Installation and operating instructions B2KSV Classic

Transcription

1 Installation and operating instructions B2KSV Classic

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3 Contents 01. GENERAL... 5 Description... 5 Declaration of conformity... 6 Safety directions TECHNICAL DATA... 8 Type designation B Dimensions... 8 Burner capacity... 8 Recommended nozzle... 8 Table of nozzles INSTALLATION... 9 Acceptance inspection... 9 Preparations for installation... 9 Distribution of oil... 9 Electrical connections... 9 Choice of nozzle... 9 Setting of the shrouded disc and air flow BASIC SETTINGS Nozzle Adjustment of the nozzle assembly Air adjustment Pressure in front of the shrouded disc MAINTENANCE Suspension of burner Removing the blast tube Shrouded disc Setting the ignition electrodes Cleaning the fan wheel Trimming Automatic air damper Service position electric package Pump filter INSTRUCTIONS PUMP TYPE BFP 41L Technical data Components Venting BFP 41L3 operating principle Suction line tables Mounting/dismounting return plug OIL FILTER BENTONE ELECTRICAL EQUIPMENT LOA Wiring diagram List of components Function Technical data FAULT LOCATION Burner fails to start Burner fails to start after normal operation Delayed ignition, burners starts violently... 20

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5 01. GENERAL Description Shrouded disc 2. Preheater 3. Photoresistor 4. Electric contact X1,X2 (see wiring diagram) 5. Air damper 6. Oil pipe 7. Electrodes 8. Fan housing 9. Adjustment of nozzle assembly 10. Frame 11. Control box 12. Blast tube 13. Oil pump 14. Ignition transformer 15. Motor 16. Air adjustment 17. Suction plate 18 Fan housing, part

6 01. GENERAL Declaration of conformity Manufacturer: Enertech AB, Bentone Division Street address: Näsvägen SE Ljungby Address: P.O. Box 309 SE Ljungby Sweden Product: Oil burner Type: B 1, B 2, B 9, B 10, B 11, B 20, B 30, B 40, B 45, B 50, B 55, B 60, B 65, B 70, B 80, ST 97, ST 108, ST 120, ST133, ST 146 Certfikat TÜV Süddeutschland Certifikat Nr Burner B B p15001 ST97, ST108, ST120, ST133, ST B9, B10, B B20, B30, B40, B B50, B60, B70, B B B65 Enertech AB declares under sole responsibility that the above mentioned product is in conformity with the following standards or other normative documents. Document: EN 267 and follows the provisions of applicable parts in the following EU Directives: 89/336/EEC Electromagnetic compatibility 73/23/EEC Low-voltage directive 89/392/EEC Machinery directive 92/42/EEC Efficiency directive In that the burner conforms to the above mentioned standards it is awarded the CE mark. Enertech AB, Bentone Division is quality certified according to SS-EN ISO 9001:2000 Ljungby Sven-Olov Lövgren

7 01. GENERAL - The contents of this manual are to be observed by all who work for any reason on the unit and its appertaining system parts. - This manual is intended especially for authorised personnel. - This manual is to be regarded as part of the burner and shall always be available near the place of installation. - Ensure that the supply of fresh air to the place where the burner is fitted is always unobstructed. - Bentone recommends that the burner is switched off while the cistern is being filled and for a period of six hours after filling to reduce the risk of clogging. - Ensure that the burner is protected against direct spraying with water. - An oil filter should be fitted. Safety directions The electrical installation shall be made according to valid regulations for heavy current and in a professional way, so that the risk of leaking oil, fire or personal injury is avoided. Care should be taken by the installer to ensure that no electrical cables or fuel/gas pipes are trapped or damaged during installation or service/ maintenance. Condensation in chimney Setting the burner A modern burner works with less air surplus and often with a smaller nozzle than older models. This improves the efficiency but increases also the risk of condensation in the chimney. The risk is greater if the cross sectional area of the chimney flue is too big. Temperature of the flue gases should be higher than 60 C measured 0.5 m from the top of the chimney. Measures to raise the temperature: Insulate the chimney thermally in cold loft area. Fit an insert tube in the chimney. Install Dragex or equivalent (to dry and ventilate the chimney during standstill). A flue-gas analysis and measuring of the temperature should be done to facilitate a correct setting. There is otherwise a risk of soot, poor efficiency or condensation in the chimney

8 02. TECHNICAL DATA Type designation B2 Model KSV Dimensions ø89 B Length of Projecting from blast tube flange, size B , ø89, Burner capacity Boiler overpressure mbar 2,5 2,0 1,5 1,0 0,5 3,9-11,1 kg/h kw 0,0 Recommended nozzle -0, Burner output kw Both 60 and 80 and both types S and H can be used. Which nozzle type gives the best result depends on the shape of the combustion chamber. In the first place 60 S should be used. Table of nozzles With preheater 8 bar 9 bar 10 bar 11 bar 12 bar Gph kg/h kw kg/h kw kg/h kw kg/h kw kg/h kw 0,85 2,90 34,4 3,08 36,5 3,24 38,4 3,40 40,3 3,55 42,1 1,00 3,26 38,6 3,46 41,0 3,65 43,2 3,82 45,3 3,99 47,3 1,10 3,72 44,0 3,94 46,7 4,16 49,2 4,36 51,6 4,55 53,9 1,20 3,90 46,2 4,14 49,0 4,36 51,7 4,57 54,2 4,78 56,6 1,25 4,13 48,9 4,38 51,9 4,62 54,7 4,84 57,4 5,06 59,9 1,35 4,53 53,7 4,81 57,0 5,07 60,0 5,31 63,0 5,55 65,8 1,50 5,12 60,7 5,43 64,3 5,72 67,8 6,00 71,1 6,27 74,3 1,65 5,33 63,2 5,65 67,0 5,96 70,6 6,25 74,1 6,53 77,3 1,75 5,74 68,0 6,09 72,2 6,42 76,1 6,73 79,8 7,03 83,3 2,00 6,50 77,1 6,90 81,7 7,27 86,2 7,63 90,4 7,97 94,4 2,25 7,32 86,7 7,76 92,0 8,18 97,0 8,58 101,7 8,96 106,2 2,50 8,14 96,5 8,64 102,3 9,10 107,9 9,55 113,2 9,97 118,2 2,75 9,19 109,0 9,75 115,6 10,28 121,8 10,78 127,8 11,26 133,4 3,00 9,98 118,4 10,59 125,6 11,16 132,4 11,71 138,9 12,23 145,

9 03. INSTALLATION Acceptance inspection Ensure that everything is delivered and that there is no transport damage. If there is anything wrong with the delivery, please report it to the supplier. Any transport damage should be reported to the forwarding company. Preparations for installation Distribution of oil Electrical connections! Warning Choice of nozzle Ensure that the size and capacity range of the burner are suitable for the boiler. Power data on the data plate refer to the minimum and maximum power of the burner. To ensure satisfactory operation it is essential that the oil distribution system is correct. Observe the following: - See Pump instructions for choice of tube diameter, tube length and height difference. - Fix the tubing with a minimum number of screw fittings. - Fix the tubes so that the oil hoses are not subjected to tensile stress or sharp bending when swinging out the burner or removing it for service. - Fit the oil filter so that the filter cartridge can easily be replaced, see Oil filter Bentone. The main power switch must be turned off before beginning the electrical installation. If the boiler has a 7-pole contact device type Eurostecker it will most often fit the burner direct. Otherwise use the accompanying contact device. The operating thermostat and maximum thermostat, and also any fire-door switch, can then be connected in series with the incoming phase or be connected between T1 and T2. In the first case T1 and T2 are to be strapped. If another electrical connection is used than the one recommended by Bentone, there might be a risk of material damage or personal injury. See under Technical Data: Recommended nozzle and table of nozzles. Setting of the shrouded disc and air flow The burner is pre-set on delivery in relation to the nozzle provided. If the size of the nozzle is changed the burner can be initially set according to Basic settings. Note that it is only a question of a basic setting that should be trimmed when the burner is started. This should include a flue gas analysis and measurement of soot

10 04. BASIC SETTINGS Nozzle Burner output with preheater Pump pressure, bar ,10gph 1,25gph 1,50gph 1,75gph 2,00gph 2,25gph 2,50gph 10 2,75gph Adjustment of the nozzle assembly Nozzle assembly, scale Burner output, kw Burner output, kw Air adjustment Air, scale Burner output, kw Pressure in front of the shrouded disc Fan pressure, mbar 4,5 4 3,5 3 2,5 2 1, Burner output, kw

11 05. MAINTENANCE Suspension of burner During service the burner can be hung up on the screw in the burner flange. For this there is a hole on the right side of the burner.the blast tube, shrouded disc, nozzle, preheater and electrodes are then easily accessible. Removing the blast tube 1. Loosen the two fastening screws one turn. 2. Turn to the right and withdraw the blast tube. Shrouded disc The preheater plug and the electrodes shall be placed on either side of the oil tube. Setting the ignition electrodes Proper setting of the electrodes is essential to ensure satisfactory operation of the burner. If the spark hits the metal the efficiency will be lower and will also cause radio disturbance. There is also a risk that carbonisation will occur. Since the electrode pack is of the factory-set twin electrode type it will be necessary to bend the wires to make any adjustment. 2,3-3,1 0,5-1,5 10,0-11,0 ø24 ø73 ø

12 05. MAINTENANCE Cleaning the fan wheel The outer fan housing half is kept firm by 5 screws. Trimming If the size of the nozzle is changed, it is suitable to first set the nozzle assembly and air according to the recommendations in section Basic settings. For the individual boiler installation, adjustments can then always be made to optimise economy, operational reliability and environmental effects. The most important instruments for the task are one instrument for flue-gas analysis and a soot meter. The principle of the adjustment is: - reduce the air, either with the air regulation or the nozzle assembly, until a soot coefficient is achieved. - increase the air to give a safety margin of 0,5-1% CO 2 before soot is created. To throttle more with the shrouded disc (smaller reading on the nozzle assembly scale), gives a short, more bluish flame and often better combustion, but if one goes too far there will be starting problems. Throttling less with the shrouded disc gives a longer and more yellowish flame and can give a smoother start. The pressure in front of the shrouded disc can be utilised as an aid in the adjusment. Recommended pressure, see under Basic settings. Remember to refit the rubber gasket on the pressure outlet after making the adjustments. Automatic air damper Remove the blast tube. Unscrew the 3 screws holding the cover on the back of the burner. Check that the air damper is moving easily

13 05. MAINTENANCE Service position electric package Loosen the hexagon nut from the stud bolt. Pull the electric package backwards and rotate it ca. 90 clockwise. When required the electric package can be suspended in the cables. Pump filter When changing pump filter, see chapter

14 06. INSTRUCTIONS PUMP TYPE BFP 41L3 Technical data Components Venting Viscosity range: 1,3-12,0 mm 2 /s Pressure range: 7-15 bar Oil temperature: -10 to+70 C. 1. Nozzle connection G 1/8" 2. Pressure gauge connection G 1/8" 3. Pressure control 4 mm Allen key 4. Cartridge filter 5. Vacuum gauge connection G 1/8" 6. Return pipe G 1/4" 7. Suction pipe G 1/4" 8. Return plug Venting is only necessary in a one-pipe system. In two-pipe systems the pump is automatically vented by the return pipe. Changing cartridge filter Unscrew the filter screw from the cover using a 4 mm Allen key and pull out the filter cartridge. Insert a screwdriver between the filter and screw, if necessary, to carefully ease out the filter. Replace the old filter by a new one, pushing it on the filter screw. Reassemble the cartridge and tighten lightly. Remember to change the O-ring. 1(3)

15 06. INSTRUCTIONS PUMP TYPE BFP 41L3 BFP 41L3 operating principle V P NC E H S G C P 1 D R A When the pump is started, oil is drawn from the suction port (S) through the filter (H) to the suction port (C) of the gear-set. The oil then moves to the pressure side of the gearwheel and is thus pressurised. The pressure is controlled and maintained at a constant pre-set level by diaphragm (D) of the control valve (P 1 ) The control valve (P 1 ) distributes the oil supplied by gear-set (C) between the nozzle connection (E) and the return port of the pump (R). The amount of oil consumed is determined by the pressure set on the control valve (P 1 ) and by the size of the oil nozzle in the nozzle line. The control valve (P 1 ) operates as follows: - When the oil attains opening pressure, the port to the return side opens. - The diaphragm and the spring keep a constant pump pressure at the set value. - If the pump becomes overloaded, i.e. if an attempt is made to take out more oil than the gear-set can deliver in the prevailing circumstances, the oil pressure will fall below the set value causing the valve to close, by diaphragm (D), to the return port (R) and return to the starting position. This can be remedied by: - Lowering the pump pressure. - Reducing the amount of oil delivered, i.e. changing to a smaller nozzle. - Changing to a pump with higher capacity. 15 2(3)

16 06. INSTRUCTIONS PUMP TYPE BFP 41L3 Suction line tables H H One-pipe system Height Pipe diameter H ø4 mm ø5 mm ø6 mm m m m m 4, , , , , , , , Two-pipe system Height Pipe diameter H ø6 mm ø8 mm ø10 mm m m m m 4, , , , , , , , One-pipe system Height Pipe diameter H ø4 mm ø5 mm ø6 mm m m m m With an underlying tank a one-pipe system is not recommended Two-pipe system Height Pipe diameter H ø6 mm ø8 mm ø10 mm m m m m , , , , , , , , The suction line tables consist of theoretically calculated values where the pipe dimensions and oil velocity have been matched so that turbulent flow will not occur. Such turbulence would otherwise result in increased pressure losses and noise in the piping. A piping system consists normally of drawn copper pipes and four bends, a non-return valve, a shut-off valve and a prefilter. The sum of these individual resistances is negligible. The tables do not include any lengths exceeding 100 m because experience shows that longer lengths are not needed. The tables apply to standard fuel oil of normal commercial quality according to current standards. On commissioning with an empty tube system the oil pump should not be run without oil for more than 5 minutes. The tables state the total length in metres of the suction line at a nozzle capacity of 2.5 kg/h. Maximum allowed pressure at the suction and return port is 2.0 bar. Mounting/dismounting return plug One pipe system Two pipe system 16 3(3)

17 07. OIL FILTER BENTONE We recommend the use of a fine filter in front of the oil burner. For certain markets this is delivered enclosed in the carton. Specification Oil filter for light oil with disposable filter cartridge Connection: 1/4" Filter grade: 20 μm Water repellent Filter area: 0.17 m 2 Direction of flow from the outside in Transparent bowl Connection for vacuum gauge Max. pressure: 2 bar Max. temperature: 70 C Max. flow: 85 kg/h (100 l/h) For a 2-pipe system the maximum flow is determined by the constant pressure capacity of the pump For a 1-pipe system the nozzle capacity is decisive Suspension console Installation and changing the filter The filter may either hang on the lines or be fixed to the wall with the aid of the accompanying suspension bracket. A shut-off valve should be fitted in front of the filter to facilitate changing the filter cartridge on installations that are pressurised by gravity. Options for changing the filter cartridge: A yearly B when the vacuum becomes 0.4 bar greater during operation than when still C when the entire filter appears to be dirty Remember to remove the flat gasket between the cartridge and cover, and fit a new one each time the filter cartridge is replaced. Also replace the O- ring between the plastic hood and cover. The air will easily flow through a new filter cartridge. All the air will therefore be evacuated and the filter will be filled with oil. If the oil is subjected to a certain vacuum during operation, gases will be emitted and collected in the filter. Air will only pass through the filter with difficulty now that the paper is oily. Consequently, the level in the bowl will drop. The effective area of the filter will then only consist of a small part at the bottom. In step with contamination of the filter the level will rise and thus indicate the degree of contamination. This phenomenon, which does not occur in installations that have pressurised oil, does not affect the degree of filtering. NOTE! Do not pour oil into the drain. Your local municipal recycling centre will accept minor quantities of contaminated oil. O-ring Gasket

18 09. ELECTRICAL EQUIPMENT LOA24... Wiring diagram (1)(2) * 1(2)

19 09. ELECTRICAL EQUIPMENT LOA24... List of components Function Technical data Control of photo current A1 Oil burner control P1 Time meter (optional) A2 Twin thermostat R1 Photoresistor E1 Preheater S3 Main switch F1 Fuse, max. 10A T1 Ignition transformer H1 Alarm lamp Y1 Solenoid valve H2 Signal lamp (optional) X1 Plug-in contact, burner M1 Burner motor X2 Plug-in contact, boiler The colours of the preheater cable: A Blue B Brown C Black Mains connection and fuses in accor-dance with local regulations. 1. Switch on operating switch and twin thermostat Voltage is applied to the preheater and the preheating period starts. This period lasts till the operating temperature of the oil has been reached and the preheater thermostat closes (2). 2. Preheater thermostat closes The burner motor starts, an ignition spark is formed, the prepurge goes on till the prepurge period expires and the solenoid valve opens (3). 3. Solenoid valve opens Oil mist is formed and ignited. The photocell indicates a flame. (1) The ignition spark goes out 15 s. after flame indication (LOA ). (2) The ignition spark goes out 2 s. after flame indication when the ignition transformer is connected to terminal 7 (LOA ). 4. The safety time expires a. If no flame is established before this time limit the control cuts out. b. If for some reasons the flame disappears after this time limit, the burner will make an attempt to re-start Operating position If the burner operation is interrupted by means of the main switch or the thermostat, a new start takes place when the conditions in accordance with point 1 are fulfilled. The oil burner control cuts out A red lamp in the control is lit. Press the reset button and the burner re-starts. Post-ignition (2) If a post-ignition of 15 s. is wanted, move the ignition transformer from terminal 7 to terminal 6 (LOA ). Pre-ignition time: 13 s Pre-purge time: 13 s (1) Post-ignition time: 15 s (2) Post-ignition time: 2 s Safety lock-out time: 10 s Reset time after lockout:» 50 s Reaction time on flame failure: max. 1 s Ambient temperature: from - 20 to +60 C Min. current with flame established: 65 μ A Max. photo current at start: 5 μ A Enclosure: IP 40 (Under voltage proof only LOA24...) Current through photo unit is measured with a d.c. ammeter (a moving coil instrument connected in series with the photo unit). Outer electrical connection * If there is no plug-in contact (X2) on the boiler, connect to the contact enclosed. In case the twin thermostat is in series on incoming phase L1, a loop between the terminals T1 and T2 is necessary. X2 X1 2(2)

20 10. FAULT LOCATION Burner fails to start Situation Possible causes Remedies Motor runs Burner pre-purges Flame occurs Burner locks out Motor runs Burner pre-purges No flame occurs Burner locks out Flame instability Incorrect head settings Low oil pressure Excess air Photocell not seeing light Photocell failed Control faulty False light No spark No oil Check nozzle to burner head dimension and electrode position Check oil pressure Adjust air damper Check that photocell is clean and unobstructed Confirm with new photocell Confirm with new control. (NB. it is advisable to change the photocell if also changing control) Check that photocell is not seeing ambient light Check that H.T. leads are sound and are not arcing other than at electrode gap Check oil supply to burner - check that pump is not airlocked Check operation of magnetic valve Burner fails to start after normal operation Burner fails to start Fuse has blown Appliance thermostat has not reset Check or replace fuse if necessary. Check reason for failure Adjust thermostat Lamp not lit Appliance overheat device has operated Control relay or photocell defective Reset overheat device. Find reason for its operation and rectify Check by replacement Motor runs Burner runs to lockout No oil being delivered Excessive flue draught is preventing flame establishment No spark Check that tank, oil lines, fire valve, pump and nozzle are all in good order Rectify condition Check ignition transformer. Check electrode gap and porcelain Delayed ignition, burners starts violently Burner pulsates on start-up only with hot flue Excessive draught Adjust the burner Burner pulsates on start-up Nozzle partly blocked Replace nozzle Oil pressure too low Check and adjust Flue blocked or damaged Check and rectify Fan slipping on shaft Check and retighten Pump coupling loose or worn Check and replace Burner starts violently Delayed ignition Check the electrode adjustment, see diagram Check electrodes for damage Check H.T. leads for damage and disconnection