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Summary of Contents for elco Firebird FB 3 K LN
- Page 1 FB 3 K LOW NOx KEROSENE BURNERS 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 3 K 73 LN 414851 3146164 FB 3 K 100 LN...
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Page 3: Table Of Contents
CONTENTS 1 SAFETY Overview ..............5 Intended use. - Page 4 5 COMMISSIONING Safety during commissioning ..........33 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 3 K LN is a latest generation single-stage burner fuelled by kerosene. 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
Burner factory tested Danfoss 2.00 GPH 60° S - Pump: 7.0 bar Air and head set for CO2 12.5% +/-0.2 Temp 20°C +/-5, CF d 80 mm, L 1.5 m Burner ELCO code Electrical supply Week and year of manufacture Protection level... -
Page 10: Structure
GENERAL Structure 2.4.1 Structure of the burner Heat demand LED Fastening screws for equipment plate Connection PLUG-IN between equip- Fan housing ment and ignition transformer Flame sensor Snorkel Reset button Air setting screw Control box Air box Air valve indicator Fig. - Page 11 GENERAL Combustion head Extended pressure port Cover fixing screw Electric motor Front panel Maintenance position plate Burner fixing screw Oil pressure regulator Burner flange Oil pump Conventional flue carter (optional) Solenoid valve Cable kit with 7 and 5 pin connectors Ignition transformer Capacitor Fig.
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Page 12: Structure Of The Combustion Head
GENERAL 2.4.2 Structure of the combustion head Blast tube Electrodes fixing screw Diffuser Blast tube fixing screw Electrodes Nozzle Diffuser fixing screw Fig. 4 12/60... -
Page 13: Control Box
GENERAL Control box The EBR-M1 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 (170 ±... -
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 30 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 Ø80 Ø 190 Ø 163 Ø 147 15 Max Øi 115 Fig. 7 Weight (kg) Model with packaging FB 3 K 73 LN 10,1 12,8 FB 3 K 100 LN 10,1 12,8 4 0 0 All measurements are given in millimetres. -
Page 16: Technical Data
TECHNICAL DATA Technical data FB 3 K 73 LN FB 3 K 100 LN 68,0 kW 92,8 kW Burner output factory setting 58.480 kcal/h 79.808 Kcal/h Oil throughput factory setting 5,7 kg/h 7,7 kg/h Fuel oil Kerosene, visc 1÷2,5 mm /s at 20°C (Hi=11,97 kWh/kg) <... -
Page 17: Electrical Diagram
TECHNICAL DATA Electrical diagram Fig. 9 17/60... -
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: Burner Assembly
INSTALLATION Burner assembly CAUTION Install the burner on the boiler according to the installation position shown in “Fig. 10”. CAUTION Installation 2,3 and 4 are forbidden for safety reason. Fig. 10 The burner is secured to the boiler using the connection flange supplied with the burner. Follow the instructions below: –... - Page 21 INSTALLATION – position the gasket and the flange (2), with the screw (1) facing upwards, onto the boiler and secure it with the four 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 22: Removing And Fitting The Burner Cover
INSTALLATION – in case of balance flow, insert the air intake pipe (8) on the snorkel (10) and fix it by a clamping collier (9), not supplied – in case of conventional flue applications remove snorkel (10) and replace with the conventional flue carter (11) (optional) after removing the front side (12). -
Page 23: Oil Systems
INSTALLATION Oil systems FUEL LEAKS - Fuel leaks may cause fire to break out. - They may be toxic via inhalation and cause skin irritation. CAUTION - Act swiftly to remove the cause of the leak. If it is connected to a maintenance operation, use the dedicated personal protective equipment. -
Page 24: Hydraulic Diagram
INSTALLATION 4.6.1 Hydraulic diagram Pressure Suction Return Bypass screw Pressure gauge port Diaphragm Pressure adjustment Nozzle outlet Return outlet Filter Suction inlet NC Valve Pressure regulator Constriction Vacuum gauge port Fig. 16 4.6.2 Oil pump Fuel-oil solenoid valve Suction connection Solenoid valve electrical connection Return connection Fuel delivery pipe... - Page 25 INSTALLATION • One-pipe system (standard) The pump is supplied for operation with one pipe. The return connection is capped. Inside the pump, there is a screw with a by-pass washer (10) which allows the fuel to recirculate inside the pump. To apply the fuel delivery pipe, proceed as follows: –...
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Page 26: Oil Feed And Suction Line With One-Pipe System
- Y must be kept as lower as possible in order to avoid cavitation. Anyway Y< 4 m. CAUTION CAUTION ELCO recommends a good quality fuel filter at the tank and a secondary filter (15µ) are used to protect the burner pump from contamination. CAUTION Burner higher than tank Fig. -
Page 27: Oil Feed And Suction Line With Two-Pipe System
- Y must be kept as lower as possible in order to avoid cavitation. Anyway Y< 4 m. CAUTION CAUTION ELCO recommends a good quality fuel filter at the tank and a secondary filter (15µ) are used to protect the burner pump from contamination. CAUTION Burner higher than tank Fig. -
Page 28: 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 29: Electrical Connection To The Boiler
INSTALLATION 4.7.1 Electrical connection to the boiler Burner FB 3 K LN leaves the factory configured for connection to a 7 pin electrical cable. An adaptor cable kit from 7 pins to 5 pins is also supplied and factory mounted. Proceed as follows to connect the burner to the boiler: –... -
Page 30: Removing The Burner
INSTALLATION 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. If it becomes necessary to remove the burner, proceed as follows: –... - Page 31 INSTALLATION – remove the fuel delivery pipe (5) and the return pipe (6), only for two pipes system Fig. 27 – drain any fuel still inside the burner and in the fuel delivery pipe and collect it in a basin –...
- Page 32 INSTALLATION – 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. 29 CAUTION Dispose of any fuel that comes out of the burner in accordance with applicable legislation in the CAUTION destination country.
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Page 33: 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 34: Factory Pre-Setting
COMMISSIONING Factory pre-setting The combustion head and pump pressure are pre-set to obtain the proper output and head drop pressure. The air flap is adjusted to set CO2% according to the curve (“Fig. 31”) with a tollerance of ± 0,2%. Kerosene version Combustion head Burner... -
Page 35: Burner Adjustment
COMMISSIONING 5.3.2 Burner adjustment Check and, depending on the system, eventually adjust the oil pressure (“Fig. 30”) in accordance with the table 5.3. Adjust the air flow gradually, operating on air flap setting (“Fig. 31”), if necessary. Note. Do not adjust the combustion head, factory scaled. Fig. -
Page 36: Air Flap Position
COMMISSIONING 5.3.3 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. 32 36/60... -
Page 37: 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 38: Setting And Values Recorded
COMMISSIONING 5.4.1 Setting and values recorded Customer: _________________________________________________________________ Heating system: _____________________________________________________________ BOILER Type Output kcal/h BURNER Type FB 3 K 73 LN FB 3 K 100 LN Serial number Output Nozzle size Spray angle/cone type Fan pressure mbar Combustion chamber pressure mbar Air flap scale... -
Page 39: 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 40: 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 41 MAINTENANCE – remove the fuel delivery pipe (5) and the return pipe (6), only for two pipes system Fig. 35 – drain any fuel still inside the burner and in the fuel delivery pipe and collect it in a basin –...
- Page 42 MAINTENANCE – loosen the nut (9), rotate the burner clockwise (10) slightly to the right, slide it off the boiler. Fig. 37 CAUTION Dispose of any fuel that comes out of the burner in accordance with applicable legislation in the destination country.
- Page 43 MAINTENANCE To facilitate maintenance operations, secure the burner to the boiler by inserting the fastening screw (11) into the hole (12) on the burner base. Use one of the three square grooves on the burner base to secure the burner, which should be rotated to the best position for the maintenance operation to the carried out.
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Page 44: 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 45: Diffuser Position Check
MAINTENANCE 6.3.2 Diffuser position check To check the position of the diffuser: – remove the blast tube as described in paragraph “6.3.1 Cleaning and replacing combustion head components” on page 44 – use the key provided to loosen screw (8) and allow the diffuser position check. One turn of the key is sufficient. -
Page 46: Combustion Head Position Check
MAINTENANCE – after having adjusted the position of the diffuser tighten the screw (8). – refit the blast tube. Fig. 42 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. -
Page 47: Electrode Position Check
MAINTENANCE 6.3.4 Electrode position check – Check the distance between tips of electrodes (2 mm) Fig. 44 – Check the position of the electrodes assuring that they are centered as shown in “Fig. 45”. A-A 1 : 1 Fig. 45 47/60... -
Page 48: Replacing The Coil
MAINTENANCE 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: – remove the connector (1) – remove the nut (2) using the key supplied –... -
Page 49: Cleaning The Internal Rotor
MAINTENANCE 6.3.7 Cleaning the internal rotor Check there is no dust inside the fan wheel because this could reduce the combustion performances. Carry out maintenance operations, avoiding to damage the fan. Verify the correct position of fan wheel within the burner housing. Follow the sequence –... -
Page 50: Cleaning The Pump Filter
MAINTENANCE 6.3.8 Cleaning the pump filter To be able to clean the filter (H), it is necessary to remove the pump cover. Check the pump cover seal and replace the gasket if necessary. Fig. 50 6.3.9 Replacing oil pump CAUTION If the pump is blocked, proceed as follows. -
Page 51: Replacing Control Box
MAINTENANCE – rotate manually the shaft (3-4 rotations both clockwise and anticlockwise) Fig. 52 – refit the pump to the motor – reconnect the oil pipe to the pump. Check that there is no oil leakage on the pump side after this operation. -
Page 52: 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 53: Troubleshooting Diagram
TROUBLESHOOTING Troubleshooting diagram Boiler control Burner supplied with motor heat demand runs Replace Check green Motor Pump motor blocked LED lights seized capacitor Check boiler Replace Check Dirty Clean filter control motor pump filter Cleaned Unblock/Replace pump Lock out after 20 sec pre-purge Check flame Check pump... - Page 54 TROUBLESHOOTING Boiler control Burner Lock out Is there a Remove supplied with motor during pre false flame false flame heat demand runs purge phase signal causes Boiler control Burner Lock out Is there a Remove supplied with motor during pre false flame false flame heat demand...
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Page 55: Spare Parts List
SPARE PARTS LIST SPARE PARTS LIST Fig. 57 55/60... - Page 56 SPARE PARTS LIST FB 3 K 73 LN FB 3 K 100 LN Description 3146164 3146165 0010 OIL PUMP 65327227 65327227 0020 COIL 65327245 65327245 0030 COUPLING 65327229 65327229 0040 FLEXIBLE OIL HOSE 65328371 65328371 0050 BURNER COVER 65327543 65327543 0060 MOTOR + CAPACITOR 65327544...
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Page 57: Manufacturer Certificate
MANUFACTURER CERTIFICATE MANUFACTURER CERTIFICATE Manufacturer Certificate / EU Design Conformity Declaration We, Firebird, declare under our sole responsibility that the kerosene burners named FB 3 K ... LN is conform to the following standards: – EN 267 – EN 55014-1 –... -
Page 58: Appendix
APPENDIX APPENDIX 10.1 Use of bio fuel blends The burner is suitable for kerosene with a biofuel content of up to 30%. It is a minimum requirement that the fuel blend (up to 30% Biofuel) is obtained with kerosene in accordance with the relevant standards, regional regulations and FAME in accordance with EN 14214. - Page 59 APPENDIX Wherever an existing tank is to be used to store the oil, in addition to the above mentioned checks on the materials, it is essential that the tank is first inspected to verify its condition and check for the presence of water or other contaminants. If contaminants are found, a deep clean should be carried out.
- Page 60 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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