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

E.04.2000 • G. 06.02.19

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

E. 04.2000 • G. 06.02.19

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!

E.04.2000 • G. 06.02.19

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

/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

Safety valve Pressure gauge

Solenoid valve

Primary air actuator

Pressure controller

Connecting line

baffle plate

Burner pipe

Nozzle

Nozzle assembly

Oil line

Fan wheel

Micro-switch,

overflow protection

Micro-switch,

level control

E. 04.2000 • G. 06.02.19

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

E.04.2000 • G. 06.02.19

Setting the ignition electrodes

12.Setting the ignition electrodes

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

E. 04.2000 • G. 06.02.19

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

= pre-ignition cycle + pre-aeration 12 secs.

= safety interval 10 secs.

= 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

tv1

Ventilator

Magnetic valve

Ignition

Fault indicating lamp

Flame detector

Oil preheater

Operation

Fault

Start without flame formation

Start with flame formation

safety period

Ventilator

Magnetic valve

Ignition

Fault indicating lamp

Flame detector

Oil preheater

E.04.2000 • G. 06.02.19

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

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

200µA

E. 04.2000 • G. 06.02.19

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

= 4 - 5%

The CO

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.

E.04.2000 • G. 06.02.19

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.

E.04.2000 • G. 06.02.19

Troubleshooting

21. Troubleshooting

Observation Cause Remedy

Burner does not start

Oil not combustible due to sludge and / or water

Oil tank empty

Oil level in burner tank too high

Filter dirty, oil or air lines leaky

Faulty feed pump solenoid valve

Nozzle dirty or faulty

Feed pump blocked

No current

Motor faulty

Thermostat faulty

Photocell dirty or not correctly inserted

Control unit faulty

No ignition

No compressed air

Solenoid valve faulty

Compressor or air line faulty

Open the water drain cock on the burner tank,

drain off sludge and water or

use a higher-grade heating oil

Refill tank with oil

Correct the oil level by draining off oil by means

of the water cock (readjust the level control

float switch, if necessary)

Clean the filter, feed pump filter and lines

Check the feed pump solenoid valve and

replace if necessary

Replace nozzle

Strip the feed pump and clean the gear

Switch on the heater switch

Replace

Clean the photocell, replace it or connect it

properly

Replace

Adjust the ignition electrode, replace the igni-

tion transformer if necessary and check the

ignition cable

Connect and/or open the compressed air and

set the pressure

Replace

Burner starts very late Heating cartridge and thermocouple in burner

tank encrusted or faulty

Clean or replace the heating cartridge and

thermocouple in the burner tank

Burner starts without

pre-ventilating

Solenoid valve sticking in open position Replace

No oil feed Solenoid valve faulty Replace

Flame is interrupted or

extinguishes

Oil not combustible due to sludge and / or water

Oil supply used up

Clogged nozzle

Dirty feed pump filter

Oil line to tank frozen

Supply tank to far away from burner

Filter or oil lines dirty

Solenoid valve faulty

Too much or not enough compressed air

Safety temperature limiter is in the safety posi-

tion because the heater has overheated

Micro-switch in burner tank cuts out

Open the water drain cock on the burner tank,

drain off sludge and water or use higher-grade

oil

Refill tank with oil

Replace nozzle

Clean feed pump filter

Clean oil lines, and insulate tank and oil line

Install an additional feed pump

Replace filter and clean oil lines

Replace

Check compressed air and gauge pressure

using primary airflow control

Troubleshoot the heater and unlock the safety

temperature limiter

Adjust the level control float

Nozzle and baffle plate

are heavily soiled with

oil or soot

Incorrect baffle plate setting

Combustion airflow rate too high or too low

Boiler room is not sufficiently ventilated

Correct the baffle plate setting dimensions

Set the primary airflow rate

Set the secondary airflow rate at the air control

flap

Pay attention to sufficiently large ventilation

ports

E. 04.2000 • G. 06.02.19

Exploded view drawing / spare parts list

22. Exploded view drawing / spare parts list

E.04.2000 • G. 06.02.19

Exploded view drawing / spare parts list

Position Benennung VE Art.-Nr.

1 Burner pipe EMB 20 1 47-90-22291-01

2 Mounting flange seal 5 47-50-24429

3 Mounting flange EMB 20 1 47-90-29981

4 Diaphragm plate compl. with holder 1 47-90-22826

5 Nozzle assembly compl. 1 37-90-11391

5 Nozzle assembly compl. 100 mm extension 1 47-90-29210

5 Nozzle assembly compl. 200 mm extension 1 47-90-29216

6 Nozzle Delavan SNA 30609-11 1 47-90-22804

7 Zündelektrode 2 47-50-22381

8 Ignition electrodes 1 47-90-27621

8 Ignition electrodes 100 mm extension 1 47-90-29242

8 Ignition electrodes 200 mm extenseion 1 47-90-29243

9 Air control handwheel 1 47-90-12100

10 Air damper flange 1 47-90-12099

11 Air damper compl. 1 47-90-12096

12 Housing cover 1 47-90-12095

13 Sight glass 5 47-50-12105

14 Sight gflass cover 5 47-50-12106

15 7-pin socket with cable 1 47-90-11839

16 Control unit bottom part S98, 9-pin, compl. 1 31-90-22664

17 Satronic TF 834.3 control unit 1 37-90-11285

18 Fan wheel 146 x 52 1 47-90-12014

19 Motor 140 W 1 47-90-27395

20 Motor with fan wheel compl. 1 47-90-29964

32 Oil tank connection compl. 1 47-90-27627

35 Intake tube compl. 1 47-90-24514

36 Heating coil 1100 W 1 47-90-24505

37 Oil tank EMB 50 1 47-90-29960

38 Oil tank cover 1 47-90-29926

39 Pre-assembled electrical box 1 47-90-29953

40 Safety thermostat 1 47-90-29935

41 Flush-type thermostat 1 47-90-29933

42 Twin microswitch 1 47-90-10601

43 Float 1 47-90-22420

44 Control housing cover 1 47-90-29928

45 Oil tank - nozzle assembly connecting tube 1 37-90-10287

45 Oil tank - nozzle assembly connecting tube 100 mm extension 1 47-90-29211

45 Oil tank - nozzle assembly connecting tube 200 mm extension 1 47-90-29214

46 Electronic ignition unit Mod. 26/48 1 47-90-26930

47 Air distributor connecting tube 1 47-30-27631

48 Air distributor, compl. preassembled 1 47-90-29962

50 Pressure gauge 0-2.5 bar 1 47-90-12121

52 Double reduction nipple 1/4“ - 1/8“ 1 44-90-23075

53 Replacement pressure regulator 1 47-90-24594

54 Double nipple NR 280 R 1/8“ 1 44-90-23087

55 Flame detector MZ770 compl. with cable 1 47-90-22816

58 Float switch 1 47-90-29932

59 Power relay 56.328 1 47-90-27681

- Motor cable 1 37-90-11812

10-2018 • Art. No. 70-14-58325-GB • Printed in Germany •

MVZ GmbH • Heizung Sanitär Solar

Kalkwerkstraße 32 • D-71737 Kirchberg a. d. Murr • Telefon 07144/865 99 00•

Telefax 07144/130 56 09 • E-Mail: i[email protected]

All information in this technical documentation as well as the drawings, photos

and technical descriptions placed at your disposal remain our property and may

not be duplicated without our written permission given in advance.

Subject to change.

23. Burner dimensions / boiler connection dimensions

24.Working range

Burner type d1 k

EMB 20 90 125 - 160

X= Burner tube extension 100 mm and 200 mm

45°

30 35 40

Heizöl EL

45 50

Rapsöl

Feuerraumwiderstand [mbar]

2,5

1,5

0,5

GU/GUPO20

Brennerleistung [kW]

Burner output [kW]

Rapeseed oil

Furnace resistance [mbar]

EMB 20

Fuel oil

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 50

E.04.2000 • G. 09.10.18