOUT __________________________________________________________ 9
WORKING DIAGRAM OF THE ELECTRICAL DEVICE ___________________________________________ 9
START-UP AND CALIBRATION
BURNER CALIBRATION _____________________________________________________________ 10
PUMP CALIBRATION _______________________________________________________________ 10
TABLE OF ADVISABLE CALIBRATIONS ___________________________________________________ 11
TABLE OF ADVISABLE CALIBRATIONS FGP 50/2 EVO-2 ____________________________________ 11
MAINTENANCE
EXTRACTION OF THE COMBUSTION HEAD _______________________________________________ 12
ELECTRODES POSITIONING _________________________________________________________ 13
POSSIBLE CAUSES - SOLUTIONS _______________________________________________________ 14

TECHNICAL CHARACTERISTICS 070002_3_B
FGP 50/2 EVO-2 2
TECHNICAL CHARACTERISTICS
TECHNICAL DATA FGP 50/2 EVO-2
* Reference conditions: Environment temperature 20°C - Barometric pressure 1013 mbars - Altitude 0 metre (sea level).
** Measured sonourous pressure in the combustion lab, with funcional burner on beta boiler in a distance of 1 m (UNI EN ISO 3746).
*** For burner FGP 50/2 EVO-2 with long head add 1 kg to the weight.
OPERATING RANGE DIAGRAM FGP 50/2 EVO-2
The firing rates has been obtained based on test boilers in accordance with EN267 standards and are indicative of matching the burner to the boiler.
For the correct operation of the burner, combustion chamber dimensions must be in accordance with current regulation. In case of non-compliance,
contact the manufacturer.
MODEL FGP 50/2 EVO-2
Flow min. 1°st. / min. 2°st. - max. 2°st. * [kg/h] 9.9/20-53.1
Thermal power min. 1°st. / min. 2°st. - max. 2°st. * [Mcal/h] 100.1/204-541.8
Thermal power min. 1°st. / min. 2°st. - max. 2°st. * [kW] 117.4/237-630
Fuel: LIGHT-OIL 1.5°E at 20°C = 6.2 cSt = 35 sec Redwood N°1
Intermitted working operation (min. 1 stop every 24 hours) two stages
Environmental conditions operation / storage: -15...+40°C / -20...+70°C, rel. humidity max. 80%
Max. temperature combustion air [°C] 60
Nominal electric power [kW] 1.1
Fan motor [kW] 0.74
Nominal motor current absorption [A] 1.8
Nominal auxiliary absorption [A] 0.3
Power supply: 3~400V, 1N~230V - 50Hz
Electric protection degree: IP 40
Noisiness ** min-max [dBA] 71-73
Burner weight *** [kg] 31
Fig. 1 X = Thermal power Y = Pression in the combustion chamber
0
2
4
6
8
10
12
0 200 400 500 600 700 [kW]
[mbar]
100 300

TECHNICAL CHARACTERISTICS 070002_3_B
FGP 50/2 EVO-2 3
DIMENSIONS [MM]
TC - TL: Please see chapter "Flame tube length"
Fig. 2 Dimensions
MODEL A B C D E F O P
FGP 50/2 EVO-2 187 314 150 558 417 100 207 200
O
P
AB
C
TC - TL
20
D
E F

TECHNICAL CHARACTERISTICS 070002_3_B
FGP 50/2 EVO-2 4
BURNER INSTALLATION
For the installation of the burner to the generator, follow to the diagram shown below:
Fig. 3 Burner installation
LEGEND
1) Generator 7) Pipe connection
2) Counterflange 8) Screw
3) Stud bolt 9) Burner's body cover
4) ISOMART gasket 10) Screw
5) Washer 11) Head group
6) Nut

TECHNICAL CHARACTERISTICS 070002_3_B
FGP 50/2 EVO-2 5
BURNER SIGNAL DESCRIPTION
In the picture below there are indicated all the signalation present on the burner:
Fig. 4 Burner signal description
LEGEND
1) ON/OFF button
2) Reset from lockout button + status lamp
The multicolor signal lamp in the lockout reset button (pos.2) is the key indicating element for visual diagnostics
and interface diagnostics.
In normal operation, the different operating states are indicated in the form of color codes; please refer to
electrical device handbook supplied with the present instructions.
After a non-alterable lockout, the red signal lamp in the lockout reset button (pos.2) lights up.
By pressing the lockout reset button (pos.2) for more than 3 seconds, the visual diagnostics of the cause of fault
can be activated; please refer to electrical device handbook supplied with the present instructions.
For close the diagnostics mode and for switch on the burner again, it is necessary to reset the burner control.
Press the lockout reset button (pos.2) for about 1 second (<3 seconds).
After a non-alterable lockout, the red signal lamp in the lockout reset button (pos.2) lights up.
For reset the control box press the lockout reset button (pos.2) for about 1 second (<3 seconds).
2
1

INSTALLATION 070002_3_B
FGP 50/2 EVO-2 6
INSTALLATION
SAFETY
Before burner installation, clean carefully all around the area where the burner will be installed and arrange the correct
lighting of the room.
PRELIMINARY CHECKS
CHECK SUPPLY, TRANSPORT, PACKAGING, STORAGE
BURNER CHARACTERISTICS CHECK
The installation, adjustment and maintenance of the appliance must be carried out by professionaly
qualified person in compliance with the standards and regulations of the laws in force as a wrong
installation may cause damages to people, animals and things for which the Manufacturer will not be
responsable.
Before starting installation, maintenance and disassembly turn off the electrical supply and check that it is
not possible to turn accidentally the main switch on, close fuel inlet valves and make sure they could not
accidentally be opened.
CHECK SUPPLY
Check that the supply is complete and without transport damages. After removing all the packaging,
check the integrity of the contents. If in dubt do not use the burner and contact the supplier.
TRANSPORT
The transport weights of the burner and the gas train are indicated in the technical data.
STORAGE
Observe the environment temperatures which are allowed for storage and indicated in the technical data.
The packaging materials must not be abandoned as they may cause danger and pollution, but they should
be collected and left in a appropriate place.
The data plate of the burner shows:
A. the model;
B. fuel family;
C. fuel category;
D. fuel 1 pressure (if appicable, fuel 2 pressure);
E. minimum and maximum thermal power;
F. the data for electrical supply, absorbed electrical power
and electric protection degree;
G. the code;
H. the serial number.
Moreover the data plate includes CE labeling and the list
of countries where the certification is applicable.
Check that the capacity of the boiler is within the operating range of the burner.
Violation, removal or loss of the data plate of the burner and any other components compromise the
correct identification of the burner and hinder the installation and maintenance operation.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING

INSTALLATION 070002_3_B
FGP 50/2 EVO-2 7
CORRECT BURNER POSITION
BOILER PLATE
FLAME TUBE LENGTH
Flame tube length must be selected based on the specifications supplied by boiler manufacturer and, in any case, it
must be greater than the thickness of the boiler door included its insulation.
In case of boilers with flame inversion or front flue combustion chambers, it is necessary to insulate the area between
the flame tube and front door with refractory material. This protection material must not impede flame tube extraction.
** For different flame lengths, please contact our Technical-Sales Department.
The burner is designed to work only in the positions as
shown in the picture.
Any other position could compromise the correct working
of the burner.
Crossed positions are forbidden for safety reasons.
Fig. 5 Correct burner position
* Suggested dimension of connection between burner
and generator.
Fig. 6 Boiler plate
MODEL L min L max M N min N* N max
FGP 50/2 EVO-2 mm 205 226 M10 160 160 180
MODEL TC TL **
FGP 50/2 EVO-2 mm 250 335

HYDRAULIC SYSTEM 070002_3_B
FGP 50/2 EVO-2 9
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM LAYOUT
1ST PHASE - PRE-WASHING:
At the burner starting, the light-oil, sucked by the pump (pos.2), is cleaned by the filter (pos.1) and sent to the return
pipe through the by pass regulator (pos.3).
2ND PHASE - 1ST STAGE IGNITION:
After about 15secs. of pre-washing, the valve V1 opens, the light-oil comes out atomized by the nozzle (1ST) and it is
ignited by the voltaic arc generated by the ignition transformer. The pump light-oil excess delivery is by-passed on the
return pipe through the pressure regulator (pos.3).
SAFETY TIME:
After about 5-10 secs. from excitation of the 1st stage valve V1, if the light-oil does not ignite, the burner stops (lock).
3RD PHASE - 2ND STAGE IGNITION:
After about 5-10 secs. from the igniton of the 1st stage, the 2nd stage valve V2 gets excited and the light-oil is sent to
the 2nd nozzle (2ND) and at the same time to the jack (pos.4) which causes the opening of the 2nd stage air shutter.
ELECTRICAL SYSTEM
ELECTRICAL PANEL LAYOUT
Please refer to elctrical panel layout supplied with the present Instructions.
WORKING DIAGRAM OF THE ELECTRICAL DEVICE
Please refer to electrical device handbook supplied with the present Instructions.
Fig. 9 Hydraulic system layout

START-UP AND CALIBRATION 070002_3_B
FGP 50/2 EVO-2 10
START-UP AND CALIBRATION
BURNER CALIBRATION
PUMP CALIBRATION
ATTENTION: Before starting the burner it is necessary to respect the general norms of security; especially
check:
- Electrical supply
- The tightness of the plant and its correct realization
- The presence of water in the plant
- The ventilation of the boiler location
- The correct function of the thermostats and pressure switches of the boiler.
WARNING
Fig. 10 Pump calibration
LEGEND
1) Delivery 1st stage
2) Delivery 2nd stage
3) Pressure checking
4) Pressure calibration screw
3
4
12

START-UP AND CALIBRATION 070002_3_B
FGP 50/2 EVO-2 11
TABLE OF ADVISABLE CALIBRATIONS
TABLE OF ADVISABLE CALIBRATIONS FGP 50/2 EVO-2
Calibrations effected with pressure in chambers 0,1 mbar.
The definitive calibration must be done in operation by means of a combustion analyser.
NOZZLES G.P.H. PRESSURE FLOW HEAD
ADJUSTMENT
AIR OPEN
1st STAGE
AIR OPEN
2nd STAGE
I°
60°
II°
45°
[bar] [kg/h] [NOTCH N°] [NOTCH N°] [NOTCH N°]
2.50 2.50 13 20 1 0.5 2.5
3.00 3.00 12 24 1 1 3.5
3.50 3.50 11 28 2 2 4
4.00 4.50 11 32 3 2 4.5
4.50 5.00 11 36 4 2 5
5.00 5.50 11 40 5 2.5 5
5.50 6.00 12 44 6 3 6
6.00 6.00 12 48 7 3 7
6.00 6.50 12 50 8 3 8
6.50 6.50 12 53 8 3.5 9
Fig. 11
LEGEND
1) Pressure calibration
2) 2nd stage adjustment
3) 1st stage adjustment
4) Head adjustment

MAINTENANCE 070002_3_B
FGP 50/2 EVO-2 12
MAINTENANCE
EXTRACTION OF THE COMBUSTION HEAD
it is possible to take out the head group without removing the burner from the boiler:
a) Take off the cover (pos.9) by loosening the 3 screws (pos.10)
b) Loosen the connection (pos.7) and the screws (pos.8)
c) Take out the head group (pos.11) and pull the ignition cables.
ATTENTION: REMOVE VOLTAGE!
Fig. 12 Extraction of the combustion head
DANGER

MAINTENANCE 070002_3_B
FGP 50/2 EVO-2 13
ELECTRODES POSITIONING
Fig. 13 Electrode positioning
LEGEND
1) Disc-Nozzle distance=8mm
2) Distance between the electrodes=4mm
3) Disc-Electrodes distance=4mm

MAINTENANCE 070002_3_B
FGP 50/2 EVO-2 14
POSSIBLE CAUSES - SOLUTIONS
TYPE OF IRREGULARITY PROBABLE CAUSE RIMEDY
The control-box stops
with flame (red light on).
The failure is limited to the
flame-controlling device.
1) Photoresistance is cut off or dirty with
smoke.
1) Clean or replace it.
2) Insufficient draught. 2) Check all smoke circuits inside the boiler
and the chimney.
3) The photo-resistance circuit is broken. 3) Replace the control-box.
4) Dirty disk or mouth. 4)To be cleaned.
Not well-shaped flame with
smoke and soot.
1) Insufficient combustion air. 1) Increase combustion air.
2) Insufficient nozzie since it is dirty or worn
out.
2) Clean or replace it.
3) Clogged boiler pipe or chimney. 3) Clean them.
4) Low spraying pressure. 4) Bring it to the prescribed value.
The burner does not start 1) Open contact in (Boiler or room)
thermo-stats or pressure-switches.
1) Increase the value or wait for them to
close by natural
decrease in temperature or pressure.
2) Short-circuited photo-resistance. 2) Replace it.
3) There is no voltage because of the
an open contact in the main switch or the
meter overload-release, or no
voltage in the line.
3) Close the contact of the switches or
wait for voltage to be supplied again.
4) The thermo-stats line was not carried
out according to the diagram or
thermo-stats did not close their contacts.
4) Check thermo-stat connections.
5) Failure inside the control-box. 5) Replace it.
Defective flame with sparks. 1) Spraying pressure is too low. 1) Bring it to the expected value.
2) Too much combustion air. 2) Decrease combustion air.
3) Insufficient nozzle since it is dirty or worn
out.
3) Clean or replace it.
4) Water in fuel. 4) Discharge it from the tank by using a su-
itable pump
(never use the burner pump to carry out
this operation).
The control-box stops the burner
without spraying fuel (red light on).
1) There is one phase missing. 1) Check the feeder line.
2) Insufficient electric motor. 2) Repair or replace it.
3) Light-oil does not reach the pump. 3) Check the suction pipe.
4) No light-oil inside the tank. 4) Fill with fuel.
5) Closed gate-valve in suction pipe. 5) Open it.
6) Clogged nozzle 6) Disassemble and clean it completely.
7) Motor (three-phase) rotating in the op-
posite direction as that indicated by the ar-
row.
7) Invert a phase in the input switch.

MAINTENANCE 070002_3_B
FGP 50/2 EVO-2 15
The control-box stops the burner
with fuel spraying but no flame (red light
on).
1) The ignition circuit is broken. 1) Check the circuit completely.
2) The ignition transformer cables have dri-
ed over time.
2) Replace them.
3) The ignition transformer cables are not
well connected.
3) Fasten them.
4) The ignition transformer is cut off. 4) Replace it.
5) The electrode faces are not at the right
distance.
5) Adjust them to the prescribed position.
6) Electrodes discharge to earth since they
are dirty or with a cracked insulation;
also check under the clamps fastening the
insulating materials.
6) Clean or, if necessary, replace them.
TYPE OF IRREGULARITY PROBABLE CAUSE RIMEDY

F.B.R. Bruciatori S.r.l.
Via V. Veneto, 152 _ 37050 Angiari (VR) _ Italy
Tel. [phone] _ Fax + 39 0442 97299
www. fbr.it _ email: [email protected]
The illustrations and data here shown are indicative. F.B.R. Bruciatori S.r.l. reserves the right to bring, without any obligation of warning, any changes that would be appropriate to the continuing development
of their products.