Kroll EMB Series User manual

Technical Information • Installation Instructions
Oil
October 2018 edition
In the interests of continuous product
improvement, technical specifications
are subject to change without prior notice.
Universal Oil Burner EMB 20
GB

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Contents
1. General information ................................................................................................................... 3
2. Checking scope of supply and electrical ratings ........................................................................ 3
3. Operating instructions ................................................................................................................ 3
4. Instruction .................................................................................................................................. 3
5. Maintenance and customer service ........................................................................................... 3
6. Technical specifications ............................................................................................................. 4
7. Functional description ................................................................................................................ 4
8. Air/oil flow schematic.................................................................................................................. 4
9. Installing flange and burner........................................................................................................ 5
10. Connecting to power supply....................................................................................................... 5
11. Compressed air connection ....................................................................................................... 5
12. Setting the ignition electrodes.................................................................................................... 6
13. Control unit ................................................................................................................................ 7
14. Table of settings ........................................................................................................................ 8
15. Settings for primary airflow ........................................................................................................ 9
16. Combustion air flow rate ............................................................................................................ 9
17. Flue connection.......................................................................................................................... 9
18. Flue gas thermometer................................................................................................................ 10
19. Maintenance .............................................................................................................................. 10
20. Wiring diagram........................................................................................................................... 11
21. Possible errors .......................................................................................................................... 12
22. Exploded view drawing / parts list.............................................................................................. 13
23. Burner dimensions / boiler connecting dimensions.................................................................... 16
24. Operating range ......................................................................................................................... 16

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General information
1. General information
An oil-fired system must be installed in compliance with a number of regulations and requirements. It is
therefore the duty of the installer to be familiar with all applicable regulations and requirements. Installation,
start-up and maintenance must be performed with utmost care.
The burner must not be operated in rooms with high levels of air humidity (laundry rooms), dust or corrosive
vapours.
The burner series is certified according to EN 267 for fuel and colza oil.
Operation with other combustibles, especially highly combustible liquids as thinner, pet-
rol, alcohol and corresponding composites, as well as brake fluid and antifreeze mixture,
is not allowed.
Composites made up of high- and low viscosity liquids could separate .
Danger of autoignition !
Danger of injury !
Danger of material damage !
The use of flammable liquids with solid-sludge- or water content causes malfunction and
breakdowns.The design and degree of protection of the burner make it suitable for oper-
ation in enclosed rooms.
2. Checking scope of supply and electrical ratings
Before installing the universal oil burner EMB 20 please check the items supplied for completeness.
Scope of supply:
burner, mounting unit, separate operating instructions, technical information, flange seal.
Near wear-free compressed air atomising nozzles are pre-fitted at the factory.
3. Operating instructions
This technical information should be displayed in a visible position in the boiler room as operating instruc-
tions. It is essential to write the address of the nearest customer service centre in the operating instructions.
Caution !
Improper installation, adjustment, modification, operation or maintenance may result in
physical injury or damage to property/equipment. Read the instructions prior to use.
This product must be installed in accordance with the applicable regulations
(e.g. DIN-VDE).
4. Instruction of operating personnel
Faults are often caused by operator error. The operating personnel must be properly instructed in how the
burner works. In the event of recurring faults, Customer Service should be notified.
5. Maintenance and customer service
The complete system should be checked once a year for proper functioning and leak tightness by an au-
thorised representative of the manufacturer or by another expert. We accept no liability for consequential
damage in cases of incorrect installation or repair, the fitting of non-genuine parts or where the equipment
has been used for purposes for which it was not intended.
Caution!
For maintenance and service work, the burner must be switched off!

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Technical specifications
6. Technical specifications
7. Functional description
The fuel is pumped out of the supply tank and into the burner tank. A float switch controls the level inside
the burner tank. An additional microswitch serves as a limiter, switching over to fault mode when the tank
is overfilled. A thermostat regulates the oil temperature in the burner tank and starts the burner when the
set temperature is reached. Thereafter, the automatic oil burner control system controls and monitors the
operation of the burner. Fuel is aspirated and finely atomised by a special nozzle using the compressed air
flowing through the burner, which is used as primary air for the combustion process. The burner blower
supplies the secondary air which is added to the atomised spray at the baffle plate. This ensures full com-
bustion and operational reliability.At the oil temperature in excess of 150° C, the safety switch automatically
deenergises the burner.
8. Air/oil flow schematic
Burner type
Technical specifications EMB 20
Output, fuel oil kW 33 - 52
Oil throughput, fuel oil kg/h 2.8 - 4.4
Output, rapeseed oil kW 27 - 40
Oil throughput, rapeseed oil kg/h 2.7 - 4.0
Compressor output m
3
/h 4
Primary air connection bar 0.4-0.8
Motor output W 90
Heating element W 1100
Voltage 1/N/PE ~50 Hz 220 - 240 V
Weight kg 20
Noise emission in dB A 71
Feed line
Contact switch
Heating cartridge
E1 + F6
Overflow tank
Burner tank
Thermostat
F1
Safety valve Pressure gauge
Solenoid valve
Y1
Primary air actuator
Pressure controller
Connecting line
baffle plate
Burner pipe
Nozzle
Nozzle assembly
Oil line
Fan wheel
M1
Micro-switch,
overflow protection
S1
Micro-switch,
level control
S2

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Install flange and burner
9.Install flange and burner
Attach the burner flange and the seal to the heat
generator.
10.Connect to power supply
• Connect the burner to the power supply using the
supplied connector unit as indicated in the wiring
diagram.
• HEED LOCAL REGULATIONS !
• Use flexible wiring.
Overcurrent protection configuration
The overcurrent protection devices must be rated for
the electrical current range indicated in the technical
specifications and to provide protection against electri-
cal shock according to DIN IEC 60364-4-41
(VDE 0100-410).
11. Compressed air connection
Connect a compressed air line to the pressure regula-
tor (1).
7-pin
1

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Setting the ignition electrodes
12.Setting the ignition electrodes
The ignition electrodes are preset. The specified dimensions (Fig.) are for checking purposes.

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Function testing the control unit
13. Function testing the control unit
Carry out the following checks after start-up and after the burner has been serviced:
• Restarting with a covered flame detector:
the control unit must go into fault mode on expiration of the safety period.
• Burner start-up with flame detector exposed to external light, e.g. fluorescent lamp, lighter, light bulb
(daylight is not enough):
The control device must switch over to fault mode during the pre-aeration period as a consequence of
the external light.
• Normal start-up - if the burner is in operation, darken the flame detector during the post-ignition
period (e.g. unplug and cover flame detector)
TF 834: the ignition must switch on and upon expiration of the safety period the device must switch
over to fault mode.
• Post-aeration after flame cut-off.
Safety and switching functions
If a flame failure occurs during operation, the fuel feed shuts off immediately and the system tries a restart,
with pre-aeration and retarded ignition. If no flame results, the control box indicates a fault after the safety
interval expires. In any case, the control unit is restarted following a mains power failure. The control unit
indicates a fault if an external light source is detected during the pre-aeration cycle after expiration of the
safety cycle.
The control unit may only be plugged in or unplugged if the master switch is in the "OFF" position
or if the 7-pin plug connector is disconnected, because the bottom part of the control unit
carries 230 V.
Incidence of external light on the photoresistor or flame detector must be prevented (e.g. through
a sight glass or red-hot fireclay lining). Only then is fault-free operation of the system assured.
Honeywell: TF 834.3
t
v1
= pre-ignition cycle + pre-aeration 12 secs.
t
s
= safety interval 10 secs.
t
n
= post-ignition time 20 sec.
Post-aeration after flame cut-out. -
Delay after switching-off fault approx. 60 sec.
Photoresistor (flame detector) MZ770
Ölvorwärmung
Ventilator
Zündung
Magnetventil
Flammenwächter
Störlampe
Anlauf mit Flammenbildung (Normalbetrieb)
Betrieb
Störung
Ölvorwärmung
Ventilator
Zündung
Magnetventil
Flammenwächter
Störlampe
Anlauf ohne Flammenbildung (Störbetrieb)
Sicherheit
Sicherheit
ts
tv1
tv1
ts
tn
Ventilator
Magnetic valve
Ignition
Fault indicating lamp
Flame detector
Oil preheater
Operation
Fault
Start without flame formation
Start with flame formation
safety period
safety period
Ventilator
Magnetic valve
Ignition
Fault indicating lamp
Flame detector
Oil preheater

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Adjustment table
Measuring the photocurrent (MZ 770S only)
To measure the photocurrent, disconnect the plug unit
from the flame failure controller and install the pair of
measuring cables* between the plug and socket unit.
Both measuring connections should be connected to
the measuring instrument. If there is a negative deflec-
tion of the measuring instrument, reverse the plug on
the measuring instrument lead ! Set the measuring in-
strument to ampere metering for DC, measuring range
up to approx. 200 µ mA !
Recommended measuring accessories
Digital measuring instrument Art. No. 59-20-50263
* Pair of measuring cables
for photocurrent Art. No. 59-20-50408
14.Adjustment table
The values given in the table are only setting values for start-up. The system settings required
in each case must be redefined if values such as boiler output, calorific value and altitude deviate.
Adjustment is required in any case (due to the system design).
• For initial start-up, fill the burner tank up to the oil mark by hand.
Caution !
If the oil level is too high, the float switch will switch off the burner.
If the oil level is too low, the heating cartridge will become encrusted or damaged.
Adjustment table for rapeseed oil
Adjustment table for fuel oil
The thermostat on the burner tank must be set to between "min." for heating oil EL and 140°C
for rapeseed oil, depending on the viscosity of the oil.
Burner type EMB 20
Output in kW 30 35 37 40 42
Oil throughput in kg/h 2.8 3.3 3.5 3.8 3.9
Primary air in bar 0.3 0.4 0.5 0.6 0.7
Secondary air
(scale on air damper)
7.0 11.0 12.5 14.0 14.5
Thermostat setting in °C 140
Burner type EMB 20
Output in kW 33 38 43 47 50
Oil throughput in kg/h 2.8 3.2 3.6 3.9 4.2
Primary air in bar 0.2 0.3 0.4 0.5 0.65
Secondary air
(scale on air damper)
8.0 12.0 16.0 19.0 23.0
Thermostat setting in °C 0° do not heat
Flame failure controller
Control unit
bottom part
500µA
or
200µA

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Settings for primary airflow
15. Settings for primary airflow
The primary airflow should be set using the pressure
regulator (1) according to the required burner output.
The information given in the diagram can be used as
guide values.
Higher-viscosity fuels require higher air pressures.
16. Combustion air flow rate
Setting the combustion air flow rate (2).
Ideal values:
- Soot index according to Bacharach <1
- O
2
= 4 - 5%
The CO
2
values of a commercially available measuring in-
strument can only be used for processing the combustion
process for heating oil EL.
Flue gas temperature according to the operating instructions
of the heat generator.
17. Flue connection
The prerequisite for perfect operation of the furnace is a correctly dimensioned flue.
Dimensioning is effected in accordance with DIN 4705 in consideration of DIN 18160 and based on the
boiler and burner outputs.
For operation on a sliding basis, provide flues as per DIN 18160 part, group 1. The flue gas mass flow
of the total rated heat output must be factored into the calculation. The effective flue height is counted from
burner level. Furthermore, we refer you to the statutory building regulations of the individual German fed-
eral states.
Select a flue design which minimises the danger of condensation or of a cold flue inner wall.
For exact adjustment and stabilisation of the flue draught we recommend the installation
of a draught limiter.
Thus:
• any draught fluctuations are equalised
• moisture in the flue is largely excluded
• stoppage losses are reduced.
Connection pieces should be introduced into the flue with a gradient of 30° or 45° viewed in flow direction.
It is best to provide flue gas pipes with thermal insulation.
1
2

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Flue gas thermometer
18. Flue gas thermometer
For flue gas temperature monitoring the heating system should be equipped with a flue gas thermometer.
The higher the flue gas temperature, the greater the flue gas loss.
Rising flue gas temperatures indicate increasing deposits that will reduce the degree of combustion effi-
ciency. In the event of an increasing flue gas temperature have the heating installation cleaned and read-
justed by a skilled person.
19. Maintenance
Depending on the quality of the oil used, we recommend the following maintenance intervals:
After more than 3 days downtime:
• drain off residual water and sludge through the water drain cock in the burner tank,
Monthly:
• Clean the filter in the supply tank or the unit tank and strainer on the floating suction unit
• Remove and clean the feed pump filter
• Remove sludge and residual water from the supply tank or unit tank
• The quantity can be determined by using water indication paste and a gauging rod
• Clean the photocell
• Clean the ignition electrode and baffle plate and blow out the nozzle with compressed air, check the
spacing between the ignition electrodes (refer to checking dimensions for ignition electrodes)
Annually (before or after the heating period):
• Carry out monthly maintenance as described
• Clean the heating cartridges in the burner tank
• Clean the ignition electrodes and baffle plate, blow out the nozzle with compressed air and check the
spacing between the ignition electrodes
• Clean the burner tank, supply tank and unit tank thoroughly.