Bigflame Propane Flame Projector Safety instructions and operating manual 1
Flame projector Bigflame Safety instructions Caution The directions in this manual must be followed strictly. It is imperative that the safety instructions and the manual are completely read and understood before start-up The device may only be operated under the constant supervision of trained personnel. Maintenance of the device may only be carried out by the manufacturer. In occurrence of malfunctions or dangerous situations the device must immediately be shut down The unit must not be used in heavy airflow or precipitation (e.g. rain or snowfall). WARNING Non-observance of the following safety instructions can result in severe damage to persons and/or property, by fire, explosion or electric shock 1. Transport and storage Check the incoming goods for damage and completeness. Notify the shipper immediately of any transport damage. The parts must be unpacked with great care and caution to prevent damage to sensitive components, such as controls. The components of the device must not be stored unsheltered outdoors. Protect against moisture and precipitation. The permissible ambient temperatures are -5 C to +50 C. 2
2. Installation The device may only be used indoors if the ceilings are high enough to ensure safe operation. When installing it on outdoor stages, make sure the unit is protected against strong winds and precipitation. Ensure good stability when setting up the device. The device must be fully secured against dislocation. The assembly of the unit must be carried out de-energized. The unit must not be exposed to impact or vibration. Installation may only be carried out in a manner that the flame is either projected vertically upwards or directed horizontally. The device must be secured against unauthorized access. Any contact with the hot parts of the burner must be excluded. Sufficient safety distance to the area involved in performance and to flammable materials must be considered when assembling the device. Performers and participants must be clear of the safety distances beforehand, and the operation must be rehearsed. In dangerous situations the device must immediately be shut down The sideway safety distance in still air is 8m. The safety distance above the burner is at least 20m. In draft or wind the emitted flame may drift. That means the safety distance must possibly be extended to a range where danger to persons and property is excluded. Maintenance on the device may only be performed by the qualified personnel of the manufacturer. The casings of the burner or the control panel must not be opened. Risk of electric shock By opening the casings of the burner or the control panel any guarantee and/or warranty expires and we assume no liability for consequential accidents and damage to persons or property. The disassembly of the burner must not be carried out until it has sufficiently cooled down. For the assembly and operation of the device, only original parts from the manufacturer may be used. The use of other parts can result in severe damage to persons or property. Keep suitable fire extinguishers ready. Never insert your hand or any other object into the burner opening. Risk of death by electric shock 3
3. Start up The initial operation may only be carried out after complete assembly of all necessary components and safeguards by trained personnel, in consideration of all topics addressed in these safety instructions and the operating manual. We disclaim liability for faulty start-up carried out by an untrained third party, and the warranty expires. 4. Operation The flame projector is used at events or shows. Before start-up, the use of the device must be clarified with preventive fire protection. The operation of the unit is only allowed for the designated purpose, within the boundaries of design, by trained personnel. We assume no liability for inappropriate use, which can lead to severe damage to persons and/or property. Furthermore, warranty expires. Safeguards must not be removed or disabled Do not open components of the unit (e.g. casing covers or front panels), as that poses great risk of injury, like burns, electric shock etc. In dangerous situations the device must immediately be shut down, disconnected from the power source and the propane bottle valve must be closed. Before start-up, check the gas loaded parts of the unit for tightness (see operating manual). Any leakage must be eliminated immediately. Never run a leaky system Also make sure that all hoses and connections are intact; defective or damaged parts must not be used. When connecting the unit to the propane gas bottles and checking for tightness, the power supply must be shut off. Eliminate all sources of ignition, like open flame and spark-producing equipment, and never smoke during these tasks. The device may only be operated by trained personnel. Sufficient safety distances during operation of the unit, protection against accidental contact with hot burner parts and safe assembly must be ensured. Extended safety distances in draft or even breezes must be considered. The device must not be operated in strong winds or precipitation. The device may only be fueled with propane gas. No liability is assumed for consequential damage caused by use of other gases. Moreover, any warranty from the manufacturer expires. 4
5. Shut-down During longer idle periods the unit must be depressurized (see operating manual) and de-energized. At least once a year the device must undergo a safety inspection, maintenance and adjustment by the manufacturer. Please make an according appointment with the manufacturer and send the unit in. 5
Flame Projector Bigflame Operating manual 1. Note: please read and follow the safety instructions closely 2. Preface The Bigflame is a propane gas driven flame projector, capable of emitting effect flames with a height of up to 13m, or a width of up to 8m (when installed horizontally). Latest burner technology and control systems allow operating the unit with the highest possible functional safety. The device is basically designed for outdoor use; the use on indoor stages is only possible if sufficient safety distances are ensured (see safety instructions). The flame can be triggered with the included cable remote control from a distance of up to 10m. An extension cable for the remote control is separately available. 3. Components of the unit The unit consists of: Cable remote control (length of cable 10m) Flame projector Bigflame (effect burner) Gas hose with reducing valve (length 10m) 4. System functionality By activating the key switch on the device, a 30l buffer tank in the Bigflame is filled with the gas phase of a propane bottle under pressure rise. By pressing the pushbutton on the remote control, an electromagnetic valve in the flame projector is opened and releases propane gas into the nozzle of the flame projector. At the same time a high-voltage arc is generated in the head of the burner, igniting the expanded propane gas (which is blended with an ideal amount of air) and emitting a flame column of up to 13m of height or 8m of width. The flame height can be adjusted with a reducing valve on the propane gas bottle. 6
5. Installation of the unit Flame projectors: start with installing the flame projectors. Ensure that there are no flammable materials in the safety area and make sure that nobody is in the safety area during operation (see safety instructions). The flame projectors shall be mounted on a horizontal, flat and fire-proof base. Flammable materials in the safety area must either be impregnated flame-retardant with appropriate agents or covered with fire-proof materials, so no ignition can occur. Dust accumulations above the flame, also outside the safety area, must be removed at all costs, as they can be stirred up by the flame and cause dust explosions. Keep in mind that the flames drift in winds or draft, probably necessitating a considerable increase of the safety distance. The device may only be operated on outdoor stages if a sufficient protection against the effects of weather, as heavy draft or winds, and precipitation (rain, snowfall, etc), is ensured. The flame projector must be secured against dislocation or falling over. For the place of installation, select a location that is not exposed to impacts or strong vibrations. Propane bottles and hose lines: Either a single or several 11.4 kg bottles connected in series turned out to be ideal for the purpose, they can be obtained at outdoor equipment suppliers or specialty shops. Connecting several propane bottles in series has the advantage that the propane bottles will not ice up so quickly if the burner is frequently used in a short period of time. Due to the vaporization of the propane in the bottles, it is normal that the bottles cool down or develop frost on the outside. However, the colder the bottles become, the longer the next re-load will take. Therefore we recommend interconnecting several propane gas bottles. The bottles must be set up on a site that is easily accessible, so it is ensured that they can be closed and removed quickly in case of emergency. The bottles must be placed in an upright (vertical) position on a stable and horizontal base, and secured against falling over. A steel chain, loosely tightened around the bottle, delivers a good performance in practice; the loose tightening allows a quick removal of the bottle. There should be no rooms or hollow spaces below the installation site of the propane gas bottles. Propane is heavier than air and would collect in lower situated areas when leaking out, thus forming an explosive air/gas mixture. These rooms must be monitored with a gas detector (available as accessory) in case of need. Now check the included gas hose for visible damage. Cracked or damaged hoses or fittings must not be used; any defective equipment must be replaced immediately. If the hose is intact, connect it to the propane gas bottle by tightly screwing it on with an open-end wrench of proper size. CAUTION: LEFT-HAND THREAD Now connect the other end of the hose to the effect burner in the same manner, after removing the protective cap from the thread of the burner's connection. Ensure safe routing when installing the hose at all costs; it must not be exposed to the heat of the burner and mechanical or abrasive influences (e.g. kinking, running over by equipment) and must not present a tripping hazard. The hose must possibly be secured with a protective host duct. A cut and age resistant steel-braided hose is optionally available. 7
After the hose is connected, the system must be checked for leak tightness: Open the propane bottle shortly and set the reducing valve to a pressure of 4 bar. Now connect the power cable of the burner to a power socket fused with 16A (230V AC 16A) and turn the red handle of the ball valve on the Bigflame to horizontal position. Then put the key into the key switch and activate it by turning the key clockwise. In doing so, the buffer tank of the device is filled with gas, noticeable by a hissing filling noise. Wait until you cannot hear the noise anymore (10-20 sec). If gas should leak from the hose connections or from any other part of the unit, immediately close the propane gas bottle again If the leakage cannot easily be eliminated, do not continue operating the unit. When the propane supply line is tight and the buffer tank is filled (no more filling noise), the unit can be checked. Close the propane bottle again. There must be no noticeable pressure loss (check the gauge on the reducing valve) after a holding time of 5 minutes. If necessary, the source of the leak must be detected with leak spray or soap water (bubbling from the leakage) and eliminated. A leaky system must not be operated. Cable remote control: Now plug in the Neutrik-connector of the cable remote control and twist it approximately a quarter turn clockwise until you can hear it snapping in. Choose a position from which the flame projectors can be directly observed at all time before placing the remote control. Make sure this device is protected againt the effects of weather and moisture. The unit is now ready. 6. Operating the unit with the cable remote control Operation with connected propane gas bottle: Open the valve of the propane bottle and the hand valve of the burner and set the desired pressure with the reducing valve on the propane bottle (approx 4 bar). Insert the key into the key switch and turn it slightly clockwise. You will hear a distinctive hiss, caused by the filling of the burner's buffer tank. If the buffer tank was completely filled during the previous pressure check, probably no noise will be caused. The filling pressure, and with it the width of the flame burst, depends on the setting of the preselected filling pressure with the reducing valve on the gas bottle. The reducing valve should basically be set to the highest possible pressure setting (approx 4.5 bar). When all cables are connected and the Bigflame is filled with propane, it can be triggered. Keep the safety distance of 8m. By pushing both buttons on the cable remote control the Bigflame projects a fire ball with a fire column. Do not push the buttons for longer than 2 seconds. When the buttons are released, the buffer tank of the device is re-filled and can be fired with the same flame width as before after complete reload (approx 20 seconds). However, if the device is triggered before the pressure has fully built up again, the fireball will respectively be smaller. On principle, the width of the flame burst should only be set with the pressure reducer on the propane gas bottle. ENSURE THAT NOBODY IS IN THE SAFETY AREA OF THE BURNER WHEN TRIGGERING THE FLAME DURING OPERATION, THE PERSON TRIGGERING THE BURNERS MUST OBSERVE THEM AT ALL TIME 8
Instead of triggering manually with the push-buttons on the remote control, the device can optionally also be triggered via DMX. A special DMX controller is available for this purpose. Operation with the DMX controller: The DMX controller has additional 5-pin connectors for DMX signal cables. The input channel can be selected and saved by push-buttons. The DMX signal for firing should not be sent for more than 2 seconds In case of danger or malfunction, firing can be prevented with an emergency stop button on the controller. Do not connect the DMX line before the safety area of the Bigflame is clear of personnel. Operation with disconnected propane gas bottle: The Bigflame can also be used short-term if the propane bottle is disconnected. The buffer tank of the device has the capacity to contain 30l of propane gas under pressure as gas phase; that amount is sufficient for one shot with the full burst width. This is especially advantageous if you want to fire only once and a larger gas supply is undesired. Proceed as described above. When the buffer tank is filled, turn off the valve on the propane bottle. Now close the gas connection to the Bigflame by turning the handle of the ball valve to vertical position. You can now disconnect the propane bottle. Then release the hose connection from the device (left-hand thread). Eliminate all sources of ignition, like open flame or spark-producing equipment, and do not smoke during these tasks, as some propane gas will escape from the hose due to the pressure loss. However, these small amounts of gas pose no risk of explosion to the room. CAUTION THE PROPANE GAS BOTTLE MUST BE SHUT TIGHT The Bigflame is now disconnected from the propane gas bottle and its buffer tank is filled with 30l of propane gas (from the gas phase). To trigger the unit, continue as described above. 7. Shut-down Turn the unit off with the key switch on the Bigflame, pull out the key and keep it with you. The key should never remain unattended in the key switch. When operating with connected propane gas bottle, its valve must be turned off now. As the buffer tank is still filled, it must be emptied by triggering the unit. To do so, close the ball valve on the Bigflame (by turning the handle to vertical position). Then fire the unit again as described above and depressurize it by pressing and holding the pushbuttons. An initial flame should very quickly (< 10 sec.) become smaller and eventually extinguish. If one or more burners are still emitting flames for any length of time, the respective valves were not properly closed and the procedure must be repeated. The unit can now be turned off again with the key switch and disconnected from the power source. Disassembly can now begin in reverse order. Please keep in mind that the burner heads become very hot, do not dismount them before they have cooled off. Do not forget to put the protective caps back on the burner's threaded connectors. It is imperative that no dirt particles get into the gas inlet pipes 9
8. In case of emergency If serious malfunctions occur that pose a threat to persons and property, the device must immediately be shut down. To do so, turn off the key switch on the device and remove the key. The unit then immediately shuts off the gas and power supply. Now immediately close the valves of the propane bottles. In case of a fire in the immediate area, extinguish the bottles and remove them from the site at once. 9. Care, maintenance and storage Dirt on the unit should be removed with a soft and moist cloth. Suck up sooting from the lattice of the burner head with a vacuum cleaner and wipe it clean with a cloth afterwards. Never try to clean the electrodes inside the burner head by inserting your hand or any other object Do not use aggressive cleaning agents. Maintenance of the device can only be carried out by the manufacturer or by TBF- PyroTec certified Technicians. Maintenance must be carried out annually, please make an appointment with the manufacturer, or send the unit in. The unit should be stored and carried in the designated hard cases (optionally available) after usage. 10
10. Technical specifications Dimensions: approx 110 x 39 x 40 cm Weight: 60 kg Power input: 230V AC, 50~60Hz Power consumption: 310W Bigflame TBF-PyroTec GmbH Lichterfelder Str. 5 A 21502 Geesthacht Tel.: + 49 (0)4152 157 9950 Fax: + 49 (0)4152 157 9951 11