elco Firebird FB 4.1 R LN Assembly, Commissioning And Maintenance Instructions
Low nox light oil burner
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Summary of Contents for elco Firebird FB 4.1 R LN
- Page 1 FB 4.1 R LOW NOx LIGHT OIL BURNER Instructions to Assembly, Commissioning and Maintenance Before installing and using the burner, read this manual carefully and keep it close to the burner.
- Page 2 RANGE This manual refers to the following products: BURNER MODEL FIREBIRD CODE ELCO CODE FB 4.1 R 20 LN 416364 3149697 BURNER DESIGNATION FB 4.1R 20 LN FB 4.1 Burner Series...
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Page 3: Table Of Contents
CONTENTS 1 SAFETY Overview ..............5 Intended use. - Page 4 5 COMMISSIONING Safety during commissioning ..........28 Checks before commissioning .
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Page 5: Safety
SAFETY SAFETY Overview These instructions for the installation, commissioning and maintenance of the burner are for use by technicians from professional heating companies that are qualified 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. -
Page 6: Symbols Used
SAFETY 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 DANGER 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. -
Page 7: Requirements For Personnel Or Operators
SAFETY Requirements for personnel or operators CAUTION It may be hazardous to assign activities to personnel that are not sufficiently qualified. It may CAUTION 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 specifically qualified to perform these tasks. -
Page 8: General
GENERAL GENERAL Burner description FB 4.1 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. -
Page 9: Identification
GENERAL Identification Check the identification label of the burner (“Fig. 1”). Burner code Electrical supply Week and year of manufacture Protection level Burner model Electrical consumption Factory power setting Types of fuel used Burner power output Serial number Fig. 1 CAUTION It is strictly forbidden to remove the identification label. -
Page 10: Structure
GENERAL Structure 2.4.1 Structure of the burner Power indication LED Air valve indicator Connection PLUG-IN between control Fastening screws for equipment plate box and ignition transformer Housing for internal rotor Snorkel Flame sensor Air setting Reset button Air intake Control box Fig. - Page 11 GENERAL Blast tube Extended pressure port Cover fixing screw Burner base Burner fixing bolt Oil pressure regulator Burner flange Fuel-oil pump Conventional flue carter (optional) Solenoid valve Cable kit with 7 and 5 pin connectors Ignition transformer Electric motor for pump and fan Front panel Capacitor Fig.
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Page 12: Structure Of The Combustion Head
GENERAL 2.4.2 Structure of the combustion head Blast tube Electrode group fixing screw Diffuser Combustion head fixing screw Electrode group Nozzle Diffuser fixing screw Fig. 4 12/56... -
Page 13: Control Box
GENERAL Control box The EBR-M18 control box, controls and monitors the forced draught burner. The microprocessor- controlled program sequence ensures maximum stability of time periods, regardless of fluctuations in the power supply or ambient temperature. The design of the control box protects it from the effects of flame outs. Whenever the supply voltage drops below its rated minimum level (160 ±... -
Page 14: Controlled Shutdown
GENERAL 2.6.2 Controlled shutdown – Boiler temperature control interrupts heat request. – The fuel-oil solenoid valve closes and the flame 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:... -
Page 15: Technical Data
TECHNICAL DATA TECHNICAL DATA Dimensions and weights Ø 80 Ø 175 Ø 151,5 15 Max Ø 126,5 Øi 100 FB 4.1 R 20 LN 301 138 163 Fig. 7 Weight (kg) Model with packaging FB 4.1 R 20 LN 10,1 3 9 0 All measurements are given in millimetres. -
Page 16: Technical Data
TECHNICAL DATA Technical data FB 4.1 R 20 LN 20,6 kW Burner output factory setting 17.716 kcal/h Oil throughput factory setting 1,72 kg/h Fuel oil Light oil, visc 1,6-6 mm /s at 20°C (Hi=11,97 kWh/kg) < 120 mg/kWh NOx emissions (according to European Commission Regulation No 813/2013 and to pr EN267/2016 Class 4) Control box... -
Page 17: Electrical Diagram
TECHNICAL DATA Electrical diagram Fig. 9 17/56... -
Page 18: Installation
INSTALLATION INSTALLATION Safety during assembly DANGER Danger of death! - Contact with live electrical components may cause serious incidents. - Only professionally-trained and qualified 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. -
Page 19: Installation Area
INSTALLATION Installation area Before installation, make sure that the installation area satisfies the following requirements: – operating temperature between -10°C and +60°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.) –... -
Page 20: Preliminary Checks Before Mounting The Burner
INSTALLATION 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 Fig. -
Page 21: Burner Assembly
INSTALLATION Burner assembly CAUTION Install the burner on the boiler according to the installation position shown in “Fig. 12”. CAUTION Installation 2,3 and 4 are forbidden for safety reason. Fig. 12 The burner is secured to the boiler using the connection flange supplied with the burner. Follow the instructions below: –... - Page 22 INSTALLATION – position the flange (2), with the screw (1) facing upwards, onto the boiler and secure it with the nuts (5) supplied – tighten the nuts (5) of the flange evenly and diagonally with a tightening torque of 3,5 Nm max.
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Page 23: Oil Systems
INSTALLATION – insert the air intake pipe (8) and secure it using a pipe clamp (9), not supplied – in case of conventional flue applications remove snorkel and air conveyor (10) and replace with the conventional flue carter (11) (optional) after removing the front side (12). Fig. -
Page 24: Hydraulic Diagram
INSTALLATION 4.6.1 Hydraulic diagram Pressure Suction Return Bypass screw Pressure adjustment Diaphragm Return outlet Nozzle outlet Suction inlet Filter Pressure regulator NC Valve Vacuum gauge port Constriction Pressure gauge port Fig. 17 4.6.2 Oil pump Fuel-oil solenoid valve Suction connection Solenoid valve electrical connection Return connection Fuel delivery pipe... - Page 25 INSTALLATION • Two-pipe system (standard) For two-pipe operation it is necessary to remove the by-pass washer. To apply the fuel return pipe, proceed as follows: – remove the cap (14) from the connection and screw in the additional return pipe (15), supplied with the burner –...
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Page 26: Oil Feed And Suction Line With Two-Pipe System
INSTALLATION 4.6.3 Oil feed and suction line with two-pipe system Burner lower than tank H = x-y Fig. 21 Pipe length (m) Pipe length (m) H (m) H (m) Ø6 mm Ø8 mm Ø10 mm Ø6 mm Ø8 mm Ø10 mm CAUTION - X <... -
Page 27: Electrical Connection
INSTALLATION Electrical connection DANGER Danger of death caused by live components! Contact with live parts can lead to serious injury, take the following precautions: - ensure that the power is switched off for all electrical parts - electrical wiring installation must be carried out by qualified personnel and in compliance with the regulations currently in force in the country of destination. -
Page 28: Commissioning
COMMISSIONING COMMISSIONING Safety during commissioning CAUTION It may be hazardous to assign activities to personnel that are not sufficiently qualified. It may harm the operators themselves if they perform manoeuvres or operations incorrectly, with a CAUTION 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 specifically qualified to perform these tasks. -
Page 29: Factory Pre-Setting
COMMISSIONING Factory pre-setting Burner Nozzle Pump* Type spray type FB 4.1 R 20 LN 0,45 60° S Danfoss 12,0 Reference conditions – Conventional Flue system: diameter 80 mm / length 1.5 m – Ambient temperature: 20°C +/-5 – CO2 = 12.5% ± 0,2. (*) The pump pressure is referred to a stability period of 5 min. -
Page 30: Air Flap Position
COMMISSIONING 5.4.1 Air flap position Turn the hex key (1) supplied: – clockwise to increase the air flap opening (O rises, CO decreases). – counterclockwise to reduce the air flap opening (O decreases, CO rises). Fig. 25 Adjusting burner output Fuel-oil solenoid valve Suction connection Solenoid valve electrical connection... -
Page 31: Burner Start
COMMISSIONING 5.5.1 Burner start Before starting the burner, draw oil in until the filter is completely filled. Then start the burner by creating a heat demand on the boiler (refer to boiler installation manual). Open the bleed screw on the oil filter to allow the oil line to bleed fully during the preventilation phase. The negative pressure (vacuum) must not fall below 0.4 bar. -
Page 32: Check Pump Rotation
COMMISSIONING 5.6.4 Check pump rotation CAUTION If the pump is blocked, proceed as follows. CAUTION – Disconnect the oil pipe from the pump – remove the pump (1) from the motor loosening screws (3) using the key supplied (2) Fig. 28 –... -
Page 33: Commissioning Record
COMMISSIONING Commissioning record ✓ Confirm the work carried out in the commissioning report below by marking and X or an Commissioning work Note Done Check the heating system has been filled correctly and the air has been removed Check the flue system Check there are no leaks in the fuel supply system Start the burner and check that it is operating... -
Page 34: Setting And Values Recorded
COMMISSIONING 5.7.1 Setting and values recorded Customer: _________________________________________________________________ Heating system: _____________________________________________________________ BOILER Type Output kcal/h BURNER Type FB 4.1 R 20 LN Serial number Output Nozzle size Spray angle/cone type Fan pressure mbar Combustion mbar chamber pressure Air flap scale Oil throughput kg/h Oil pressure (oil... -
Page 35: Maintenance
MAINTENANCE MAINTENANCE Safety during maintenance The periodic maintenance is important for safety, good operation and long life cycle of the burner, reducing also consumption and polluting emissions. The burner must be serviced at least once a year. Only qualified and authorised personnel shall carry out maintenance and the calibration of the burner, in accordance with this manual and in compliance with the local standards and regulations. -
Page 36: Removing The Burner
MAINTENANCE Removing the burner DANGER Danger of death caused by live components! Before carrying out any operations on the burner, operate the main power switch for the system to cut off the power supply. To remove the burner from the boiler, proceed as follows: –... - Page 37 MAINTENANCE – remove the fuel delivery pipe (5) and the return pipe (6) Fig. 32 – drain any fuel still inside the burner and in the fuel delivery pipe and collect it in a basin – loosen the pipe clamp (7) and remove the air intake pipe (8) Fig.
- Page 38 MAINTENANCE – loosen the nut (9) securing the burner to the boiler and, rotating the burner (10) slightly to the right, slide it off the boiler. Fig. 34 CAUTION Dispose of any fuel that comes out of the burner in accordance with applicable legislation in the destination country.
- Page 39 MAINTENANCE Fig. 35 Position A: – inspection and cleaning of the internal rotor. Position B: – inspection of the combustion head – inspection and maintenance of the nozzle – inspection and maintenance of the electrode group. Position C: – inspection and maintenance of the pump –...
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Page 40: Burner Maintenance
MAINTENANCE Burner maintenance – Check the fuel supply components (pipe, pump, fuel delivery pipe) and their connections for leaks and signs of wear, replace parts as necessary. – Check that the electrical connection and connection cables are not damaged, replace them if necessary. -
Page 41: Diffuser Position Check
MAINTENANCE CAUTION If the air distributor (1) is removed from its housing, it must be repositioned, making sure that the hole (2) is aligned with the pin (3). CAUTION Fig. 37 6.3.2 Diffuser position check To check the position of the diffuser: –... - Page 42 MAINTENANCE – check the distance between the diffuser (1) and the nozzle (2) as shown in the figure. Fig. 39 – after having adjusted the position of the diffuser tighten the screw (8). – refit the blast tube. Fig. 40 42/56...
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Page 43: Combustion Head Position Check
MAINTENANCE 6.3.3 Combustion head position check To check the position of the combustion head: – check the distance between the blast tube (1) and the nozzle (2) as shown in the figure. Fig. 41 6.3.4 Electrode position check – Check the distance between tips of electrodes (2 mm) Fig. -
Page 44: Replacing The Coil
MAINTENANCE – Check the position of the electrodes assuring that they are centered as shown in “Fig. 43”. A-A 1 : 1 Fig. 43 6.3.5 Replacing the coil The pump coil is designed and built to withstand temperatures of up to 85°C. In the event of malfunctions or faults, replace the coil using the following procedure: –... -
Page 45: Replacing The Capacitor
MAINTENANCE 6.3.6 Replacing the capacitor Proceed as follows to replace the capacitor: – remove the protection cup (1) from the capacitor (2) – detach the electrical connection from the capacitor – check with an electrical tester if the capacitor is damaged. Connect the tester to the capacitor pins: if the value read is different from the nominal capacity (+10%) written on the capacitor, it means the capacitor is damaged Fig. - Page 46 MAINTENANCE Follow the sequence – loose the screws (1) and remove the air intake duct (2) – clean the fan (3) and the inside of the air intake using a brush – if necessary, disassembly and re-assembly the fan. Fig. 47 Observe the positioning diagram below when replacing the motor and blower wheel (3).
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Page 47: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING Combustion performances After carrying out commissioning, cleaning or maintenance, combustion parameters must be verified. Boiler has to maintain in operation at least 15 min. or reach a steady condition of operation, then check: – pump pressure – flue gas temperature –... -
Page 48: Troubleshooting Diagram
TROUBLESHOOTING Troubleshooting diagram Boiler control Pre heater Burner supplied with consent motor heat demand (within 400s) runs Replace Check green Motor Pump motor blocked LED lights seized capacitor Check green Pre heater LED lights damaged Check boiler Replace Check Clean Dirty control motor... - Page 49 TROUBLESHOOTING Boiler control supplied with Boiler control heat demand supplied with heat demand Burner Lock out Is there a Remove Pre heater motor Burner during pre Lock out false flame Is there a false flame Remove functionality Pre heater runs motor purge phase during pre...
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Page 50: Spare Parts List
SPARE PARTS LIST SPARE PARTS LIST Fig. 52 50/56... - Page 51 SPARE PARTS LIST FB 4.1 R 20 LN N° Description 3149697 0010 OIL PUMP 65327502 0020 COIL 65327245 0030 COUPLING 65327229 0040 FLEXIBLE OIL HOSE 65328371 0050 PRESSURE ADJUSTMENT CUP 65327503 0060 MOTOR + CAPACITOR 65327504 0070 CAPACITOR 65327505 0080 IGNITION TRANSFORMER 65329839 0090...
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Page 52: Appendix
APPENDIX APPENDIX Use of bio fuel blends The burner is suitable for light oil with a biofuel content of up to 30%. It is a minimum requirement that the fuel blend (up to 30% Biofuel) is obtained with light oil in accordance with the relevant standards, regional regulations and FAME in accordance with EN 14214. -
Page 53: General Instructions And Information
APPENDIX 9.2.2 General instructions and information The supplier of the fuel must demonstrate compliance with an accredited quality management system for their storage, mixing and delivery processes. During installation, make sure that all the materials and sealing devices used on the storage tank and oil delivery pipe to the burner are compatible with biofuels. -
Page 54: Manufacturer Certificate
MANUFACTURER CERTIFICATE MANUFACTURER CERTIFICATE 10.1 Manufacturer Certificate / EU Design Conformity Declaration We, Firebird, declare under our sole responsibility that the light oil burners named FB 4.1 R ... LN is conform to the following standards: – EN 267 – EN 55014-1 –... -
Page 55: Note
NOTE... - Page 56 Phoenix House, Eastern Wood Road, Langage Industrial Estate, Plympton, Plymouth, Devon PL7 5ET, United Kingdom. t: +44 (0)1752 691177 f: +44 (0)1752 691131 - e: sales@firebird.uk.com web: www.firebird.uk.com ELCO Via Roma, 64 - 31023 Resana (TV) - Italy Tel. +39 0423 719500 - Fax +39 0423 719580 Company subject to the direction and coordination of Ariston Thermo SpA.
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